POWERPLUS

Leaders in fuel saving and emission reduction technology


INSTALLATION INSTRUCTIONS

FOR PETROL & DIESEL APPLICATIONS




GENERAL

(a)

Powerplus units are fuel enhancement devices and are not designed as an alternative to repairing or replacing faulty and/or worn components. To obtain the best results all mechanical, ignition and fuel systems must be maintained in accordance with the manufacturers specifications.

(b)

All normal safety precautions should be observed when working with fuel systems.

(c)

You may need to extend / renew sections of the vehicles fuel line when installing Powerplus units. Fuel lines and fittings should be rated to at least 150% of the fuel system operating pressure.

(d)

Though not obligatory, it is helpful to our technical dept. when answering queries later, if you have an exhaust emission test carried out on your vehicle both before and after fitting your Powerplus unit. The emission test printouts should be stapled to the back page of this manual. (Smoke test on diesel).


Please read the following instructions carefully before starting the installation.


RECORD IDLE (TICK OVER) SPEED (Prior to fitting Powerplus)




PRE-FITTING INSTRUCTIONS

(a)

Carry out exhaust emission test (see d. above)

(b)

Offer the Powerplus unit up to the vehicle and decide the most suitable location for it to be fitted. This will be a position that allows fuel lines to be connected to each end without the need for tight bends which might restrict fuel flow, and one that avoids subjecting the unit to extremes of heat and, where possible, keeps it away from electrical cables / connections.

(c)

Units must always be positioned / fitted lower than the highest point in the fuel system, and connected into the fuel line after any fuel filter/s and as close as practicable to the carburettor/s or injector pump.


The unit must be fitted into the fuel supply line and not the return.

(d)

Once you have decided on the final location for the unit you should securely mount the brackets supplied onto a suitable surface such as an inner wing or bulkhead. Under no circumstances should the unit be suspended from cables, hoses etc.

NOTE

To avoid the possibility of air becoming trapped in P3 & P4 units these should be mounted either vertically or at a 45% angle with the outlet at the top, wherever possible.

(e)

Check that the hose ends supplied with the unit are the correct size and type for the fuel pipe into which they are to be connected. If they are, tighten the ends into the unit using two spanners, one to hold the body of the unit, the other to tighten the hose end. Do not clamp the body of the unit in a vice as this will damage the finish and could cause the unit to leak. In some cases the ends supplied may be unsuitable i.e. for connecting to high pressure metal fuel lines on LPG vehicles etc. If this is the case appropriate fittings are available through motor factors etc. (The thread in the unit is ½" BSP parallel ).




FITTING INSTRUCTIONS -  PETROL & DIESEL

(a)

With the unit sitting in the brackets you are now ready to connect it into the fuel system. If the existing fuel line is of sufficient length you can simply cut it and connect the pipe from the fuel filter outlet to the inlet end of  the Powerplus unit. The inlet pipe to the diesel injection pump/petrol injection rail/carburettor inlet is then connected to the outlet end of the Powerplus unit. Be sure to purge all air from the unit and pipes before connecting the final fuel pipe.


When cutting the fuel lines ensure that any swarf or debris is cleared before securing the fuel line to the unit.

(b)

If the existing fuel line is too short to allow step 1 above you will need to extend the existing pipe/s or insert replacement pipe/s.

(c)

Tidy up the pipework, clip back where possible to avoid chafing and dry off all connections.

Tip:

A plastic cable tie around the P1 and P2 brackets helps prevent the unit vibrating out over rough ground.

(d)

Once the unit is fitted, closely examine all joints and connections for fuel leaks both before and after starting the engine. Take the vehicle for a 5 mile (8 Km) road test and then carefully re-check the installation for possible fuel leaks.

(e)

Carry out another exhaust emission test - see pre-fitting instructions.




FITTING INSTRUCTIONS - LPG / CNG


No adjustments are required. The appropriate Powerplus unit should be installed on the liquid gas line before the Vapouriser. Ensure appropriate fittings are used to avoid leaks


RECORD IDLE (TICK OVER) SPEED (After fitting Powerplus)




POST INSTALLATION ADJUSTMENTS


This section applies where there is provision to make manual adjustments to the fuel system.



(a)

PETROL

Adjust ignition timing to the manufacturers specifications. Where adjustments are possible adjust the fuel/air mixture at idle to give the leanest mixture possible without inducing a misfire.

(b)

DIESEL

After a 5 mile (8 Km) road test check the smoke density using an MOT approved smoke meter and procedure. In some cases it is possible to reset the maximum N/S speed for improvements to smoke density without detriment to the vehicle's performance. This procedure should only be carried out by a competent technician with an understanding of diesel fuel injection equipment.




POST INSTALLATION CHECKS AFTER 1500 MILES (2400 KM)


PETROL

Change oil, oil filter and air filter and re-check ignition timing and CO/HC. Adjust where necessary and possible to lowest CO without a misfire. On 3 way catalytic converters with full electronic control, there is no provision to adjust CO. However, provided the Lambda sensor O2  range is wide, the system will tune itself accordingly with improvements to the HC emissions.


DIESEL

Change engine oil, oil filter and air filter. Recheck smoke density, adjust where necessary and possible.



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