MANUFACTURER Alfa Romeo

TYPE 159 Sport wagon

ENGINE DISPLACEMENT 1750cc TBI
NUMBER OF VALVES 16v
ENGINE CODE / NUMBER 939.B.1000
VEHICLE CATEGORIES M
TRANSMISSION MT
VERSION Direct LiquiMax-2.0
PETROL ECU MANUFACTURER / CODE Bosch (FPT) Motronic MED 17.3.1
HIGH PRESSURE PETROL POMP Bosch 261.520.053 / 261.520.054
HIGH PRESSURE PETROL INJECTOR Bosch 261.500.067
MODEL YEAR: 2009-2011
SYSTEM APPROVAL NUMBER ( R115 ) ---
LOCATION SYSTEM STICKER right side, centre door post
ENGINE SET NUMBER 341/070001/A
MANUAL NUMBER 076/0100600
DATE 2014-06-24

Copyright © Prins Autogassystemen B.V. 2013 Version 2012-11-02 D

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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

TABLE OF CONTENTS

General instructions......................................................................................................................... 2
Required equipment / tools / materials for installing a complete system ........................................... 3
Vehicle check .................................................................................................................................. 3
Tightening moments ........................................................................................................................ 4
Direct LiquiMax ............................................................................................................................... 5
Overview Direct LiquiMax ................................................................................................................ 6
Direct LiquiMax parts / approval numbers ........................................................................................ 7
DLM component location overview .................................................................................................. 8
Removal of the Bosch High Pressure Pump .................................................................................... 9
Installation of the Bosch High Pressure Pump................................................................................ 10
High pressure pump installation ..................................................................................................... 11
Fuel Supply Unit / Fuel Return Unit ................................................................................................ 13
Mounting the Fuel Return Unit / Fuel Supply Unit ........................................................................... 14
Boost pump ................................................................................................................................... 15
Lpg / petrol fuel lines ..................................................................................................................... 16
Fuel hose connections................................................................................................................... 17
Supply hose – Return hose – Tank wiring ...................................................................................... 18
Hose / Tank wiring routing ............................................................................................................. 19
Mounting the AFC ......................................................................................................................... 20
Relays, fuses & diagnostic location / Wiring routing ....................................................................... 21
Wiring routing / Grommet............................................................................................................... 22
Mounting the fuel selection switch / Wake-up connection ............................................................... 23
Electrical connections .................................................................................................................... 24
Electrical connections .................................................................................................................... 25
Electrical connections .................................................................................................................... 26
Electrical connections .................................................................................................................... 27
Petrol ECU K-connector ................................................................................................................ 28
Electrical connections .................................................................................................................... 29
Electrical connections .................................................................................................................... 30
Checklist after installation .............................................................................................................. 31
FOR EXPLANATION AND CIRCUIT DIAGRAMS SEE : INSTALLATION MANUAL GENERAL PART 1 / 2
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

General instructions

 The installation of the system shall be done in accordance with the installation manual provided by Prins Autogassystemen.

 This manual is based on Dutch regulations, always install the system in accordance to the local regulations.

 For an optimal functioning of the Direct LiquiMax system, maintain a clean and organized work environment during
installation and maintenance to prevent pollution of the LPG components.

 Always download the “general manual 1/2 “ from our website for basic instructions and diagrams.

 Always disconnect the battery when installing the lpg system. Make sure the ignition key is outside the car.

Be aware of central door locking, radio / telephone memory code, alarm system.

 Wear safety goggles when working on petrol filled system / connections ( pressurized petrol )

 Do not place the main fuse into the fuse holder before having completed the installation of the system.

 The AFC has to be activated by means of the Prins diagnosis software.

 Never disconnect the AFC connector, unless you have removed the main fuse.

 When installing the wiring harness, ensure that it does not run near any of the ignition components.

Solder and insulate all electrical connections.

The wires in the loom are provided with numbers and text. The text on the wire explains the function of the wire.
The wire harness is not model specific, therefore is it may be necessary to adjust the length of the wires.
Ensure maximum care is taken when connecting wiring.
Make professional joints using solder and shrink sleeve. Do not stretch the wiring harness.

 No component of the LPG-system shall be located within 100 mm of the exhaust or similar heat
source, unless such components are adequately shielded against heat.

 If holes have to be drilled (wear safety glasses) for installing brackets, etc., the drilled holes must always be treated
with an anti-corrosion agent, after the chips have been removed ( especially when mounting a exterior filler into body work).

 After having completed the installation, check the whole system for lpg leakage; use a lpg leak detection device.
Also check for leak of engine coolant, petrol and air.

 Fitting and maintenance is only allowed by Prins Autogassystemen selected LPG engineers.

 Failure to follow the instructions in this manual can result in a poor or non-working lpg installation or a dangerous situation.

 For maintenance instructions and filter registration see owner manual.

 Prins Autogassystemen is not responsible for any damages to people or objects as a result of changes to Prins products.

 Check our website regularly for diagrams, certificates, updates, info-bulletins and product information.

Register ( warranty card ) the system on the Prins warranty portal .

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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Required equipment / tools / materials for installing a complete system

- Complete workshop toolbox ( wrenches, screwdrivers, cutters, pliers, ratchet, sockets )

- Car lift
- Portable computer
- Vehicle fuel system scan tool or OBD scan tool Prins ( part nr. 099/99928 )
- Exhaust gas analyser
- Multimeter
- Oscilloscope
- Prins diagnostic software
- Prins serial interface
- Torque wrench ( 5-50Nm )
- Torque wrench ( 200-250Nm )
- Portable light
- Assortment drill bits 4 to 12 mm
- Assortment cutters ( ø 20, 30, 50, 70 mm )
- Portable drill or pneumatic drill
- Thread cutting device ( male M6x1, M8x1, M10x1 )
- Socket 46mm
- Air gun
- Vacuum cleaner
- Safety goggles
- Hot air gun
- Soldering iron, soldering tin
- Wire-stripping pliers
- Adhesive tape
- Adhesive sealant
- Thread locking compound
- Anti-corrosion agent / black body coating
- Gas leak detection device or foam leak spray
- Shrink sleeves

Vehicle check
- Check the vehicle drivability on petrol
- Check the fuel system for error codes ( scan tool )
- Check if the catalytic converter is in good condition ( exhaust gas analyzer )
- Check the condition of the ignition system ( spark plugs, cables, coil )
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Tightening moments

Nm SW
M 4 x 0,7 3.3 7
M 5 x 0,8 6.5 8
M 6 x 1,0 11.3 10
M 7 x 1,0 14.5 11
M8x1 24.5 13
M 8 x 1,25 27.3 13
M 10 x 1 52 15-16-17
M 10 x 1,5 54 15-16-17

( filtered )Banjo bolt 10 14

Supply line connection 15 13
Fuel module Allen bolts 20 7
Filler hose connection 50 22

EXPLANATION OF SYMBOLS :

= IMPORTANT, CAUTION = WEAR SAFETY GOGGLES

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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Direct LiquiMax
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Overview Direct LiquiMax

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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Direct LiquiMax parts / approval numbers

st 1st generation
1 generation

2nd generation 2nd generation

Fuel Supply Unit : E4-67R-010269 Fuel Return Unit : E4-67R-010270

Pressure Sensor : E4-67R-010051

Boost pump High Pressure Pump : E4-67R-010266

High Pressure Rail : E4-67R-010267
High Pressure Injectors : E4-67R-010309

Prins ECU : E4-67R-010098 Fuel lines series XD : E4-67R-010247 XD3

E4-10R-030507 E4-67R-010247 XD4
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

DLM component location overview

HPP pump Petrol ECU

FSU AFC

FRU System relay 2x

Boost pump System Fuses

R115 approval sticker :

Right side centre door post

R115
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Removal of the Bosch High Pressure Pump

-REMOVAL-
-WARNING-
In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, there may be
injury caused by leakage of the high pressure fuel.
Don’t do any repair work right after engine stops ( HOT engine ).
 Turn the ignition switch OFF and disconnect the battery negative (-) cable.
 Ware safety goggles.
 Disconnect the fuel pressure regulator valve connector
 Disconnect the High Pressure fuel feed pipe (B)
 Remove the Low Pressure fuel pipe / hose (A).
 Remove the installation bolts (E), and then remove the high pressure fuel pump from the
cylinder head assembly.
CAUTION:
Unscrew in turn the two bolts in small steps (0.5 turns). In case of fully unscrewing one of the
two bolts with the other bolt installed, the housing surface of the cylinder head may break
because of tension of the pump spring.

CAREFULLY store the removed petrol pump. Make sure no pollution can come into the pump.
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Installation of the Bosch High Pressure Pump

-INSTALLATION-

Before installing the high pressure fuel pump, position the roller tappet ( B&C ) in the lowest position
by rotating the crankshaft. Otherwise the installation bolts may be broken because of tension of the
pump spring.

Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the
protrusion (C). ( roller tappet, only if removed from cylinder head )
Also apply engine oil to the groove on the location where the protrusion (C) is installed.

Installation bolts:
When tightening the installation bolts of the high pressure fuel pump, tighten and turn the bolts in
small step ( 0.5 turns ) after tightening them with hand-screwed torque.
High pressure fuel pump installation bolt: 12.8 ~ 14.7 N.m

Fuel pipe:
First hand-tighten the nut(s) fully until they are not fastened any more in order to have them inserted
in place and then completely tighten to the specified torque using a torque wrench.
If not tightening the bolts or nuts in a straight line with the mating bolt holes or fittings, it may cause a
fuel leak due to broken threads.
High pressure fuel pipe installation nut: 26.5 ~ 32.4 N.m

Installation is reverse of removal.

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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

High pressure pump installation

Replace the high pressure pump for the adapted high pressure pump.
( Follow the workshop manual of the car )

Original high pressure pump.

Adapted high pressure pump (Bosch type 6).

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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Fuel Supply Unit / Fuel Return Unit

Black filtered banjo will only be used on inlet Filter inside sensor banjo
connections !
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Mounting the Fuel Return Unit / Fuel Supply Unit

Mount the FSU & FRU on the fuel bracket

Mount the FSU & FRU on the fuel bracket. Mount bracket with FSU / FRU on original mounting points.

Mount bracket with FSU / FRU on original mounting points.

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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Boost pump

Mount boost pump with clamp and rubber ring to fuel bracket.
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Lpg / petrol fuel lines

Hose from to Length ( cm )

1 XD-4 Adapter original petrol hose Petrol boost pump 40
2 XD-3 Fuel supply unit High pressure petrol pump 40
3 XD-3 Petrol boost pump Fuel supply unit 20
4 XD-3 High pressure petrol pump Fuel return unit 65
5 XD Fuel return unit High pressure petrol rail n.a.
1 2 4 3

Install the fuel line using two bonded seal washers and banjo bolt :

Filtered banjo: ( FSU supply inlets / boost pump inlet : black filtered banjo ) :
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Fuel hose connections

Connect hose from original fuel hose to boost pump. Connect hose from boost pump to FSU.
Connect fuel hose from FSU to High Pressure Pump.

Connect fuel hose from High Pressure Pump to FRU. Mount protection around hoses to & from High Pressure pump.

Mount hoses to tank to FSU & FRU.

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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Supply hose – Return hose – Tank wiring

Protect the supply- and return hose together with tank-wiring using the Ø16 split tube.
Mount the “hose assembly “ with clamps, with a maximum distance of 40cm.
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Hose / Tank wiring routing

Mount hoses to tank to FSU & FRU. Hose routing.

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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Mounting the AFC

Remove battery and replace support to the front. Mount plastic AFC clip to bracket with quick clips.

Mount plastic AFC clip to bracket with quick clips. Mount AFC bracket to original bolt from battery support.

Mount AFC. If necessary, bend support from battery cable to the front to “extend” cable routing.
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Relays, fuses & diagnostic location / Wiring routing

Mount relays and fuse housings to bracket.

Mount bracket to original bolt on left suspension strut just behind the AFC.

Mount fuses to fuse holders. Also the location for the diagnosic connector (with pull strap).
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Wiring routing / Grommet

For wiring transit, remove wipers, wiper box and wiper engine. Mark hole for drilling with grommet.

Drill hole Ø16mm for grommet mounting, treat anti-rust. Mount grommet and stab wiring through grommet.
Seal grommet/wiring with a sealant. Remount wiper engine, wiper box and wipers.
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Mounting the fuel selection switch / Wake-up connection

Option 1. Option 2 (12V connection).

Remove instrument cluster. Connect Wake-up to black connector (see electrical connections)

Wiring routing Wake-up.

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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Electrical connections
Check and measure the wiring in case of changes in the cars wiring colours.
Insulate not used wires.
Driver room
Wire number / code Wire colour Connection
3-pole micro connector
66 Ground fuel switch Brown Connect the 3-pole connector to the Prins fuel selection switch.
3 +12V fuel switch Red
49 LIN fuel switch Yellow

51 CAN-High Blue-yellow Not connected

70 CAN-Low Blue Not connected
For waking up DLM-system
121 Wake-up Red-grey Wire colour : grey
Wire location : pos 6 from black connector behind instrument cluster
(see picture)

1-32 Brown Connect to the '–' of the battery ( -31 ) ;

MAIN GND ecu use a ring terminal.
MAIN GROUND SENSE Wire colour : Black
MAIN GND pump driver Wire location : battery ground cable
MAIN GND boost pump

4 – 13 – 44 Red Connect to the '+' of the battery ( +30 );

+12V BATT sense use a ring terminal.
+12V BATT fused Do not place the fuse in the
+12V BATT boost pump holder before having completed
+12V BATT pump driver the installation of the lpg system.
Wire location : battery +connection on top of battery clamp
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Electrical connections
Check and measure the wiring in case of changes in the cars wiring colours.
Insulate not used wires.

Connector A

Connector K
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Electrical connections
Check and measure the wiring in case of changes in the cars wiring colours.
Insulate not used wires.

Not used wires:

119 Digital input 2 Yellow-grey

97 Digital input 5 Yellow-orange

113 Digital input 6 Yellow-purple

23 Digital Simulation Green-red

6 Lambda1 WB Orange

42 Lambda2 WB 10KΩ Orange-white

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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Electrical connections
Check and measure the wiring in case of changes in the cars wiring colours.
Insulate not used wires.

Wire number / code Wire colour Connection

8 RPM Purple-white For measuring the engine speed signal.

Wire colour : purple-white or grey-white
Wire location : pos A53 petrol ECU

15 T-ect Grey For measuring the engine coolant temperature.

Wire colour : green - white
Wire location : pos A57 petrol ECU

High pressure petrol sensor signal interruption

18 Analog 1 Blue-red Sensor side.
25 Simulation 1 Green-grey ECU side.
Wire colour : pink or grey
Wire location : pos A40 petrol ECU

High pressure petrol sensor ground

19 Analog 4 Blue-white Wire colour : red–purple or brown-purple
Wire location : pos A13 petrol ECU

MAP connection
17 Analog 2 Blue-black Wire colour : yellow
Wire location : pos A55 petrol ECU

High pressure petrol sensor +5V supply

117 Digital input 3 Yellow-black Wire colour : blue - red
Wire location : pos A29 petrol ECU
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Petrol ECU K-connector

27 +5V sensor Red :insulate

37 C ground Brown :insulate
20 Analog 3 Blue :use blue wire for Wideband lambda probe connection
Cut off connector !
Wideband lambda probe connection
Wire colour : red - green
Wire location : pos K79 petrol ECU

10 Simulation 2 Green-black To resistor

20 Analog 3 Blue In parallel with red-green wire K79

Connect wire 10 (simulation 2) with the 2,2 kOhm resistor to wire 20

(Analog 3). Use heat shrink for protection
When connected like pictures, connect wire 20 to petrol ECU.

Connect wire 10 (simulation 2) with the 2,2 kOhm resistor to wire 20 (analog 3). Use heat shrink for protection.

7 +12V IGNITION Grey - white Make a connection to ignition + / contact + ( +15 ).

Do not place the fuse in the holder before having completed the
installation of the lpg system.
Wire colour : green-orange
Wire location : pos K3 petrol ECU

Airflow sensor
115 Digital input 4 Yellow-red Wire colour : green-black
Wire location : pos K18 petrol ECU
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Electrical connections
Check and measure the wiring in case of changes in the cars wiring colours.
Insulate not used wires.
Engine room
Wire number / code Wire colour Connection
3-pole connector Connect the 3-pole connector to the Psys sensor positioned
into the Fuel Return Unit.
35 C Ground pin A Brown Sensor wire pin A
9 +5V sensor pin B Red Sensor wire pin B
16 Psys pin C Green Sensor wire pin C

14 T-LPG Grey Not used, insulate.

2-pole connector Boost

Pump Red Connect the 2-pole connector to the lock-off valve
106 + Lock-off Boost Pump White-yellow of the Boost Pump.
98 Ground lock-off

2-pole connector FSU

108 + Lock-off FSU Red Connect the 2-pole connector to the lock-off valve
100 Ground lock off Pink-yellow of the Fuel Supply Unit

2-pole connector FRU

90 + Lock-off FRU Red Connect the 2-pole connector to the lock-off valve
82 Ground lock off Blue-yellow of the Fuel Return Unit

4-pole diagnose connector Diagnose connector for service / diagnosis

46 Service TxD Grey Connector pin 1
65 Service RxD Grey Connector pin 2
68 C ground Brown Connector pin 4

Boost pump relay

107 + relay boost pump Red Pin 86 of the boost pump relay
99 GND relay boost pump Green-yellow Pin 85 of the boost pump relay
+12V fused BATT Red Pin 30 of the boost pump relay
+12V Boost pump Red Pin 87 of the boost pump relay

Wiring tank pump driver relay

2 + driver relay Red Pin 86 of the driver relay

26 Ground driver relay Green-yellow Pin 85 of the driver relay
+12V BATT fused Red 2.5mm2 Pin 30 of the driver relay
+12V driver Red 2.5mm2 Pin 87 of the driver relay
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Electrical connections
Check and measure the wiring in case of changes in the cars wiring colours.
Insulate not used wires.
Lpg tank housing
Wire number / code Wire colour Connection
3-pole tank level connector
40 Ground tank gauge Brown Connect the 3-pole connector to the tank level sensor.
12 Tank level in Blue
11 + tank level supply Red

1. 2-pole connector tank lock-off Green-yellow From tank pump driver

Brown From tank pump driver
2
2. 3-pole connector tank pump Red 2.5mm From tank pump driver
Brown 2.5mm2 From tank pump driver
2
3. 2-pole connector driver Red 2.5mm From tank pump relay 87
2
Brown 2.5mm From main ground

4. 2-pole connector driver Green From AFC pin 22 pwm

Grey From AFC pin 64 diagnose
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Copyright © Prins Autogassystemen B.V. 2013 Alfa Romeo 159 1.75 TBI 2009 - 2011

Checklist after installation

1. Install the system fuses.

Turn on ignition.
Connect the Prins interface wire and run the Prins diagnosis program.
When working on the car, beware of moving and rotating parts in the engine compartment
( even when the engine is not running !! ).

2. When commissioning the LPG system, you must activate the AFC with the diagnosis software.

3. Check whether the program in the AFC matches with the car ( dedicated engine set ):
See “Identification” in the diagnosis program.

4. Check all components and connections for any LPG leakage, use a LPG leak detector device or
a fluid detection like soap. Also check for petrol leakage. Make sure the solenoid valves are in open position.
No evidence of leakage is permitted.
Caution for moving and rotating parts in the engine compartment !

5. Use the diagnosis software to check again all input and output signals.

6. Check the system for error codes and solve these, if required.
Check the petrol MMS for EOBD error codes.
Place the protection connector back on the diagnose connector.

7. Make a test drive and check the cars drivability on LPG and petrol.