Always disconnect the battery terminals. Battery terminals should only be disconnected with the ignition key on STOP or the key removed; never with the key on MAR-ON or the engine started. The battery terminals should only be disconnected after waiting at least one minute after turning the ignition key to STOP.
In the event of LPG system component maintenance or replacement operations involving disconnection of the pipes, the section of the circuit involved must be bled proceeding as described in Op. 1043A02 of the Service Manual.
After having removed one or more of the LPG system components, carrying out the leak detection test is compulsory (see Op. 1043A04 of the Service Manual) either with the leak detector (2000037100) or a foam solution.
The tank must be disconnected after draining all the LPG in the tank itself. To this purpose, placing the switch in LPG mode, make sure that the system automatically switches to petrol operation mode.
If the car cannot be run in LPG mode, before disconnecting the tank, drain all the LPG from the tank itself and inertise the tank complying with the prescriptions of the standard UNI EN 12979:2004.

For LPG tank emptying and inertising procedures, comply with the relevant specific national regulations in force in the destination countries.

For Italy, these interventions are allowed only to personnel authorised to work on pressurised LPG systems, after getting the certificate for the CNG and LPG system installation, according to the UNI CEI EN ISO/IEC 17024 standard.

Authorised personnel must comply with current legal regulations and take care to observe all safety requirements learnt during the training course

If the necessary authorisation is not available, contact certified workshops to have the tank drained and inertised. The tank can be removed from the vehicle only after this operation.

One of the list of the workshops authorised to work on LPG systems is available on the www.ecogas.it website.

GENERAL SAFETY PRESCRIPTIONS

The general prescriptions to be followed during service operations on LPG system components are listed below.

The operations should be carried out paying utmost care to avoid personal injury and damage to the components.
Pay special attention to the engine compartment, that contains many moving parts, very hot components and live electrical wires; strictly comply with the following precautions while working in the engine compartment:

1 - switch off the engine and wait for it to cool down.

2 - do not smoke.

3 - do not use naked flames.

4 - make sure that there is a fire extinguisher nearby.

5 - do not use driers and power tools,

6 - do not use incandescent lamps,

7 - do not wear acrylic clothing that generates static electricity.

For some procedures of the Service manual, special tooling are recommended; the use of such tooling is indispensable for a safe working.
Comply with the safety standard in force for working inside the workshop; the Service Manual contains specific procedures to be followed to prevent dangerous situations from arising.
Wear the special helmet with visor and heavy-duty gloves meeting the UNI standards listed (see General Information - GROUP 10). Wear antistatic cotton clothing, to cover also lower and upper limbs.
Avoid synthetic clothing. Wear antistatic, spark-proof shoes.
For the use of chemical products follow the safety instructions on the safety sheet from the supplier to the consumer (for Italy in accordance with Ministerial Decree No. 47/1992).
To release parts that are sticking, tap gently using an aluminium or lead hammer if iron materials are involved; use a wooden or resin hammer for light alloy parts.
When dismantling, check that components that should be marked have the appropriate references.
When refitting, lubricate the parts, where necessary, to prevent seizing or binding during the initial operating period.
When refitting it is vital to follow the tightening torques and adjustment data.
Each time they are refitted, replace gaskets, oil seals, spring washers, circlips, self-locking nuts and all parts that have deteriorated.
Never park the vehicle, when stored in the workshop, next to working pits, drain holes for intake ducts, closed areas without suitable ventilation; RISK OF EXPLOSION: LPG is heavier than air and tends to sink to the lowest possible level. It will therefore fill any openings near the car creating dangerous, potentially explosive gas pockets.
Do not use workshop tools such as air compressors, current generators, suction devices, power tools etc. that could generate sparks and trigger explosions in the event of leaks.
Do not use any type of suction device; always work in ventilated areas.
Do not park vehicles with LPG systems in closed environments if they have been in an accident or if the condition of the system sealing devices is uncertain.

PAINTING INTERVENTIONS AND FOLLOWING DRYING

In the event of operations on the bodywork of vehicles equipped with LPG system, involving painting and subsequent drying using lamps, comply with the following precautions:

Carry out a system seal test, see operation 1043A04.
Make sure the LPG inside the tank is lower than 80% of the rated capacity.
Drain LPG from the pipes according to the correct procedures and complying with the provisions in force described in the operation 1043A02.
Make the required bodywork repairs complying with the standard procedures for petrol-fuelled vehicles.
LPG system components, and the tank in particular, should not be exposed to naked/direct flames or high temperature heat sources (e.g. electric welding, etc.). In any case, no component must ever exceed a temperature of 80°C at any point.
At the end of the operation, wait until the vehicle has cooled down, then start the engine and make sure there are no irregularities during LPG operation.
If the risk of exposure to direct flame or high temperature of LPG system tank and components is unavoidable, disassemble the tank and drain all pipes.
If the components of the LPG system are disassembled, a new check of the circuit's seal is compulsory; see operations 1043A04.

LPG TANK

The tank is made entirely from steel (in accordance with regulations) and must undergo, by law, a hydraulic test at a pressure of 30 bar (for class A tanks).

The LPG tank is certified according to the regulations in force; it underwent the impact and crash tests on the vehicle (according to ECE 1024 and ECE 34).

In Italy, the tank has a life of 10 years starting from the car registration date. If the car has been registered in a country other than Italy, the duration and the testing/inspection procedures of the LPG tank may vary depending on the national legislation in force in that country. In any case, when the time limit in the individual country has run out, the Customer should have the tank replaced.

To remove the LPG tank, refer to Op. 1043A10 of the Service Manual; the main prescriptions to be complied with are the following:

The LPG tank must be moved and positioned on mountings always keeping the multivalve unit facing upwards, complying with the assembly position in the car. Do not overturn.
Once removed, the LPG tank which has not been inertised must be left outside, in a safe place, sheltered from bad weather.
Place a sign on the LPG tank, with the following instruction: Do not touch - Do not overturn - No naked flames - No smoking - Do not use electrical equipment or heat lamps.
The LPG tank must be scrapped according to the regulations in force on dangerous waste.

INTRODUCTION

LPG SYSTEMS

GENERAL SAFETY PRESCRIPTIONS

PAINTING INTERVENTIONS AND FOLLOWING DRYING

LPG TANK