DIY Car to Natural Gas
Natural gas vehicles operate on alternative fuels which release less harmful byproducts than their fossil fuel counterparts. Alternative fuel cars are much more expensive than regular cars, but conversion kits are available on the market today with everything you need to make the conversion included. Converting a car to natural gas costs between $10,000 and $12,000 upfront, as of the date of publication, but cuts the amount a consumer spends on gas in half. Consult a specialist before beginning the conversion; it's a good idea to have an experienced person supervise you as you make the conversion.
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Instructions
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Make sure that it is worth it to convert your car to natural gas. Older cars are usually not worth it because you want to make the conversion to get the most out of your vehicle. Make sure that natural gas is accessible in your area, otherwise you will have to take extra measures to acquire it.
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Check that the vehicle structure is in good shape to hold the gas tanks, pressure regulator, high-pressure pipe clamps and other parts. Check the spark plugs, spark plug cables, contact points, condenser, ignition coil, ignition plate and distributor to make sure that the motor ignition system will function properly.
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Make sure the car battery is capable of giving off 12 volts of electricity. Check to make sure that the carburetor system is clean and operates properly. If any of these parts are not working correctly, do not proceed with the installation without repairing these parts because the kit will not operate correctly.
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Check to make sure your kit has all of the following parts: pressure regulator (reducer), gas/air mixer (or electronic fuel injector), NGV filling valve, high-pressure lines, NGV tank and valve, fire resistant hose with maximum gas flow adjuster, gasoline/NGV selector switch, manometer and heating system emulator. These parts vary by kit, so make sure that all of the parts listed in your instruction booklet are included.
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Attach the pressure regulator, making sure the support bracket is firmly fixed to a flat surface in the body of the car. Make sure it is perpendicular to the direction the vehicle moves, and placed in an area where it will be clearly visible once the manometer is attached. Fix the manometer to the pressure regulator.
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Follow the instructions for attaching the gas and vent lines to the regulator. The process for this varies with each kit. Attach the gas/air mixer in a spot close to the regulator so that the gas doesn't have to run down a long line when starting.
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Install the filling valve while as far away from the car battery as possible to avoid fire or sparks. If possible, place it close to the regulator so that the manometer can monitor the filling pressure. Make sure the valve is mounted tightly so that it does not move or come loose with the motor movement of the car.
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Install the high pressure pipe by attaching one end to the filling valve and running it to the reducer. Make a loop in the piping each time you need to turn it around a corner, and make sure there is at least one loop in the piping.
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Use plastic or metal clamps to attach the piping to a place inside of the vehicle body so that they do not flap around. Make sure no piping hangs down underneath the car. Run the piping from the filling valve and attach to one of the fittings on the cylinder. Refer to the instruction manual of your kit to see which is the appropriate fitting.
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Run the piping to the trunk of the car on the same side as the filling valve, away from the exhaust and motor.
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Bolt the brackets for the NGV tanks inside of the trunk in a spot where they will take up minimal space. Check the valves on the tanks and make sure they're tight (most kits come with the valves pre-installed). Mount the tanks in the brackets. They should fit tight and not be able to slide around.
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Run the piping between cylinders if you are using a kit that has more than one. Make a loop in the piping to absorb vibrations, and for any corner that the piping turns.
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Follow the instructions included in your kit for installing the gas/NGV selector switch, control system and heating system. The installation process for these parts varies. The existing heating system can be modified in most cars to work with your NGV installation.
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Place the ventilation bag included in your kit on the ventilation nozzle on the tank valve. Attach the ventilation tube to the high pressure piping. Close the ventilation bag and add another piece of piping to the other nozzle on the tank. Secure with the metal clamps included in your kit.
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Place the mixer in its designated spot and connect it to the fire resistant hose with the gas flow adjuster affixed. Place the mixer as close as possible to the pressure regulator, so that the hose spans the least possible distance.
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Check for any additional components and follow the instructions for installing them. Most kits come with a pamphlet with instructions for testing and tuning your new system. Test and tune the system, and test it again before driving.
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References
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