ROUSH CleanTech LPG System Overview

Roush CleanTech Propane Powered Trucks

ROUSH Clean Tech LPG System Overview

The ROUSH Clean Tech LPG system is a dedicated liquid propane injected system and completely replaces the OEM fuel system.  The conversion process involves removing the OEM fuel tank assembly, the evaporative emissions assembly, the fuel line assembly and the fuel rail assembly.
The vehicle then has the ROUSH Clean Tech LPG system installed on it.  An overview of the system hardware can be seen in Figure1.

 ROUSH Clean Tech LPG Fuel System

Figure 1: ROUSH Clean Tech LPG System

The ROUSH Clean Tech LPG system consists of four major subsystems.  A list of these subsystems and the key components that make up those subsystems can be found in Table 1.

Subsystem

Component

Comment

Fuel Rail Assembly

Fuel Rails

 

Fuel Injectors

See Table 2: I/O Changes

 

Injection Pressure/Temperature Sensor

See Table 2: I/O Changes

Fuel Line Assembly

Fuel Lines

Flow Control Solenoid

See Table 2: I/O Changes

Fuel Tank Assembly 

Fuel Tank

 

Fuel Pump

 

Fuel Level Sender

See Table 2: I/O Changes

Powertrain Control System

PCM Calibration

Modified Strategy and Calibration for LPG.

Wiring Harness

Overlay harness to interface with PCM

Table 1: ROUSH Clean Tech LPI Subsystems

Subsystem Description:

Fuel Rail Assembly

The ROUSH Clean Tech LPG system uses two symmetrical billet aluminum rail halves.  Each rail half is fitted with four LPG specific fuel injectors.  One rail half is fitted with an injection pressure and temperature sensor (IPTS).  This sensor contains an OEM spec thermistor and a 0-500 psi pressure transducer.

Fuel Line Assembly

The ROUSH Clean Tech LPG system features a return fuel system.  The return line contains a flow control solenoid.  The flow control solenoid is used by the Powertrain Control Module, PCM, to control fuel pressure in the fuel rail in order to ensure there is liquid propane in the fuel rail.  The solenoid is a normally closed solenoid with an orifice drilled between the inlet and outlet ports of the solenoid body to permit some flow back to the tank when the solenoid is closed.   When the solenoid is energized, the orifice is bypassed and return fuel flow to the tank is increased.  The flow control solenoid can be seen in the upper left corner of Figure 2.

Roush CleanTech Fuel Rail Assembly and Flow Control Solenoid

Figure 2: Fuel Rail Assembly and Flow Control Solenoid

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