Gas Injection Conversion Territory Ghia Turbo

[CountryPhoon]

An interesting post from another Forum:

Gday Guys,

I am the Australian LPG Warehouse's Managing Engineer. The Liquid Injection system you are discussing above is made by Icom and developed for Australian vehicles and conditions by us. We have been doing extensive durability testing and development on the system (Called JTG) over the past year with great results.

We have been developing emission compliant kits for the most common vehicles first. On that list is BA/BF sedan, Territory 1&2, Expensive Daewoo 5.7lt sedan and Expensive Daewoo 6lt sedan.

We have given our first training session on the JTG liquid injection system to our first group of installers with positive feedback. As the demand for this system is huge, we have made a decision to only supply to the first 2 groups trained for the first 6 months. To be a certified installer of this product the installer must first attend the training and have the appropriate tooling as the technology is quite different to traditional systems.

Just to cover a few topics discussed above. The system has no requirement for any injection timing strategies. Full control of the system is via the factory engine management system. This is quite different to standard vapour injection systems as they need to manipulate the injection pulse with due to pressure, temperature, and flow issues. The JTG controller is only there to switch the pulse from the petrol to lpg injectors and control the LPG pump.

The system is quite similar to a petrol system. The cylinder has a pump integrated that pushes the LPG to the injectors common rail. This is then ran through a pressure regulator similar to a petrol regulator and fed back to the tank via a return line. The pressure is kept 3 bar over tank pressure.

The injectors deliver liquid LPG directly into the manifold via a small tube. This is installed much the same as vapour injection. A hole is drilled in the manifold as close to the petrol injector as possible and a nozzle is taped in. The difference is that the liquid is passed through a small inner hose that is inserted into the nozzle. An outer hose is then placed over the smaller hose and onto the outside of the nozzle.

The injector is made by Siemens specifically for the JTG system. The flow of this injector is matched to the flow of the petrol injector via a calibration tip inserted into the housing. This is all developed by us before the kit is sent out. We measure the flow of the petrol injector for each vehicle type and then select the appropriate calibrator and injector combination. This is then tested for power, drivability, economy and Emissions. Once we have a final match, this system is then sent to the emission lab for certification.

The end result is a complete kit with laser cut brackets, plug and play wiring and ready to bolt on and drive. We have seen huge fuel savings and power gain using this system. The fuel usage using JTG is within 5% of petrol unlike vapour injection which is only within 20%. This makes it a very viable option. As with all technology it is more expensive than its predecessor. However it will only be from $300 to $400 more per kit depending on the vehicle. This is well made up for in the 15% benefit over vapour injection economy.

The system can run as straight gas or duel fuel. The only issue with straight gas is that there is a delay of 3 seconds before start up. JTG requires a purge of the supply and return lines before start up. This is to remove any vapour from the lines. On duel fuel systems this is set for about 30 seconds. The system during this time will run on petrol while it circulates LPG. After this time it will then switch to LPG by itself. Straight gas vehicles have this purge time set at a minimum.

The system cannot be upgraded from traditional systems as mentioned above. The cylinder has an integrated pump and uses a return line (This pump however can be accessed). The fill line in the JTG system also has a filter. This is to stop any contaminants affecting the pump. The filter can be replaced and we set an interval of 50,000km.

Our JTG system was not derived from a truck system and has been througherly tested both in Europe and Australia. In fact over 30,000 vehicles already have this system. Ford, Subaru, and a list of other manufacturers are also using this system from factory.

Our website is alpgw.com.au. At the moment there is no reference to out JTG liquid injection system as it has only just hit the market. It will soon be populated with all the information you require but in the meantime you can have a look at Icom’s site (The component manufacturer). They are at icomitalia.it/lang1/index.html. I will also soon post some images on this forum.

[kaldek]

An interesting post from another Forum:

We have been developing emission compliant kits for the most common vehicles first. On that list is BA/BF sedan, Territory 1&2, Expensive Daewoo 5.7lt sedan and Expensive Daewoo 6lt sedan.

Man this is awesome. Considering the following facts, this is almost a must-buy for me.

- My novated lease expires in 2010

- The car (BFMkII turbo) will be un-sellable by then

- I will have to cop the lease payout figure myself

I'm so excited to see what this brings. Happy to lose the spare tyre for an LPG tank - I live without one on the bike anyway and I'm a dab hand at on-road tyre repair.

Bring on liquid phase LPG and monster power tuning!

[CountryPhoon]

Hey Mal K.... Any progress to report?????

[Macktheknife]

Bump....

[cobramad]

Finally back onto the (now I find out!) new look forum. Yes, I have been a little preoccupied and work had driven the Terry conversion onto the back burner. I have now been thru the process of mounting the tank and gas filler nozzle, which as it turns out, proved a little time consuming in order to make sure that you measure five (5) times before you proceed to drill holes in your new(ish) pride and joy. In order to drill the afforementioned holes, you need to remove the rear seats and belt mounts, plastic under seat tray, spare wheel carrier and wheel. I then found that the Turbo has a bigger diameter exhaust which naturally positiones itself too close to the front gas cylinder of tank unit. That required cutting and flanging the exhaust just infront of the rear muffler and rotating the exhaust pipe a little to at least allow the fitment of the gas tank unit. As it now turns out, even this doesnt provide the necessary clearance,so its back to the drawing board and time to make a new intermediate pipe section. As the diameter is 3" (75ish mm), it will be a real challenge to keep it looking neat and tidy. Next up is completing the gas line routing and attachment, in itself interesting is as much as you need ensure that it remains the correct distances from moving suspension components and the like. All the hoses, gas fill pipe and wiring needed to be attached bafore the tank was offered up to the vehicle, as there is bugger all room to do so later, even for blokes with skinny arms and small hands like me!!

Im not convinced if the fitment of raised heavy duty Kings springs has been the right step, it has certainly raised the rear of the TGT up and the ride quality is currently crap. To be fair, I have not refitted the rear seats or filled the tank yet so it isnt really the time to judge. It was really surprising how heavy the 3rd row of seats weighed... No probs getting them out of the vehicle, refitting will be a two person job.I will now download the latest pics to the forum so you can have a gander..

Cheers, Mal K

[cobramad]

Hiya all,

Here are some more pics of the conversion, sorry if a few are a little indistinct, lighting was poor that day and I was in a bit of a hurry. Hope they show a bit more of whats involved.

Mal K

[Romulus]

Hey Mal, how's it coming along? Got the rear seats installed yet?

[cobramad]

Hey J,

Not yet installed, been flat out with a couple of engine rebuilds, so the 'ol girl is still riding high at the rear. Must pull finger and then get it tuned safely. If BPT helps out and enables the gas switch that hides in the factory PCM, then there is no reason not to map the gas completely using Sniper, with associated timing and boost strategies to suit. Dyno time is essential to be safe and still make decent power as well.

[CountryPhoon]

Hey Mal - That gas set-up going yet??????

[GreenXR6T]

How's the TT going now?

Finished the conversion?