TABLE OF CONTENTS -...

©2013 IMPCO Technologies, Inc. Page 1 of 62 2013 GM 5.3L CNG – 50-State Emissions

TABLE OF CONTENTS SAFETY (READ FIRST) ........................................................................................................................ 2

INTRODUCTION ................................................................................................................................... 4

A. Important Vehicle Owner Advisories ........................................................................................... 4 B. IMPCO Automotive Installation Kit Contents .............................................................................. 5 C. Required Tools, Equipment, & Supplies ..................................................................................... 7 D. Torque Specifications ................................................................................................................. 8 E. Installation Notes (READ BEFORE STARTING ANY WORK ON THE VEHICLE) .................... 9

INSPECT FOR CORRECT VEHICLE INFORMATION & THE OPERATIONAL INTEGRITY OF THE ENGINE .......................................................................... 10

A. Preliminary Inspection .............................................................................................................. 10 B. Scan Tool Inspection ................................................................................................................ 11 C. Vehicle Mileage Limit ............................................................................................................... 11

INSTALLATION PROCEDURE .......................................................................................................... 12 A. Pre-Installation Bench Assembly .............................................................................................. 12 B. OEM Component Removal ....................................................................................................... 16 C. Intake Manifold Modification ..................................................................................................... 17 D. Regulator Bracket Mounting & Connections ............................................................................. 21 E. OEM Heater Hose Modification ................................................................................................ 23 F. IMPCO Fuel Rail and Fuel Hose Installations ........................................................................... 25 G. PROPER WIRE SPLICING ...................................................................................................... 30 H. IMPCO ECM & Main Harness Installation ................................................................................ 32 I. Changeover Switch, Buzzer & Interior Pigtail Installation ......................................................... 44 J. Sequent Fuel Pump Simulator Module (FPSM) Installation ...................................................... 50 K. Final Connections .................................................................................................................... 57 L. IMPCO Emission Label & Installer’s Information Label Installation .......................................... 57 M. Protect & Secure the Harnesses, Hoses, Etc. .......................................................................... 58 N. Flash Device (CAN Loader) ...................................................................................................... 58 O. Initial Engine Start .................................................................................................................... 59 P. IMPCO “Delta-P” Pressure Adjustment .................................................................................... 59 Q. Owner’s Guide & Warranty Registration .................................................................................. 60 R. Maintenance ............................................................................................................................ 62


SAFETY

READ BEFORE PERFORMING ANY INSTALLATION, SERVICE,

MAINTENANCE OR REPAIR ON THE FUEL SYSTEM There are safety regulations and standards that must be followed when installing or servicing gaseous fuel equipment. It is highly recommended you obtain and read the following National Fire Protection Association (NFPA) guidelines: SERVICE TECHNICIANS AND USERS: CAREFULLY READ AND ABIDE BY THE PROVISIONS SET FORTH IN THE NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET #37 FOR STATIONARY ENGINES, #52 FOR CNG VEHICULAR FUEL SYSTEMS OR #58 FOR LPG SYSTEMS. INSTALLERS: LPG INSTALLATIONS IN THE UNITED STATES MUST BE DONE IN ACCORDANCE WITH FEDERAL, STATE OR LOCAL LAW, WHICHEVER IS APPLICABLE AND NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET #58, STANDARD FOR STORAGE AND HANDLING OF LIQUIFIED PETROLEUM GASES TO THE EXTENT THESE STANDARDS ARE NOT IN VIOLATION WITH FEDERAL, STATE OR LOCAL LAW. IN CANADA REFER TO CAN/CGA PROPANE INSTALLATION CODES. LPG AND/OR NATURAL GAS INSTALLATIONS ON STATIONARY ENGINES MUST BE DONE IN ACCORDANCE WITH FEDERAL, STATE OR LOCAL LAW AND NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET #37, STATIONARY COMBUSTION ENGINES AND GAS TURBINE ENGINES, TO THE EXTENT THESE STANDARDS ARE NOT IN VIOLATION WITH FEDERAL, STATE OR LOCAL LAW. FAILURE TO ABIDE BY THE ABOVE WILL VOID ANY IMPCO WARRANTY ON THE PRODUCTS AND MAY CAUSE SERIUS INJURY OR PROPERTY DAMAGE. DUE TO THE INHERENT DANGER OF GASEOUS FUELS, THE IMPCO PRODUCTS SHOULD NOT BE INSTALLED OR USED BY PERSONS NOT KNOWLEDGEABLE OF THE HAZARDS ASSOCIATED WITH THE USE OF GASEOUS FUELS. To order these documents, call the NFPA @ 800 344-3555 or go to www.nfpa.org. There are state standards and regulations enforced by the state fire marshal in most states. In Texas, the Texas State Railroad Commission sets standards. There may be other local standards set by counties, cities and municipalities. Be sure to consult all regulatory agencies to assure adherence to all standards and enforcement. Safety in the workplace is everyone’s responsibility. Regardless of the type of work you do, it is very important that you pay attention to what you are doing for your safety and the safety of those around you.

http://www.nfpa.org/


The following points are things to keep in mind when working on internal combustion engines and gaseous fuel systems: Before working on any fuel system, study the NFPA standard for the fuel in use. Before working on any fuel system, read and understand all manufacturers’ recommended

procedures. Before working on any fuel system, make sure you have local code approved safety goggles,

face shields, gloves and clothing. Before working on any fuel system, make sure there is adequate ventilation. Before working on any fuel system or engine, turn OFF the fuel system supply valve and

slowly bleed the fuel from all lines.


INTRODUCTION

A. Important Vehicle Owner Advisories:

• At the time of this writing, the Sequent P&D system has not been certified by the California Air Resources Board (CARB). If the vehicle is moved to California, it may not be registered without returning the vehicle to as-close-as-possible to original condition. Please inform the customer that emissions standards vary state to state and to check with the emissions enforcement agency or DMV prior to moving the vehicle into another state. The IMPCO Automotive EPA & CARB certifications are available at:

http://www.impcoautomotive.com/index.php?pagename=sequent-tech

• The EPA certification on the 2013 GM 5.3L covers vehicles with the E85 fuel option. It is important that the vehicle be run on gasoline with a MAXIMUM of 10% alcohol content with the Plug & Drive system. Operation on E85 fuel may cause rough engine running and possible check engine light illumination during or shortly after the changeover to CNG operation. Please advise your customers before installing the system.

• All 2013 Flex-fuel vehicle Bi-fuel systems have a lockout feature that inhibits the

changeover from gasoline to CNG / LPG during the gasoline alcohol content learn mode (directly after refueling gasoline). If the system attempts a changeover during this period, the Fuel Operation Indicator Lamp (Foil) will change from RED to AMBER and will remain on hold (AMBER lamp illuminated) until the alcohol learn mode has been completed (may be 7-20 minutes). When the alcohol learn mode has been completed the changeover will commence and the FOIL will illuminate GREEN indicating operation on the alternative fuel.

Print this page and place it in the vehicle for the operator’s

reference.

http://www.impcoautomotive.com/index.php?pagename=sequent-tech


B. IMPCO Automotive Installation Kit Contents:

Remove all kit package contents and verify all parts are included and undamaged. Do not attempt to repair any damaged parts. Contact IMPCO Technologies or your distributor for replacement of damaged or missing parts.

2013 GM 5.3L INSTALLATION KIT BOM (CNG – 50-State Emissions Vehicle) KIT PART NUMBER: BNG-53435-02-DE1

F4-53801-001 ADAPTER-FITTING,SAE MALE -8 1 A4-54305-001 ADAPTOR, AMP TO JETRONIX 8 AB4-52143-001 BRACKET ASM, SHIELD, FPSM 1 B4-51205-001 BRACKET, ECM SQNT '08 HD2500 1 B4-54308-001 BRACKET, FUEL RAIL 1 B4-54306-001 BRACKET, FUEL RAIL EXTENSION 1 B4-54306-002 BRACKET, FUEL RAIL EXTENSION 1 B4-54307-001 BRACKET, FUEL RAIL SUPPORT 1 B4-54309-001 BRACKET, FUEL RAIL SUPPORT 1 B4-54271-001 BRACKET, REG MNT 2500HD 1 B4-54149-001 BRKT, RAIL 12 6.0L GM VAN RH 1 C2-16653-4 Clamp Tubing 5/8 1 1077000010 CLAMP, HOSE, COBRA 10/7 W4 16 PPM01832 CLAMP-3/4 HOSE SPRING TYPE 1 PPM01828 CLAMP-3/8 HOSE SPRING TYPE 4 PPM01831 CLAMP-5/8 HOSE SPRING TYPE 4 W3-14211-000 CONDUIT, RND SLIT 13MM BK/GN 14' W3-14211-003 CONDUIT, RND SLIT 25MM BK/GY 10' W3-14211-013 CONDUIT, RND SLIT 9MM BK/GY 15' C8-53357-001 CONN, METRI-PACK 150.2 2F 1 DE815387 ECM, 13 5.3L GM PU/SUV BNG 1 F4-53867-001 FITTING, #8 SAE PLUG 1 21RG03010006 FITTING, 6MM BARBED 9 21RG99020001 FITTING, 6MM HOSE VACUUM "Y" 1 FE077246 FITTING, M6 FUEL END NOZZLE 8 FE077245-3 FITTING, M8 FUEL HOSE BARBED 8 F4-52968-8 FITTING, TEE 37° FLARE -8 SS 1 F4-53749-8-8 FITTING,45 DEG JIC TO SAE -8 1 PPM01829 FITTING-5/8 X 3/8 WYE 2 D53GMT93BNG FLASH, 13 5.3L GM PU/SUV BNG 1 F5-54600-001 FUSE TAP, MINI BLADE 1 F5-54517-001 FUSE, 5A, BLADE 1 G3-51280-002 GROMMET, 3/8"IDX1"ODX1/16" 1 AW-54154-001 HARNESS, BOSCH TO SEQUENT, CNG 1 AW-53597-001 HARNESS, GM 5.3 FUEL PUMP SIM 1 AW-51955-003 HARNESS, GM V8, INJECTOR 1-4 1 AW-51955-004 HARNESS, GM V8, INJECTOR 5-8 1


DE524014 HARNESS, P&D 8 CYL W/PTS, LPG 1 H1-19231-007 HOSE, 3/4" ID FUEL/OIL BULK 5' H1-51561-001-0254 HOSE, BRC CUT, 5MM X 254MM 8 H1-50716-001 HOSE, COOLANT 3/8 DIA 2' H1-53936-007 HOSE, EXTENSION 17.5" 1 H1-53936-001 HOSE, EXTENSION, 22.5" 1 H1-53936-002 HOSE, EXTENSION, 8.0" 1 22TB00045145 HOSE, FUEL VAPOR 5MM ID, BULK 0.56 MT PPI-A-065 IMPCO AUTO BNG OWNERS GUIDE 1 IJ-52694-001 INJECTOR, NGI2 8 R5-53291-001 ISOLATOR, RUBBER, SER 5000 2 L3-51854-001 LABEL, CNG NO E85 FLEX VEHICLE 1 L3-51853-001 LABEL, CNG OWNER ADDENDUM 1 L3-53545-001 LABEL, INSTALLER INFORMATION 1 L3-51857-001 LABEL, NO E85 FUEL DOOR 1 L3-53103-002 LABEL,1" SHRINK TUBE, MAX W.P. 3 L3-53862-001 LABEL,IMPCO POWERED CNG 1 PPI-A-107 MAN, 13 5.3L GM PU/SUV 381 BNG 0 PPI-53029-002 MANUAL, WARRANTY STATEMENT 1 MD-52542-001 MODULE, FUEL PUMP SIM, '11 GM 1 N1-30876-M06 NUT, HEX FL SR M6X1.0 3 FE077244 NUT, M8X1 ES. 10 TURN FITTING 8 R8-53761-001 RAIL,BOTTOM,BOSCH GM 6.0L 4 R8-53760-001 RAIL,TOP,BOSCH 6L W/O PTS RH 2 P214-930 REG, 9.3 BAR W / VAC & ECT 1 S1-51827-004 SCREW, #10 TEK HEX X 3/4" 2 S1-30871-02-0625 SCREW, FL HD M6X25MM 4 S1-30871-02-0610 SCREW, HEX FL M6X10MM 4 S1-50237-2021-0840 SCREW, HEX FLANGE M8-1.25X40MM 2 S1-30871-02-0616 Screw, Hex Flange, M6 x 16MM 3 S1-30871-02-0635 SCREW, HEX FLANGE-M6-35MM 12 S1-30295-0650 SCREW, HEX SOCKET CAP 2 S3-53991-001 SEAL, JIC #8 37 DEG, COPPER 7 DE802060 SENSOR ASSY, MAP 1 S8-53861-001 SENSOR, FUEL PRESSURE TEMP 1 S3-51446-001 SPACER, ECM, BRC SEQUENT 2 P31-102 -STAINLESS STEEL FITTING, 3/4 2 06LB00001981 SWITCH, FUEL SELECT (HALL EFF) 1 T4-53358-001 TERM, METRI-PACK 150.2 F 2 T4-50880-001 TERM.,EYE 1/4" STUD 12-10 GA 2 T4-50879-001 TERMINAL, WIRE SPLICE 22-16 GA 10 H5-15342-1 TUBING, HEATSHRINK 3/16" BULK 1' L3-54574-001 VECI,13 5.3L GM PU/SUV 381 BNG 1 92930400 WASHER, FENDER M8 8.4X24X2 4


AW-54322-3000 WIRE, SEQUENT PIGTAIL 1 AW-54321-1000 WIRE, SEQUENT TO GM E38 1 01/28/13 C. Required Tools, Equipment & Supplies:

• Sequent Installer’s Tool Kit (part # 90AV99004048) • USB Serial Cable (part # DE512222) • SAE and metric mechanic’s hand tools • Electric or cordless drill and assorted drill bits • Large hose clamp pliers (4) • Heat gun • Soldering iron • Solder (60/40 electronic core – 0.7 to 1mm diameter works best) • DVOM and assorted test leads • Wire/Terminal crimpers capable of handling 10-12 gauge (5.5mm2), non-insulated barrel

terminals and 18-16 gauge (2.0mm2) “U” style splices • Wire stripper • Automotive electrical wires in various colors and gauges • Electrical tape • PC or laptop with Sequent P&D software installed • Leakdown tester • Standard mechanic’s diagnostic tools • OBD-II compliant scan tool (CAN enabled) • OEM upper intake manifold gasket set • OEM factory service manual • NFPA approved CNG fuel line and fittings as necessary • Loctite 592 sealant (or equivalent) • Vehicle lift (optional, HIGHLY recommended) • Shop vacuum • 6x1mm pulley tap • Dielectric grease • GM Super Lube with PTFE (part #12371287) • 3M high-temperature aluminum tape (2113NA) or equivalent • Bungee cords and/or mechanic’s wire • High-pressure CNG coalescing filter


D. Torque Specifications:

• Fuel rail pressure / temperature sensor .................................................... 11-15 ft-lbs (15-20 Nm) • CNG high-pressure filter mounting (banjo) bolt ......................................... 15-22 ft-lbs (20-30 Nm) • CNG high-pressure filter blocking screw ................................................... 37-52 ft-lbs (50-70 Nm) • CNG Pressure Transducer ....................................................................... 22-26 ft-lbs (30-35 Nm) • Regulator temperature sensor ........................................................................... 89 in-lbs (10 Nm) • MAP sensor mounting nut ........................................................................ 20-24 ft-lbs (28-32 Nm) • Fuel nozzles ................................................................................................... Hand tight + ¼ turn • 6mm bolts / nuts ................................................................................................ 89 in-lbs (10 Nm) • 8mm bolts / nuts ................................................................................................. 15 ft-lbs (20 Nm) • Fuel nozzle nuts (8mm) ....................................................................................... 62 in-lbs (7 Nm) • Fuel rail pressure / temperature (PT) sensor ...................................................... 11 ft-lbs (15 Nm) • Fuel nozzles ................................................................................................... Hand tight + ¼ turn • #8 SAE O-ring fittings ...................................................................................... 35 ft-lbs (47.5 Nm) • #8 JIC fittings (with copper sealing washers) ......................................... 41.5-46 ft-lbs (56-62 Nm)

o The sealing washer will have a tendency to compress during the tightening process. Due to the compression of the washer, a second torquing of the nut is required. Tighten the fitting to the specified torque value, wait 15 seconds and re-torque the fitting to the same value.

o When using a crow’s foot to tighten the JIC fittings, keep the torque wrench at a 90O angle to the crow’s foot to minimize deviation from the indicated torque value.


E. Important Installation Notes:

• Anytime the OEM painted surface is broken by drilling, component removal, etc, the

exposed metal surfaces must be protected from corrosion. This is especially important in areas where salt is used on the roads during the winter months. GM recommends their Super Lube with PTFE (part #12371287, GM bulletin #03-00-89-008D). Follow the instructions in the bulletin to ensure a positive outcome.

• DO NOT use Teflon tape on any fittings. Teflon tape may get into the regulator primary and secondary seats and the fuel injector seats causing fuel pressure problems. Any warranty returned item found contaminated with Teflon tape will be returned.

• DO NOT use products containing SILICONE to lubricate or seal any components on the intake system, exhaust system or engine unless they are labeled “Oxygen Sensor Safe”.

• ALL CNG installations MUST have a coalescing filter installed in the high-pressure CNG line (refer to TSB-A-021 for more information on filter types).

Read and understand this entire manual to familiarize yourself with the kit installation BEFORE starting any work.

The following items must be protected against chaffing, cutting and damage with corrugated conduit, expandable sleeving, wire ties or clamps, etc.: • All fuel hoses. • All coolant hoses. • All wiring harnesses. Failure to heed this warning may result in equipment failure, a fire or personal injury.

NOTE: For illustration purposes, many photos do not show the protective coverings and anchors.

Always wear eye protection when working with spray chemicals and compressed air. Failure to heed this warning may result in severe eye damage and blindness.


INSPECT FOR CORRECT VEHICLE INFORMATION & THE OPERATIONAL INTEGRITY OF THE ENGINE

Installing an alternative fuel system into a vehicle with an engine or ignition system that is in poor condition will produce less than desirable results and may lead to exhaust emissions beyond acceptable levels. It is strongly advised that all of the following inspections be done BEFORE installing the Sequent P&D system. A. Preliminary Inspection:

The preliminary inspection should consist of a visual inspection of the following items: • Emissions Label for correct Model Year, Engine Group, Evaporative Emissions Family.

o Model Year: 2013 ONLY o Engine Group: DGMXT05.3381 5.3L ONLY o Evaporative Emissions Family: DGMXR0176820, DGMXR0223610 or DGMXR0223840

ONLY

OEM Emissions Label

NOTE: Even though the vehicle is a 50-state emissions vehicle, this IMPCO Automotive Bi-Fuel kit CANNOT be installed in states that have adopted California Air Resources Board (CARB) emissions standards for aftermarket systems. Contact the local state emissions regulatory board for applicable standards. • Air filter and intake plumbing condition. • Engine gaskets and seals for leaks. • Exhaust system condition. • Cooling system for leaks. • Under-hood wiring and hose condition. • Inspect the secondary ignition wire, ignition coils and suppressor caps for any signs of damage

or wear. • Repair or replace any faulty items.


B. Scan Tool Inspection:

Connect an OBD-II compliant scan tool to the vehicle DLC connector and check the following: • Active or historic fault codes (follow the OEM’s diagnostic recommendations for any codes

found and make necessary repairs). • OBD monitors for completion and passed tests.

o If all applicable monitors have not completed, drive the vehicle until they have completed & passed.

o If any monitors have failed a test, follow the OEM’s diagnostic recommendations and make any necessary repairs.

C. Vehicle Mileage Limits: Installation of IMPCO Automotive dedicated and bi-fuel systems are limited to vehicles with less than 25,000 miles (40,322 kilometers).

MAKE ANY NECESSARY REPAIRS BEFORE INSTALLING THE IMPCO SYSTEM.


INSTALLATION PROCEDURE A. Pre-Installation Bench Assembly:

DRIVER Side Fuel Rail Bracket

1) Locate: • 2 – Upper fuel rails • 4 – Lower fuel rails • 1 – Allen socket #8 SAE plug • 2 – 45O #8 SAE x #8 • Fuel rail Pressure / Temperature (P/T)

sensor • PT sensor adapter bushing

2) Find the bracket that will require two mounting extensions, (Ts), and one rail support.

Illustration shows rail support already installed.


3) Install the two mounting extensions (Ts) to make the DRIVER side fuel rail mounting bracket as shown. Tighten the bolts to 89 in-lbs (10 Nm).


4) Lubricate the P/T sensor bushing O-ring and threads with a little clean engine oil and install it into the SHORT end of one of the UPPER fuel rails torquing it to 25 ft-lbs (34 Nm).

5) Lubricate the P/T sensor O-ring and threads with a little clean engine oil and install it into the bushing torquing it to 11 ft-lbs (15 Nm).

NOTE: Both upper fuel rails have the word FRONT with an ARROW indicating the front of engine. This is NOT the case for this application. All top fuel rails have a short end and a long end. DRIVER side short end of the upper fuel rail will take the P/T sensor. PASSENGER side short end of upper fuel rail will take a plug. BOTH upper fuel rail arrows should point to the rear of the engine.


6) Install the straight male adapter fitting to the DRIVER upper fuel rail as shown. Tighten the male adapter fitting to 25 ft-lbs (34 Nm). Set DRIVER side fuel rail and bracket to the side.


PASSENGER Side Fuel Rail Bracket

7) Install the support arm to the PASSENGER side fuel rail bracket with a nut and bolt. Tighten the bolt to 89 in-lbs (10 Nm).

8) Lubricate the O-ring on the plug with clean engine oil and install the plug to the arrow side of the fuel rail. Tighten the plug to

35 ft-lbs (47.5 Nm). 9) Lubricate the O-ring on the 45 degree

male adapter fitting and install it to the PASSENGER side fuel rail, but DO NOT tighten at this time. Set PASSENGER side fuel rail and bracket to the side.

10) Apply a little Loxeal to the eight 6mm brass barbed hose nipple threads and install them into the LOWER fuel rails torquing them to 35 in-lbs (3.9 Nm). Set the lower fuel rails to the side.


11) Locate : • Bracket • 2- M8X40MM • 4- M8 8.4X24X2 Fender Washers • 1- Regulator • 2- Rubber Isolators • 1-Fuel Fitting

12) Install fuel outlet fitting to the regulator. NOTE: It’s much easier to install and torque both fuel outlet and inlet fittings before installing the regulator to the bracket (use a soft-jaw vice). OUTLET fitting torque value is 18-22 ft-lbs (24.4-29.8 Nm). INLET fitting torque value is 12-16 ft-lbs (16.3-21.7 Nm).

13) Install the regulator to the bracket using two bolts washers and isolators. Tighten the regulator bolts to 15 ft-lbs (20 Nm).


14) Locate: • MAP sensor • Bracket MAP

15) Fabricate the MAP sensor bracket as illustrated.

16) Mount the MAP sensor in the bracket torquing the nut to 20-24 ft-lbs (28-32 Nm) (noting the location of the connector security lock boss).

B. OEM Component Removal:

Prior to disassembly, clean the engine and engine compartment (with engine degreaser where necessary). Following the manufacturer’s recommended procedures, remove:

• Disconnect battery • Intake manifold (tape the cylinder head intake ports to keep dust and debris out of the engine) • Fuel rails (remove from intake manifold)


C. Intake Manifold Modifications:

1) Locate: • Pre-assembled fuel hoses • 6x1mm pulley tap NOTE: Pulley taps can be purchased through a number of tool stores on the Internet, catalog stores or locally through machine shop suppliers. A few Internet / catalog suppliers are: o ENCO o ICS Cutting Tools o Regal Cutting Tools

2) Using the long 5mm drill in the Installer’s Tool Kit, drill through the flat portion of the intake runners as illustrated. Start with the runners that have the upper manifold location nipples. NOTE: Use a 1/16” drill bit to drill a pilot hole in the center of the nipple as a guide then finish with the 5mm drill.

3) Finish drilling the other runners in the same location on the flats.

4) Tap the holes that are accessible from the top of the manifold with the combination tap in the tool kit.


5) Flip the intake manifold over and (using the 6x1mm pulley tap), tap the remaining runner holes being careful to hold the tap handle perpendicular to the hole.

6) Locate: • 8 – barbed hose fittings • 8 – 8x1mm nozzle nuts • 8 – fuel nozzles • 8 – 10.0 hose clamps • 8 – 254mm x 5mm ID injector hoses

7) Assemble the eight fuel injector hoses as illustrated torqueing the nozzle nuts to 62 in-lbs (7 Nm).

8) Secure the clamps with the hose clamp pliers.

9) Apply a light coat of Loxeal to each of the fuel hose nozzle threads.


10) Thread each of the injector hoses into the eight tapped holes hand tight plus 1/4 turn. DO NOT OVERTIGHTEN!

11) Apply a light coat of engine oil to the OEM injector o-rings and re-install the OEM fuel rail assembly (but DO NOT install the fuel rail bolts at this time).

12) If vacuum port end plug is not being used, remove the end plug for a vacuum source.

13) If OEM vacuum port is being used, drill and tap a new vacuum port in the top of the intake manifold before installing intake back on engine.

14) Install a brass nipple with a light coat of Loxeal to the threads of the brass nipple before installing into the intake manifold. NOTE: DO NOT over tighten.

15) Install the intake manifold and torque the bolts to the following values and illustrated sequence: 1st Pass: 44 in-lbs (5 Nm) 2nd Pass: 89 in-lbs (10 Nm)


16) Route all of the CNG injector hoses between the fuel rails and the intake manifold plenum.

17) Install the four OEM fuel rail bolts. Torque the four fuel rail bolts to 89 in-lbs (10 Nm).

18) Connect the OEM gasoline supply hose to the fuel rail and install the safety retaining clip.

19) Install the purge line and connector.


D. Regulator Bracket Mounting & Connections:

1) Locate: • Regulator Bracket Assembly • Pressure Relief Device (PRD) • 1 – 3/4 Spring Clamp • 3/4 Fuel Line • 3/8 hose • 2 – 3/8 Spring clamps • 1 – 06x16mm Bolt • 1 – M6 Nut

2) Remove two bolts from the PASSENGER side front fender upper brace.

3) Insert the regulator bracket bolt through the hole in the battery tray as shown.


4) Install the regulator bracket using the top two front fender upper brace bolts along with the nut and bolt at the battery tray.

5) Tighten two front fender upper brace bolts to 15 ft-lbs (20 Nm).

6) Tighten the bolt and nut at the battery tray to 80 in-lbs (9 Nm).

7) Install the PRD (3/4” hose) with a spring clamp to the regulator.

8) Run the PRD hose down and out of the engine compartment, down by truck frame. Secure hose with tie wrap.

9) Install both 3/8 coolant hose’s to the regulator with spring clamps.


E. OEM Heater Hose Modifications:

1) Locate: • 2 – 3/8 Spring Clamps • 4 - 5/8 Spring Clamps • 2 – Coolant Ys

2) Connect the 3/8 hose from the regulator to the 3/8 nipple of both Ys using spring clamps.

NOTE: Make sure when installing the Ys that the 3/8 ends of the Ys are pointed with the direction of coolant flow.

3) Using hose clamp pliers, clamp off both heater hoses on engine (inlet and outlet).

4) Lay both coolant hose’s from the regulator to the heater hose’s on the PASSENGER side of the vehicle making a smooth transition not to kink the hose.

5) Mark both heater (inlet and outlet) hose’s to be cut for the Ys.

6) Cut 2 1/2 inches out of each heater hose for installation of the coolant Ys.


7) Install the Ys so the 3/8 ends of the Ys are pointed in the right direction for proper coolant flow in and out of the regulator.

8) Install 5/8 spring clamps to all coolant connections.


F. IMPCO Fuel Rail and Fuel Hose Installations:

1) Locate: • 4 – Lower fuel rails • 2 – Upper fuel rails • 6 – Mounting bolts • 8 – Injectors • 8 – Fuel hose clamps • 8 – Bolts

2) Install the fuel hose from the intake manifold to the brass barbed nipples of the lower fuel rails.

3) Clamp the fuel hose to the brass barbed nipples and cover the fuel hose’s with conduit.

4) Install the fuel hose’s to both DRIVER and PASSENGER side lower fuel rails the same way.

5) Remove the upper coil bolts from both PASSENGER and DRIVER side and replace them with the new longer bolts when installing both PASSENGER and DRIVER side fuel rail brackets.

6) Bolt both rail brackets in place with two 6x25mm bolts in the coil upper bolt holes and torque them to 89 in-lbs (10 Nm).

7) Bolt both bracket supports, (DRIVER PASSENGER), to the top of the intake manifold and tighten to 80 in-lbs (9 Nm).


8) Install the DRIVER side lower fuel rails with four bolts.

9) Torque the lower fuel rail bolts to 89 in-lbs (10 Nm).

10) Lube the injector O-rings with clean engine oil and insert four injectors into the DRIVER’s side lower fuel rails.

11) Install the MAP sensor to the PASSENGER side front lower fuel rail as shown.

12) Torque the lower fuel rail bolts to 89 in-lbs (10 Nm).

13) Lube the injector O-rings with clean engine oil and insert four injectors into the PASSENGER side lower fuel rails.

14) Install the PASSENGER side top fuel rail to the injectors by pushing down to seat the O-rings.

15) Install the two bolts to the PASSENGER side top fuel rail and torque the bolts to 89 in-lbs (10 Nm).

16) Position the 45 degree male fitting down as shown. Tighten the male adapter fitting lock nut to 25 ft-lbs (34 Nm).


17) Lube the injector O-rings with clean engine oil and insert four injectors into both lower fuel rails of the DRIVER side.

18) Install the DRIVER side upper fuel rail with the P/T sensor to the back of the engine.

19) Install the DRIVER side top fuel rail to the injectors by pushing down to seat O-rings.

20) Install the two bolts to the top fuel rail and torque the bolts to 89 in-lbs (10 Nm).

21) Install the eight jetronix adapters to all injectors.


22) Locate the three fuel hose’s, one P- clip, copper seals, and one T fitting.

NOTE: Install copper seals to all male fuel fittings.

23) Snug the “T” in a vise (taking care not to damage the nut or exposed threads) and install three of the copper washers onto the male JIC fittings.

24) Apply a little engine oil to the fitting threads.

25) Install the three braided hoses onto the “T” and torque them to 41.5-46 ft-lbs (56-62 Nm) with an open-end crow’s foot and torque wrench.

NOTES:

• Refer to the Torque Specifications section on page 8 for proper use of a torque wrench with a crow’s foot.

• Tighten the fitting to the specified torque value, wait 15 seconds and re-torque the fitting to the same value.


26) Connect the fuel hose’s from the upper fuel rail to the T fitting and from the T fitting to the regulator.

27) Tighten fuel connections to 41.5-46 ft-lbs (56-62 Nm).

28) Install the P- clip to the air intake bolt to secure the fuel line. Cover the fuel lines with conduit.


G. Proper Wire Splicing:

Terminal Crimping: There are two types of terminals used in the installation of the Sequent P&D wiring harness. To ensure a good crimp, use the appropriate style crimping tool (including the correct gauge) as illustrated below. NOTE: Not all crimping tools are made exactly the same. Experiment with different tools to achieve the best crimps possible before working on the vehicle’s wiring harness. The first crimp style is the “U” splice crimp used to splice the Sequent P&D harness circuits to the OEM harness circuits.

“U” Style Crimping Tool

“U” Style Crimp (Before & After Crimping)

The second crimp style is the “Barrel” style, non-insulated lug terminal used to connect the Sequent P&D harness to the B+ & B– connections.

“Barrel” Style Non-Insulated Crimping Tool

“Barrel” Style Crimp (Before & After Crimping)

IMPORTANT NOTE: After crimping either style terminal, be sure to solder the connection as illustrated on the next page before shrink wrapping.


Soldering Crimps & Terminals: Solder all terminals after crimping as illustrated using an electronic grade, rosin core solder (0.7 to 1.0mm diameter works best). Make sure all wires in the terminal receive adequate solder to ensure a permanent connection.

“Barrel” Style Lug Terminals

Heat the terminal and apply the solder from the

lug side of the crimp to minimize “wicking” solder up the wires, which may lead to wire breakage.

Securing the wires to adjacent harness looms will help minimize this risk.

“U” Style Splice Crimps

Heat the terminal and apply the solder in the

center of the crimp fold, allowing it to “wick” into the joint. Do not worry if some of the solder wicks into the wires as they will be secured by the wiring

loom. Shrink Wrapping Connections: Shrink wrap all splices and the positive battery lug. Cut the adhesive lined shrink tubing into 1 to 1 ½” (25-38mm) pieces. Use a heat gun with a U-shaped nozzle to heat the shrink tubing uniformly as illustrated.

Familiarize yourself with ALL schematics and electrical diagrams BEFORE splicing wires. Some of the modules and Sequent ECU share the same electrical connections (splices).


H. IMPCO ECM & Main Harness Installation:

1) Locate: • Sequent ECU • ECU bracket • 2 – Aluminum spacers • 2 – 6x50mm socket screws • Main Electrical Harness

2) Remove the two bolts from the DRIVER’s battery tray.

3) Install the ECM bracket to the battery tray with two bolts. Tighten the bolts to 80 in-lbs (9 Nm).


4) Install the ECM to the bracket with two bolts and two spacers. Tighten the bolts to 80 in-lbs (9 Nm).

5) Locate the main sequent harness.

6) The sequent ECM connector locktab needs to be reversed in this installation.

7) Using a small screw driver, depress the locktab retainer on one side of the connector, then the other while lightly pulling out on the locktab.

8) Pull the locktab out of the connector.


9) Insert the locktab into the connector from the reverse side until the retainers click into place.

10) Install the main connector to the ECM.

NOTE: See wiring schematic attachment at the end of this manual for proper wire connections and splices.

NOTE: Although the Sequent injector connector wires are laser numbered as illustrated, it is a good idea to add numbered wire marker labels such as 3M Scotch Code TM Wire Markers (part # SPB-01)} onto the pigtail conduits.


11) Lay the main sequent harness across the engine.

12) Install the injector harness to the injector adaptors on both DRIVER and PASSENGER side.

NOTE: Be sure to match the number on the injector wiring to the CNG injector as illustrated.

13) Cut off the coolant temperature connector from the harness and install new using C8-53357-001 and

T4-53358-001. 14) Install the new connector with the

YELLOW & BLUE wires to the regulator coolant temperature sensor.


15) Install the connector with the GREEN/GREEN / BLACK stripe wire to the regulator lockoff.

16) Locate the RED power wires and BLACK ground wires.

17) Install one ring terminal end to both RED wires and one ring terminal end to the BLACK ground wires.

18) Install the two RED wires to the Power Distribution Center (PDC) stud on the DRIVER’s side.

19) Torque the nut to 80 in-lbs (9 Nm).


20) Ground the black wire’s to the DRIVER’s side bulkhead ground stud.

21) Torque the screws to 80 in-lbs (9 Nm).

22) Remove the clip from the main harness fuse block.

23) Using the two 6x12mm bolts, install the relay and fuse clip onto the DRIVER’s inside front fender as illustrated. Torque the bolts to 80 in-lbs (9 Nm).

24) Install the fuse block onto the clip

25) Locate the regulator pressure switch harness (AW-54154-001) in the kit.


26) Install the connector to the pressure switch on the regulator.

27) Open the harness covering from the main connector and find the RED wire in the harness.

28) Strip back the covering from the RED wire in the harness and solder the RED wire from the regulator pressure switch harness to it. Refer to attached wiring diagram at the end of this installation manual.

29) Cover all wires with shrink tubing.

30) Locate the WHITE wire extension to be used to jumper the main sequent ECM to the OEM PCM connector.


31) Slide the purple lock to remove the sequent ECM main connector.

32) Remove the YELLOW terminal lock form the main connector.

33) Remove the cover from the back of the main connector.

34) Use the proper tool to release the white wire terminal from pin #13.


35) Remove the WHITE wire form pin #13 of the main ECM connector. Tape over and fold WHITE wire back into the harness.

36) Install the new WHITE wire extension into pin #13. NOTE: Push and pull, the WHITE wire, to insure new terminal is locked into the ECM main connector.

37) Install the back cover to the ECM main

connector.

38) Slide the red lock on connector X1 of the OEM Power Control Module (PCM) to release the lever.

39) Lift up the X1 lock lever connector, then pull and rock connector to remove connector form the PCM.


40) Pry the terminal lock on both sides of PCM connector, as shown, taking care not to break.

41) Find terminal #40 of the PCM connector.

42) Remove the back of the PCM connector.

43) If Pin #40 cavity has a plug like this it will need to be removed.


44) Use appropriate tool to lightly punch out the molded plug from cavity #40.

45) This is the molded plug that needs to be removed before assembly. Failure to remove plug will cause permanent damage to the PCM connector.

46) Install the WHITE extension wire into pin #40 of the PCM connector.

NOTE: Pull on WHITE extension wire terminal to insure terminal is locked into the cavity.

Example shown


47) Install the connectors back together making sure that all terminal connections are secure. Wrap wires with tape as needed, cover and tie wrap secure.

48) WHITE wire extension from ECM to PCM connector now complete.

49) Cover all hoses and wires with conduit to prevent rubbing and chaffing.

50) Tie wrap all hose’s and wires to secure but allow for engine movement.


I. Changeover Switch, Buzzer & Interior Pigtail Installation:

1) Locate: • Grommet • Main harness interior pigtail (two small

connectors) • Changeover switch & buzzer • Heat-shrink tubing • Fuse tap

2) Locate the interior harness bundle and find the BROWN wire.

3) Approximately 10” from the main connector make incision into the black harness covering, big enough to pull out the BROWN wire by the underhood fues box.

4) Pull the BROWN wire out of the incision you just made.

5) Cut and remove the barrel connector from the fuse tap RED wire.


6) Solder the RED fuse tap wire to the BROWN wire from the harness.

7) Cover connection with shrink tube.

8) Cover the wires with conduit, and tape the incision where you pulled the brown wire out of the black interior harness bundle.


9) Looking on the lid of the underhood fuse box cover, find item #56 ECM IGN.

10) Remove the 15 amp fuse from #56.

11) Install the 15 amp fuse to the fuse tap with the 5 amp fuse on top as shown.


12) Install the fuse tap to the underhood fuse box #56.

13) Route the wire around the fuse box as shown, tucking it in nice and neat while also tie wrapping to secure.

14) Follow the main OEM harness out the underhood fuse box.

15) Location under hood for interior harness routing.

16) Remove the bulkhead mat cut-out from behind the cabin fuse / relay box DRIVER’s side.


17) Drill a 3/4" diameter hole where indicated (blue arrow) and install the grommet onto the interior pigtail.

18) Route the pigtail through the hole, position the grommet in the hole and seal the grommet / pigtail interface with silicone seal.

NOTE: Lubricating the grommet groove with a little WD-40 or equivalent will aid in installing the grommet into the hole.

19) The Changeover Switch will be installed in a 7/8” (22mm) diameter hole where illustrated.

20) Following the manufacturer’s procedures, remove the DRIVER side vent panel.

NOTE: DO NOT drill the changeover switch hole where there are any ribs, clips etc. on the backside of the panel.

21) Remove the outer bezel from the changeover switch.


22) Route the changeover switch and buzzer connector pigtails up to the switch location.

23) Install the switch into the 7/8” diameter hole and plug in the connector.

24) Attach the two-sided foam tape to the back of the buzzer and plug in the buzzer connector.

25) Attach the buzzer where indicated.

26) Referring to the Installer’s Wiring Diagram, make the CAN line connections at the OEM OBD-II/ DLC.

27) Lower the OBD-II/ DLC down and find the TAN wire, pin #14.

28) Take the YE/BK twisted wire and attach it to the TAN wire.

29) Take the twisted YELLOW wire and attach it to the TN/BK wire, pin #6.

30) Install the OBD-II/ DLC back under the IP. 31) Cover all connections with shrink tubing. 32) Tie the harness up and out of the way. 33) Reinstall interior panels.

NOTE: Refer to attached wiring diagram at the end of this installation manual for proper splicing and connections.

Installation is complete


J. Sequent Fuel Pump Simulator Module (FPSM) Installation:

1) Locate: • Fuel Pump Simulator Module (FPSM) • FPSM harness (AW-53597-001) • GM Super Lube with PTFE • FPSM shield kit (includes):

o Shield o 2 – 20mm long aluminum spacers o 2 – 6x55mm flange bolts o 2 – 6mm flange nuts o 2 – #14 x 3” TEK screws

Following FPSM MOUNTING PROCEDURE FOR

5.3L-1500 ONLY 2) The FPSM will be installed on the driver’s

side of the cab. 3) Make two dimples on the driver’s side rear

cab surface where indicated in the photo (102mm apart, 125mm from the bottom edge).

4) Drill two ¼” diameter holes at the dimple marks.

5) Apply a liberal amount of GM Super Lube to both sides of the holes.


6) Apply some dielectric grease to the harness connector as illustrated before connecting to the module.

7) Plug the connector into the FPSM and apply some additional dielectric grease to the outside of the connector as illustrated.

8) Slip the bracket over the module with the wires exiting the module (as illustrated).

9) Slip the spacers between the module and the bracket and install the 6-55mm bolts through the bracket, spacers and module.


10) Holding the flange bolts in the bracket with two fingers, insert the ends of the bolts through the holes drilled in the cab and install the module onto the rear face of the cab with the two 6mm nuts torquing them to 89 in-lbs (10 Nm). Refer to attached wiring diagram at the end of this installation manual for proper splicing and connections.

Following FPSM MOUNTING PROCEDURE FOR

5.3L-SUV ONLY 11) Assemble the module / shield as illustrated.

12) Apply some dielectric grease to the harness connector as illustrated before connecting to the module.


13) Plug the connector into the FPSM and apply some additional dielectric grease to the outside of the connector as illustrated.

14) Mount the FPSM / shield assembly onto the OEM bracket.

15) If the OEM bracket is going to be moved for clearance with under-chassis fuel tank(s), then mount the FPSM on the rear beam with the #14 x 3” TEK screws (closed end of the shield facing the front of the vehicle).

DO NOT mount the FPSM / shield assembly where it may interfere with the differential or other rear end / suspension components.


16) Route the fuel pump and rear lockoff pigtails up to the front of the fuel tank and secure them to the gasoline tank fuel tube.

17) Locate the OEM fuel pump connector (top of the fuel tank on the left-front corner).

18) Unplug the fuel pump connector and plug the FPSM fuel pump connectors into the OEM fuel pump and harness connectors as illustrated.

19) Route the rear lockoff pigtail as necessary to reach the CNG tank rear lockoff connector (may vary from installation to installation depending on tank orientation).

20) Keep routing the fuel pressure sensor and engine compartment pigtails along the OEM harness towards the front of the vehicle.


21) Route the fuel pressure sensor pigtail over the top of the frame rail over to the OEM fuel pressure sensor as illustrated.

22) Continue routing the engine compartment harness along the OEM harness up into the DRIVER’s side of the engine compartment.

23) The engine compartment pigtail routes into the engine compartment under the brake fluid reservoir.

24) Use the GREEN wire from the plug & drive harness and connect it to the GREEN wire of the FPSM harness.

Refer to attached wiring diagram at the end of this installation manual for proper splicing and connections.

25) Unplug the OEM fuel pressure sensor connector and plug the FPSM connectors into the pressure sensor and the OEM pressure sensor connector as illustrated.

26) Secure all of the FPSM pigtails with electrician’s tape, wire ties, etc.


27) Install the purple wire # AW-54322-3000 (pig tail) to pin #7 of the P&D ECM and splice the other end to the purple wire of Pin #1 of the fuel pressure sensor.

Refer to attached wiring diagram at the end of this installation manual for proper splicing and connections.

Installation is now complete.


K. Final Connections:

1) Leak test the entire CNG and gasoline fuel systems with applicable code approved equipment.

2) Re-install all OEM components except for the engine cover (where applicable).

3) Reconnect the battery cables. 4) Refill the coolant to the proper level.

L. IMPCO Emission Label & Installer’s Information Label Installation:

1) Locate: • IMPCO Vehicle Emission Control

Information (VECI) label • Installer’s information label

2) Attach the IMPCO Automotive VECI labels where illustrated.

• The following IMPCO Automotive EPA

VECI label information MUST match the OEM VECI label information: o Engine group o Evap family (where applicable)

If they DO NOT, call the IMPCO Automotive techline for instructions. • Both the IMPCO Automotive ARB AND

EPA VECI labels MUST be affixed to the vehicle where illustrated and BEFORE the vehicle is driven on public streets.

• DO NOT remove, alter, cover or destroy the OEM VECI label.

Consult TSB-A-019 for further information concerning VECI label placements. • Fill out the installer’s information label

completely and affix it where indicated.

The IMPCO Automotive VECI label must be affixed to the vehicle BEFORE it is driven on public streets.


M. Protect & Secure the Harnesses, Hoses, Etc:

1) Locate: • 13 & 25mm split loom

2) Protect all remaining harnesses & hoses with split loom, electrician’s tape, expandable sleeving, etc.

3) Secure any loose hoses, harnesses, etc. with plastic wire ties or clamps as necessary.

4) Protect all wiring, hoses and system components exposed to excessive exhaust temperatures with 3M high-temperature aluminum tape (2113NA) or equivalent.

5) Re-install the engine cover (modifications will be necessary).

N. Flash Device (CAN Loader):

1) Connect to the OBD-II port. 2) Turn the ignition to Key On / Engine Off. 3) Follow the on screen instructions.

NOTE: Make sure the VIN number on the flash device matches the VIN number of the vehicle.


O. Initial Engine Start:

1) After making all fuel system leak and installation inspections, make sure the changeover switch is set for Gasoline operation (key on, fuel level indicator lamps NOT illuminated).

2) Drive the vehicle for 5-10 miles on GASOLINE before operating on CNG to allow the engine to normalize.

3) Connect an OBD-II scan tool to the OEM DLC connector.

4) With the OBD-II scan tool, verify there are no pending or hard codes.

5) If any codes appear, diagnose the cause and repair before continuing.

6) Once the engine has normalized, depress the changeover switch for CNG operation. When the system begins changing over to CNG operation, the engine should continue running without hesitation or stumbling. If the engine begins running rough during the changeover cycle, then 2 or more of the injector connectors are misplaced. Perform the Injector Changeover Test [Diagnostics section of the Sequent P&D Display Software User Manual (Cert)].

7) Verify there are no OBD-II codes then disconnect the OBD-II scan tool. NOTE: The engine may stumble a little on initial changeover due to air that may still be in the CNG line.

P. IMPCO “Delta-P” Pressure Adjustment:

“P1” Pressure Highlighted with Red Box

1) With the engine running at 1200-1500 RPM, operating on CNG and at operating temperature, open the display software and select the “P1” pressure for graphing (see the Diagnostics section in the Sequent P&D Display Software User Manual (Cert) for graphing instructions). The “P1” pressure should be between 9000 to 9600 mbar. Raise the engine RPM to approximately 2500 and verify the “P1” pressure does not drop more than 100 mbar. If it does, verify there is adequate fuel in the CNG tank, then check for restricted fuel lines.

2) If the “P1” pressure is out of range, call the IMPCO Automotive technical assistance line at 888 880-6925 for instructions.


Q. Owner’s Guide & Warranty Registration:

1) Warranty registration is performed on IMPCO Technologies’ Automotive Website.

2) Click on IMPCO Automotive Warranty Registration.

3) Select IMPCO Kits.

4) ALL fields are mandatory and the system will point out any deficiencies before accepting the registration.

NOTE: Print the page for your records BEFORE submitting.

IMPCO Automotive Warranty Registration:

www.impcoautomotive.com/index.php?pagename=warranty

http://www.impcoautomotive.com/index.php?pagename=warranty


1) Owner’s guide and warranty statement needs to be in a prominent location on the dash or center console where the customer can easily locate it. It is strongly recommended to go over some of the highlights of the Owner’s Guide with the Customer.


R. Maintenance: Maintenance consists of:

• Periodic visual inspection of all vacuum lines and fittings. • Periodic visual inspection of all fuel lines and fittings. • Periodically check entire intake system for vacuum leaks. • Periodically check condition of all wiring. Refer to the maintenance schedule in the IMPCO Owner’s Guide Supplement for schedules.

1) Regulator high-pressure filter components (replace if contaminated and regulator is not affected):

Part # Description Qty

PI-140P P234-102 A00146

Inlet Filter Circlip O-ring

1 1 1

NOTE: No kit available, order all three parts for filter replacement.

All maintenance items are in the IMPCO Owner’s Guide Supplement. Consult the guide for maintenance schedules.

PPI-A-107 Rev-C January 2013

Copyright © 2013 IMPCO Technologies, Inc. All rights reserved. Reproduction by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from IMPCO Technologies, Inc. Created and published by IMPCO Automotive Technical Publications

7100 East 15 Mile.● Sterling Heights, MI 48312 ● www.impcoautomotive.com

Page 1 of 1

Technical Service Advisory Number: TSA-A-006 (Rev-A) PCM Re-flash Update

Date: December, 2012

Affected Part(s): 2013 5.3L Bi-Fuel CNG Kits (Silverado, Sierra, Tahoe) Trucks – BNG-53435-02-DE1 & DE2

This advisory is to inform you of a specific system design change in the 2013 5.3L Silverado/Sierra/Tahoe Bi-fuel CNG kits compared to previous model years, and how it will impact the installation process.

This 2013 5.3L Bi-fuel CNG system is now using a PCM re-flash in addition to the Sequent module to provide improved performance. In order to maintain the original GM functionality, we are building several different PCM calibrations, each of which include all of the necessary CNG changes while maintaining the GM system functionality. We are requesting VINs for each vehicle from the installers so that we can build these custom calibrations. Once the calibrations are built, they should be delivered to the specific vehicle for which they are intended. It is important to pay attention to the VIN labels on the kit boxes and the flashers themselves. Each flasher is loaded with a specific calibration designed for a single specific vehicle. If the vehicle is flashed with the wrong calibration, you may experience undesirable operation and/or loss of vehicle functionality. If at any point you have flashers for the 2013 5.3L vehicles and you are uncertain for which VIN they are designated for, please contact Customer Service or Tech Service and they can assist you in correctly matching flashers to the VINs.

3030 South Susan St.• Santa Ana, CA. 92704 • www.impcoautomotive.com

Page 1 of 2

Technical Service Bulletin Number: TSB-A-019 (Rev-A) IMPCO Automotive VECI Label Placement

Date: November, 2011

Affected Part(s): All IMPCO Automotive Vehicle Emission Control Information (VECI) labels

This bulletin addresses the proper placement of the IMPCO Automotive VECI labels to comply with government regulations.

The IMPCO Automotive Vehicle Emission Control Information labels must be permanently affixed to the vehicle so as to be easily seen when observing the OEM Vehicle Emission Control Information label. Also, they must be affixed to a part that is not normally removed during a normal routine maintenance procedure. Under no circumstances shall the IMPCO Automotive VECI label be affixed over the OEM VECI label. Diagrams #1 illustrates a properly installed IMPCO Automotive VECI label just under the OEM VECI label. Diagram #2 illustrates a properly installed IMPCO Automotive VECI label that is easily seen when viewing the OEM VECI label.

Diagram 1: Proper IMPCO Automotive VECI label installation.

Diagram 2: Proper IMPCO Automotive VECI label installation.

3030 South Susan St.• Santa Ana, CA. 92704 • www.impcoautomotive.com

Page 2 of 2

Diagram #3 illustrates an improperly installed IMPCO Automotive VECI label placed on top of the OEM VECI label. Diagram #4 illustrates an improperly installed IMPCO Automotive VECI label that is not easily seen when viewing the OEM VECI label.

Diagram 3: Improper IMPCO Automotive VECI label installation.

Diagram 4: : Improper IMPCO Automotive VECI label installation.

IMPCO Technologies Inc. • 3030 South Susan St. • Santa Ana, CA. 92704 • www.impcoautomotive.com

Page 1 of 1

Technical Service Bulletin

Number: TSB-A-021-B (CNG High-Pressure Coalescing Filter)

Date: January, 2012

Affected Part(s): All IMPCO Automotive Bi-Fuel CNG Installations.

This bulletin addresses the installation of a high-pressure coalescing CNG filter in ALL IMPCO Automotive bi-fuel CNG installations to protect the regulator and injectors from oil and water vapor contamination.

The IMPCO Automotive field engineers have identified the root cause of CNG injector cold weather malfunctions to be attributed to CNG water vapor and oil contamination being introduced in installations where a coalescing filter was not installed. Effective immediately, all IMPCO Automotive CNG bi-fuel installations must have a high-pressure CNG coalescing filter installed between the CNG fuel tank and the CNG regulator. The filter must be rated to 3600 PSI or higher and be serviceable in the field. IMPCO recommends the Parker FFC-112SAE-6 (or equivalent) coalescing filter (diagram #1). Table #1 lists the FFC-112SAE-6 specifications. There is a replacement filter available: Part # CLS112-6 All previously installed IMPCO Automotive bi-fuel CNG installations must have a high-pressure CNG coalescing filter installed at the earliest possible convenience. All new installations must have the filter installed BEFORE the vehicle is delivered to the customer. The recommended replacement interval is 1 year or 15,000 miles (24,000 km). As always, warranty claims for components found to be defective due to fuel contamination will be denied.

Diagram 1: Parker FFC-112SAE-6

Port Size Max Pressure

Max Temperature

Sump Capacity Weight Length Width Flow Rate

(SCFM) 9/16” SAE

3600 PSI (248 bar)

225O F 107O C)

0.5 oz (14.8 ml)

1.5 lbs (0.68 kgs)

4.75” (120.65mm)

2.25” (57.15mm) 473

Table #1

System working correctly?

Bi-Fuel Technical Support Flow Chart

Perform self-test on

Plug & Drive system and the Original Equipment

pcm

No

Did either system have any DiagnosticTrouble Codes?

Verify Reported Condition

Check for Technical Service

Bulletins, and

updated Calibration

files

Did the diagnostics resolve

the concern?

Make acquisition file of issue,

and error report with

P & D Software

Go to Sequent Automotive Test Tool Portal to start Tech Case File

Login to IMPCO or Sequent Tech Portal

Send ACQ file and error report to Customer Service Engineer for review;

[email protected]

No

CSE reviews ACQ file and error report, then

contacts technician with repair

recommendations

Did the diagnostics from CSE resolve reported

condition

Clear codes in P&D and OE PCM, retest for codes, return to the customer

Yes

Yes

Contact Technical Support

888-880-6925

No

Bi-Fuel Kit Installed at distributor or vehicle in for

service

No

Yes

Diagnose, repair and clear OEM

DTC”s

If no OEM DTC’s then Diagnose

P&D DTC’s

Yes

SHEET 1 of 1

1234

A

B

C

D

A

B

C

D

1234

Weight --- SCALE X:X

REV

HDWG NO.SIZE PART NO.

TITLE

2013 5.3L GM PU/SUV BNG Installer Wiring Diagram

THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO IMPCO TECHNOLOGIES, INC. ANY REPRODUCTION, DISCLOSURE, USE OF THEIS DOCUMENT, OR ANY INFORMATION CONTAINED THERIN, IS EXPRESSLY PROHIBITED EXCEPT AS IMPCO TECHNOLOGIES, INC. MAY OTHERWISE AGREE IN WRITING.

Sequent P&D ECM

Se

qu

en

t F

ue

l R

ail (

Ba

nk

2)

Inj #7

Inj #5

Inj #3

Inj #1

Se

qu

en

t F

ue

l R

ail (

Ba

nk

1)

Inj #8

Inj #6

Inj #4

Inj #2

Fuel Temp & Press Sensor

BK

BK

BK

RD

RD

Diagnostic Connector

-GNDSTUD

L - 1

L - 333

L - 55555

L - 7777777L - 88888888

L - 666666

L - 4444

L - 22

25 Amp Fuse

5 Amp Fuse

Relay

Front of Engine

Change Switch

Buzzer

Sequent MAP

Sensor

Lockoff #1 L–EV FRONT

Gray Heat-Shrink Tube

L–EV REARLockoff

#2

BK

CNG

REG

Coolant Temp

Sensor GN

BN

WT

YE

YE/BK

Fuel Supply Hoses

Sequent P&D

Fuel Rails

Sequent Fuel Level

Input

Sequent OEM Fuel Injector Pigtail (#5-8)

Sequent OEM Fuel Injector Pigtail (#1-4)

Inj #6

Inj #2 Inj #1

Inj #3

Inj #5

Inj #7Inj #8

OEM Fuel Rails

Plug into OEM Inj Connectors

Inj #4

GY

RD

Replace connector on harness with C8-53357-001

Connects to Sequent Fuel Level Input

CNG PRESS

1) Wire LASER imprints are indicated adjacent to wire with an “L-“ and wire color in parenthesis. Example: L – 55555 (OG)

IMPORTANT!

YE AB

Technician

Installed Splice

AW-54154-001

WH2

1

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

TN/BL

TN} To OEM ECM

OEM OBD-IIJ1962 Data Link

Connector

BU

Not UsedL-1 (BU)

L-22 (BU)}L-1 (YE)

L-22 (YE) } Not Used

Heat-Shrink Cap OverEnd of Pigtail

(Wires Hidden)

RDBN

B+PDCStud

OEM ECMConn X1

40Remove wire fromPin13 P&D ECM.Replace wire withAW-54321-1000

PUFuel

Pressure Sensor

1

PUTo Fuel Pump Flow Control

Module

PU

AddAW-54322-3000 to Pin 7 of P&D ECM Fuel Pressure Sensor

View From Wire Side

GM Fuel PumpSimulator ModuleMD-52542-001

Plug intoRear lockoff

OEM Fuel LinePressure Sensor

Connectors

OEM Fuel PumpConnectors

GN

Plug intoLockoff #2

View From Wire Side

1 3

Fuse TapF5-54600-001

Fuse 56

15A

5A

F5-54517-001

OE FUSE

SHEET 1 of 1

1234

A

B

C

D

A

B

C

D

1234

Weight NA SCALE NA

REV

GDWG NO.SIZE PART NO.

TITLE

2013 5.3L GM PU/SUV BNG Wiring Schematic

B+PDC

Power Relay

30 86 87 87 85

Diag Conn

X X X

Change Over Switch

X X X X X

Buzzer

X X

Sequent Map Sensor

X X X

YE

RD

GN

WH/GN

WH

YE

GY

RD

WH

GN/BK

WH/GN

WH/GN

WH/GN

WH/GN

BK

GN

WH/GN

WH/GN

WH/GN

WH/GN

OG

OG

OG

OG

WH

WH

L-1 BU

L-2 BU

GN

YE/BK

BK

WH/GN

BN

GN/BK

PU

OG

PU

OG

5AFuse

X X

25A Fuse

X X

BK

GN

PU

OG

PU

OG

PU

PU

PU

PU

BU

BK

BK

- +

BK

RD

RD

RD

RD R

D

RD

RD

RD

GN

GN

WH

/GN

RD

BK

WH

RD

BK

GN

WH

OG

RD

RD

BK

Sequent Fuel Level

InputX X

WH

BK

OG

WH

GN/BK GN

L-1 YE

L-2 YE

Not Used

GN/BK

GN

GN

(Front of Engine)

Se

qu

en

t F

ue

l R

ail

(B

an

k 2

)

Se

qu

en

t F

ue

l R

ail

(B

an

k 1

)

FuelTemp

&Press

Sensor

X

X

Inj #8X

X

Inj #6X

X

Inj #4X

X

Inj #2 X

X

Inj #7X

X

Inj #5X

X

Inj #3X

X

Inj #1X

X

GN

GN

L-#7777777

L-#55555

L-#333

L-#1L-#22

L-#4444

L-#666666

L-#88888888

RD

BK

WH

GN

GN

GN

GN

GN

OEM Fuel Rails

Inj #4 X

X

Inj #2 X

X

Inj #6X

X

Inj #8X

XInj #7

X

X

Inj #5X

X

Inj #3X

X

Inj #1X

X

OEM Inj 8 Conn OEM

Inj 6 ConnOEM

Inj 4 Conn OEM

Inj 2 Conn

OEM Inj 1 ConnOEM

Inj 3 Conn OEM

Inj 5 ConnOEM

Inj 7 Conn

L-88888888 PU

L-666666 PU

L-4444 PU

L-22 PU

L-88888888 OG

L-666666 OG

L-4444 OG

L-22 OG

Sequent P&D ECMCoolant Temp Sen Input 1

5V Ref Output 2

Fuel Press Sen Input 3

4

HEGO 1, Bnk 1 Input 5

HEGO 1, Bnk 2 Input 6

7

Pwr Relay Ctrl 8

Serial K-Line 9

OEM CAN (HI) 10

CKP Sen Input 11

Vbatt 12

OEM K-Line 13

Lockoff #1 Ctrl 14

#1 Gas Inj Ctrl 15

#2 Gas Inj Ctrl 16

#3 Gas Inj Ctrl 17

#4 Gas Inj Ctrl 18

Gas Inj Gnd #1 19

Pwr Relay B+ 20

#5 Gas Inj Ctrl 21

#6 Gas Inj Ctrl 22

#7 Gas Inj Ctrl 23

#8 Gas Inj Ctrl 24

OEM Inj #5 LS Input 25




Seq MAP Sen Input 29

Fuel Temp Sen Input 30

31

32

HEGO 1, Bnk 1 Output 33

HEGO 1, Bnk 2 Output 34

35

36

Spark Advance 37

OEM CAN (LO) 38

Gnd 39

OEM Inj B+ 40

VSW 41

Lockoff #2 Ctrl 42

OEM Inj #1 LS Output 43




Gas Inj Gnd #2 47

Pwr Relay B+ 48









L-7777777 PU

L-55555 PU

L-333 PU

L-1 PU

L-7777777 OG

L-55555 OG

L-333 OG

L-1 OG

Not Used

Lockoff#1

X X

Lockoff#2

X X

GN

BK

BK

BK

BK

BK

BK

BK

BK

Change Conn C8-53357-001

Coolant Temp

SensorA B

BKCNG

PRESS

3

1

2WH

RD

WH

These Two Connect Together

Technician Installed Splice

X

X

BK

Fuel Level Input1 2

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

TN

TN/BL

} To OEM ECU

OEM OBD-IIJ1962 Connector

AW-54154-1000

BN

OEM ECM CONN X1

40PU

Fuel PressureSensor

1PU

To Fuel Pump Flow Control Module

AW-54321-1000

To Fuel PumpSimulator Module

GNDSTUD

AW-54322-3000

RD

Fuse TapF5-54600-001

Fuse 56

15A 5A

F5-54517-001

OE FUSE

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