Fitting Instructions Bora System

Fitting Instructions
Bora System
Zavoli s.r.l
Via Pitagora n°400 47521 Cesena (FC) Italy
Tel. (+39) 0547 646409 Fax. (+39) 0547646411 E-mail: zavoli@zavoli.com
www.zavoli.com
Index
General Information 3
Tabel Sizing Nozzles for Injector 4
Change Over Switch Operation 6
Cut Injector Wiring 7
Map Sensor Connection 9 2
3 Cylinders Fitting Schemes 10

Standard Errors Codes Bora 34
Program Errors Codes Bora 35
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MN-IST-MTG-BR.00-E del 12/04/2016
General Information
Where to Install the Control Unit
- Far from any water leakage.
- Far from excessive heat sources (such as exhaust manifolds).
- Far from high-voltage cables.
Useful Information
Create efficient electrical connections without using any “POWER TAPS”. Properly insulated soldering is the most effective type of electrical
connection.
Advise the customer that if the GAS system fuse burns, the connections of the devices to which it is connected will be restored. It is 3
strongly recommended not to replace the fuse with another one with a higher amperage rating since it may cause irreparable damage.
Do not open the Control Unit box for any reason, especially when the engine is running or the key is in the ignition, to avoid irreparable
damage. Zavoli will not be held responsible for damage to property or injuries to persons if unauthorised personnel tamper with its devices;
such tampering will also invalidate the WARRANTY.
Incorrect Installation Incorrect Installation Correct Installation
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Tabel Sizing Nozzles for Injector
Injector JET LPG
2 CYLINDERS 3 CYLINDERS 4 CYLINDERS 5 CYLINDERS 6 CYLINDERS 8 CYLINDERS

TYPE NOZZLES ENGINE
HP HP HP HP HP HP
Ø 1,5 mm
ASPIRATED
\\ Up to 42 Up to 54 \\ \\ \\
cod. 4915025.12 SUPERCHARGED
\\ \\ Up to 73 \\ \\ \\
Ø 1,8 mm
ASPIRATED
\\ 43 to 60 55 to 80 \\ \\ \\
\\ \\ 74 to 105 \\ \\ \\
ASPIRATED
Up to 60 61 to 90 81 to 120 Up to 163 Up to 194 Up to 258
Ø 2,2 mm * use Zeta S * use Zeta S * use Zeta S 4
cod. 4915025.03 SUPERCHARGED Up to 117 106 to 156 Up to 204 Up to 243 Up to 325
Up to 77 * use Zeta S * 88 kw use Zeta S * use Zeta S * use Zeta S * use Zeta S
ASPIRATED
61 to 83 91 to 125 121 to 166 164 to 227 195 to 272 259 to 363
Ø 2,6 mm * 120 kw use Zeta S * use Zeta S * use Zeta S * use Zeta S
cod. 4915025.05 SUPERCHARGED 118 to 170 157 to 227 205 to 284 244 to 341 326 to 454
78 to 113 * use Zeta S * use Zeta S * use Zeta S * use Zeta S * use 2 Zeta S
Ø 3,0 mm
ASPIRATED
84 to 96 \\ 167 to 210
* use Zeta S
228 to 264
* use Zeta S
273 to 315
* use Zeta S
364 to 421
* use 2 Zeta S
cod. 4915025.06 SUPERCHARGED 114 to 132
* use Zeta S \\ 228 to 264
* use Zeta S \\ \\ \\
Pressure Zeta Normal Reducer: 1,20 bar
Pressure Zeta Super Reducer: 1,40 bar
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Tabel Sizing Nozzles for Injector
Injector JET CNG
2 CYLINDERS 3 CYLINDERS 4 CYLINDERS 5 CYLINDERS 6 CYLINDERS 8 CYLINDERS
TYPE NOZZLES ENGINE
HP HP HP HP HP HP
Ø 1,5 mm
ASPIRATED
\\ Up to 41 Up to 53 \\ \\ \\
\\ \\ Up to 63 \\ \\ \\
Ø 1,8 mm
ASPIRATED
\\ 42 to 58 54 to 77 \\ \\ \\
\\ \\ 64 to 90 \\ \\ \\
ASPIRATED Up to 143 Up to 173 Up to 230
Ø 2,2 mm Up to 57 59 to 87 78 to 116 * use Meta S * use Meta S * use Meta S 5
cod. 4915025.03 SUPERCHARGED Up to 101 91 to 135 Up to 169 Up to 203 Up to 296
Up to 67 * use Meta S * 90 kw use Meta S * use Meta S * use Meta S * use Meta S
ASPIRATED
58 to 80 88 to 121 117 to 160 144 to 201 174 to 242 231 to 322
Ø 2,6 mm * 90 kw use Meta S * use Meta S * use Meta S * use Meta S
cod. 4915025.05 SUPERCHARGED 102 to 141 136 to 188 170 to 235 204 to 281 297 to 375
68 to 94 * use Meta S * use Meta S * use Meta S * use Meta S * use Meta S
Ø 3,0 mm
ASPIRATED
81 to 94 \\ 161 to 190
* use Meta S
202 to 234
* use Meta S
243 to 280
* use Meta S
323 to 374
* use 2 Meta S
cod. 4915025.06 SUPERCHARGED 95 to 122
* use Meta S \\ 189 to 231
* use Meta S \\ \\ \\
Pressure Meta Normal Reducer: 1,90 bar
Pressure Meta Super Reducer: 1,90 bar
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Change Over Switch Operation
BICOLORE LEDS
OPERATION
GAS-PETROL
BUTTON
FLASHING LEDS
INDICATION RESERVE
4 GREEN LEDS
FUEL LEVEL
6
Diagnostic
In case of malfunctioning of the LPG system, detected by the same system diagnostic, the change-over switch buzzer will emit three
sounds every 50 seconds and the red petrol fuel state LEDS will flash. In such situation, the vehicle runs with petrol. To interrupt the sound
and flashing sequence, press the change-over switch.
Emergency start
To carry out the emergency forced start, follow the procedure below;
- Position the change over switch in the Petrol position,
- Keep the change over switch key pressed,
- Start the key contact,
- Wait 4 seconds,
- At the sound of the buzzer start the engine.
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Cut Injector Wiring
CONNECTION SCHEME WITH RED RED/
ORANGE RED/
GREEN
UNIVERSAL CABLE 1 2
1 2
GREEN
FOR CARS 4 CYLINDERS 3 2

“CONFIGURATION 1”
BROWN RED/
YELLOW RED/
GREEN
1 2
1 2
GREEN
4 1
CABLE ECU GAS

4
3
2 1
“JET”
INJECTORS
PETROL INJECTORS
4 3 2 1 ENGINE CYLINDERS
WHITE/RED
YELLOW +
+ + +
YELLOW/BLACK
WARNING!
Follow the sequence of con-
-
ections. The BLUE and GREEN
BLUE-BLACK wires must be GREEN/BLACK
positioned at the gas injector
marked A. The others must -
RED
be connected as indicated in the
figure. RED/BLACK
INTERRUPT THE
INJECTOR NEGATIVE -
BLUE
WIRES
BLUE/BLACK
-
CUT INJECTOR
WIRING
CONNECTOR
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Cut Injector Wiring
RED RED/
GREEN
ORANGE RED/ WARNING!
CONNECTION SCHEME WITH 1 2
1 2
GREEN
Follow the sequence of con-ections.
UNIVERSAL CABLE 7
3
6
2 The BLUE and
FOR CARS 8 CYLINDERS BLUE-BLACK wires must be
BROWN RED/ positioned at the gas injector marked
YELLOW RED/
GREEN
1 2
1 2
GREEN “1” For Bank 1 and “5” for Bank 2 .
8 5 The others must be connected as
4 1
indicated in the figure.
INTERRUPT THE
INJECTOR NEGATIVE
CABLE ECU GAS WIRES
4
3
2 1
BANK 1 BANK 2
CABLE ECU GAS
CABLE ECU GAS
WARNING! WARNING!
THE CUT INJECTOR THE CUT INJECTOR
CONNECTOR MARKED “1” CONNECTOR MARKED ”5”
MUST CORRESPOND TO MUST CORRESPOND TO RED RING
THE GAS INJECTOR MARKED “1” THE GAS INJECTOR MARKED ”5” 8
CUT INJECTOR PETROL INJECTORS

WIRING CUT INJECTOR
CONNECTOR WIRING
RED RING CONNECTOR
ENGINE CYLINDERS
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Map Sensor Connection
Not Connected: Use the Map sensor only during the self-mapping process,
then disconnect it.
Standard: Leave the Map sensor always connected.
OEM: Connect the White wire of the gas Ecu to

the original vehicle map signal.
ECU GAS
9
ORIGINAL MAP MAP CONNECTOR
SENSOR BLACK
MAP WHITE
SIGNAL
For the correct connection, you will have a variable signal from ± 0- 5 V.
Software Setting (example setting values map oem)
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3 Cylinders Bora Light LPG
CHANGEOVER
SWITCH BLACK
MAP SENSOR GROUND
DIAGNOSTIC (only for calibration)
CONNECTOR
FUSE MAX 15 A
RED/BLACK
D
C A
O
BATTERY
P
STANDARD SENSORS WHITE RED
TYPE 1050 / TYPE 0-90 OHM
WHITE
WHITE E
BLACK
BLACK
I
RED 4
PURPLE OPZIONAL 3
OXYGEN SENSOR 2 1
1° CYLINDER
10
GAS AND
PRESSURE
POSTERIOR SOLENOID INJECTORS TEMPERATURE
VALVE AND “JET” SENSOR
GAS PORTS
BLACK E1
M
WHITE/BLUE RPM SIGNAL
CUT INJECTORS
RED /WHITE
WIRING
L BROWN
- + BLUE/BLACK
BLUE
ORANGE G RPM
BLACK RED/BLACK
GAS TEMPERATURE COIL
SENSOR REDUCER RED
GREEN/BLACK
GREEN
YELLOW/BLACK
DO NOT
BLUE F YELLOW CONNECT
VAPORIZER/REDUCER BLACK
“ZETA”
+
- +
-
+
-
SOLENOID VALVES
PETROL INJECTORS CONNECTOR

ZAVOLI srl ISG-3C-BS32-LIGHT-ZTJ-LPG-008.00-E Del 05/04/2016
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3 Cylinders Bora OBD LPG
CHANGEOVER
SWITCH BLACK
MAP SENSOR
GROUND
CONNECTOR
FUSE MAX 15 A
RED/BLACK
D
C A
O
BATTERY
P
WHITE
WHITE E
BLACK
BLACK I
RED 4
PURPLE OPZIONAL 3
OXYGEN SENSOR 2 1
DO NOT
CONNECT
1° CYLINDER
INJECTORS
GAS AND
PRESSURE
11
POSTERIOR SOLENOID
VALVE AND
“JET” TEMPERATURE
GAS PORTS SENSOR
BLACK E1
L BROWN
- +
ORANGE G RPM
BLACK
GAS TEMPERATURE COIL M
SENSOR REDUCER
1 2 3
N WHITE (LINEA K) PIN 7
YELLOW (LINEA CAN +) PIN 6
CUT INJECTORS PETROL INJECTORS

YELLOW/BLACK (LINEA CAN -) PIN 14 WIRING CONNECTOR
BLUE F
“ZETA”
CONNECTOR
OBD
SOLENOID VALVES
ZAVOLI srl ISG-3C-BS32-OBD-ZTJ-LPG-010.00-E Del 05/04/2016

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3 Cylinders Bora LPG
LEGENDA:
ELETTROVALVOLA - SOLENOID VALVES - ELETROVALVULA
RIDUTTORE - REDUCER - RIDUTOR
INIETTORE - INJECTORES - INYECTOR
SENSORE MAP - MAP SENSOR - SENSOR MAP
FILTRO - FILTER - FILTRO 5
INGRESSO ACQUA - WATER INLET - AGUA DE ENTRADA
SENSORE TEMPERATURE PRESSIONE - GAS AND PRESSURE TEMPERATURE SENSOR - SENSORTEMPERATURA Y PRESION
SENSORE MAP
800DE802060 INGRESSO
NEW BORA ECU ACQUA
RIDUTTORE 10
100ZETA
ELETTROVALVOLA
495002
INIETTORI
JET SENSORE TEMPERATURA
PRESSIONE
800DE525001 12
495002
5 400.FILTER
MAX 150 mm FILTRO
ZAVOLI srl ISG-KNWB-3CPNV-GPL-002.01 Del 18/11/2013 www.zavoli.com

3 Cylinders Bora Light CNG
CHANGEOVER
SWITCH BLACK
MAP SENSOR GROUND
CONNECTOR FUSE MAX 15 A
RED/BLACK
D
C A
O
BATTERY
STA NDARD SENSO RS C NG

P WHITE RED
BLAC K BLACK
E
WHITE WHITE
I
4
INSULATE 3
PURPLE OPZIONAL 2
OXYGEN SENSOR 1
DO NOT
CONNECT 1° CYLINDER
POSTERIOR SOLENOID GAS AND 13

VALVE AND INJECTORS PRESSURE
GAS PORTS “JET” TEMPERATURE
SENSOR
BLACK
E1 M
WHITE/BLUE
RPM SIGNAL CUT INJECTORS
WIRING RED /WHITE
BLUE/BLACK
L - +
BROWN BLUE
ORANGE G
RPM
BLACK
RED/BLACK
GAS TEMPERATURE COIL RED
SENSOR REDUCER
GREEN/BLACK
SOLENOID VALVES
GREEN
YELLOW/BLACK
BLUE F DO NOT
YELLOW CONNECT
BLACK
VAPORIZER/
REDUCER -
+
- +
- +
“META”

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3 Cylinders Bora OBD CNG
CHANGEOVER
SWITCH BLACK
MAP SENSOR GROUND
RED/BLACK
D
C A
O
BATTERY
STA NDARD SENSO RS C NG P

WHITE RED
BLAC K BLACK
E
WHITE WHITE
I
INSULATE OPZIONAL 4
PURPLE 3
OXYGEN SENSOR 2 1
DO NO T
C O NNEC T 1° CYLINDER

SENSOR
BLACK
E1
WHITE/BLUE
RPM SIGNAL
L BROWN
- +
ORANGE G
RPM
BLACK
COIL M
GAS TEMPERATURE
SENSOR REDUCER
1 2 3
SOLENOID VALVES WHITE (LINEA K) PIN 7
N
CUT INJECTORS PETROL INJECTORS

YELLOW/BLACK (LINEA CAN -) PIN 14 CONNECTOR
BLUE F WIRING
BLACK
VAPORIZER/ CONNECTOR
REDUCER OBD
“META”
ZAVOLI srl ISG-3C-BS32-OBD-MTJ-CNG-010.00-E Del 06/04/2016

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3 Cylinders Bora CNG
LEGENDA:
RIDUTTORE - REDUCER - RIDUTOR RIDUTTORE
INIETTORE - INJECTORES - INYECTOR META/N
FILTRO - FILTER - FILTRO
ELETTROVALVOLA
NEW BORA ECU

SENSORE MAP
800DE802060
5
495002
INIETTORI
JET
SENSORE TEMPERATURA
PRESSIONE
10 15
800DE525001
495002
5 400.FILTER
MAX 150 mm FILTRO
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ZAVOLI srl ISG-KNWB-3CNPNV-CNG-002.01 Del 18/11/2013
4 Cylinders Bora Light LPG
CHANGEOVER
SWITCH BLACK
MAP SENSOR GROUND
CONNECTOR
FUSE MAX 15 A
RED/BLACK
D
C A
O
BATTERY
P
STANDARD SENSORS
WHITE RED
WHITE
WHITE E
BLACK
BLACK
I
RED 4
PURPLE OPZIONAL 3
OXYGEN SENSOR 2 1
1° CYLINDER
POSTERIOR SOLENOID INJECTORS

GAS AND
PRESSURE 16
VALVE AND
GAS PORTS SENSOR
BLACK E1
M
CUT INJECTORS
WIRING RED /WHITE
L BROWN
- + BLUE/BLACK
BLUE
ORANGE G RPM
BLACK
COIL RED/BLACK
GAS TEMPERATURE
SENSOR REDUCER RED
GREEN/BLACK
GREEN
YELLOW/BLACK
BLUE F YELLOW
“ZETA”
+
- +
-
+
- -
+
SOLENOID VALVES

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CHANGEOVER
SWITCH BLACK
MAP SENSOR
GROUND
CONNECTOR
FUSE MAX 15 A
RED/BLACK
D
C A
O
BATTERY
P
WHITE
WHITE E
BLACK
BLACK
I
RED 4
PURPLE OPZIONAL 3
OXYGEN SENSOR 2 1
1° CYLINDER
INJECTORS
GAS AND
PRESSURE 17
POSTERIOR SOLENOID
VALVE AND
SENSOR
GAS PORTS
BLACK E1
L BROWN
- +
CUT INJECTORS
ORANGE G RPM
WIRING
BLACK M
GAS TEMPERATURE COIL
1 2 3 4
SENSOR REDUCER
WHITE (LINEA K) PIN 7

N PETROL INJECTORS
CONNECTOR
YELLOW/BLACK (LINEA CAN -) PIN 14
BLUE F
“ZETA”
CONNECTOR
OBD
SOLENOID VALVES
ZAVOLI srl ISG-4C-BS32-OBD-ZTJ-LPG-011.00-I Del 05/04/2016

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LEGENDA:
5
INGRESSO
SENSORE MAP ACQUA
800DE802060
NEW BORA ECU
RIDUTTORE 10
100ZETA
ELETTROVALVOLA
INIETTORI 495002 SENSORE TEMPERATURA

JET PRESSIONE
800DE525001
18
10
400.FILTER
FILTRO
495002
5
ZAVOLI srl ISG-KNWB-4CPNV-GPL-001.01 Del 14/11/2013 MAX 150 mm www.zavoli.com
4 Cylinders Bora Light CNG
CHANGEOVER
SWITCH BLACK
MAP SENSOR GROUND
RED/BLACK
D
C A
O
BATTERY
STA NDARD SENSO RS C NG

P WHITE RED
BLAC K BLACK
E
WHITE WHITE
I
4
INSULATE OPZIONAL 3
PURPLE 2
OXYGEN SENSOR 1
1° CYLINDER
POSTERIOR SOLENOID
INJECTORS
GAS AND 19
VALVE AND PRESSURE
GAS PORTS
SENSOR
BLACK
E1
M
WHITE/BLUE
RPM SIGNAL CUT INJECTORS
WIRING RED /WHITE
BLUE/BLACK
L - +
BROWN BLUE
ORANGE G
RPM
BLACK
RED/BLACK
GAS TEMPERATURE COIL RED
SENSOR REDUCER
GREEN/BLACK
SOLENOID VALVES
GREEN
YELLOW/BLACK
BLUE F
YELLOW
BLACK
VAPORIZER/
REDUCER - - +
- +
- +
+
“META”

ZAVOLI srl ISG-4C-BS32-LIGHT-MTJ-CNG-009.00-E Del 06/04/2016
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CHANGEOVER
SWITCH BLACK
MAP SENSOR GROUND
RED/BLACK
D
C A
O
BATTERY
P
STA NDARD SENSO RS C NG WHITE RED
BLAC K BLACK
E
WHITE WHITE
I
4
INSULATE OPZIONAL 3
PURPLE 2
OXYGEN SENSOR 1
1° CYLINDER

SENSOR
BLACK
E1
WHITE/BLUE
RPM SIGNAL
L BROWN
- +
CUT INJECTORS
ORANGE G WIRING
RPM
BLACK M
COIL
GAS TEMPERATURE 1 2 3 4
SENSOR REDUCER
SOLENOID VALVES WHITE (LINEA K) PIN 7

N PETROL INJECTORS
CONNECTOR
BLUE F
BLACK
VAPORIZER/ CONNECTOR
REDUCER OBD
“META”
ZAVOLI srl ISG-4C-BS32-OBD-MTJ-CNG-011.00-E Del 06/04/2016

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LEGENDA:
RIDUTTORE
META/S
INGRESSO
FILTRO - FILTER - FILTRO ACQUA
SENSORE TEMPERATURE PRESSIONE - GAS AND PRESSURE TEMPERATURE SENSOR - SENSORTEMPERATURA Y PRESION ELETTROVALVOLA
SENSORE MAP
800DE802060
NEW BORA ECU
INIETTORI 3201000
JET
495002
21
10
SENSORE TEMPERATURA
PRESSIONE
800DE525001
10
400.FILTER
FILTRO
495002
5
ZAVOLI srl ISG-KNWB-4CSPNV-CNG-001.01 Del 18/11/2013 MAX 150 mm www.zavoli.com
DIAGNOSTIC CHANGEOVER
CONNECTOR SWITCH MAP SENSOR
MELTABLE RELAY
FUSE 15A
GAS CONTROL UNIT D

CONNECTOR
C
O
B
STANDARD SENSORS
WHITE
E 1 2 3 4
WHITE
BLACK M
BLACK
RED CUT INJECTORS
WIRING BANK 1
DO NOT
WARNING! CONNECT
THE CONNECTOR WITH RING “1”
SHOULD BE CONNECTED TO THE
GAS INJECTOR WITH RING “1”
POSTERIOR SOLENOID
VALVE AND
GAS PORTS I
BLACK 4 3
E1 2 1
WHITE/BLUE DO NOT
CONNECT
L
YELLOW/BLACK (LINEA CAN -) PIN 14 INJECTORS

CONNECTOR “JET”
EOBD
VIOLET
22
BANK 1 OXYGEN RED RING
SENSOR FITTING H
DO NOT CONNECT 2M
GREY
VIOLET/BLACK 5 6 7 8
BANK 2 OXYGEN
SENSOR FITTING N
DO NOT CONNECT CUT INJECTOR
GREY/BLACK WIRING
BANK 2
RPM SIGNAL
WARNING!
BROWN SHOULD BE CONNECTED TO THE
+ -
Q GAS INJECTOR WITH RING “5”
2I
RPM
+ 12 V
RED/WHITE
COIL 8 7
RED RING 6
5
TO EXTERNAL L
ORANGE/WHITE
SPARK TIMING
ADVANCER DO NOT
CONNECT
GAS AND
ORANGE PRESSURE
TEMPERATURE
BLACK G INJECTORS SENSOR
GAS TEMPERATURE “JET”
SENSOR REDUCER
P WHITE RED
BLUE BLACK
VAPORIZER/REDUCER BLACK GROUND
F A
“ZETA”
RED/BLACK
SOLENOID VALVES
BATTERY
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LEGENDA:
SENSORE MAP - MAP SENSOR - SENSOR MAP 5
SENSORE MAP INGRESSO

800DE802060 ACQUA
INIETTORI
NEW BORA ECU JET
SENSORE TEMPERATURA
PRESSIONE
800DE525001 RIDUTTORE
100ZETA
ELETTROVALVOLA
10 23
495002
400.FILTER
FILTRO
5
495002 MAX 150 mm
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ZAVOLI srl ISG-KNWB-5CPNV-GPL-003.01 Del 18/11/2013
MELTABLE RELAY
FUSE 15A
GAS CONTROL UNIT D

CONNECTOR
C
O
B
LEVEL SENSO R STANDA RD C NG
BLA C K BLACK
1 2 3 4
EE
WHITE WHITE M
CUT INJECTORS
INSULATE WIRING BANK 1
DO NOT
CONNECT
WARNING!
POSTERIOR SOLENOID THE CONNECTOR WITH RING “1”
VALVE AND SHOULD BE CONNECTED TO THE
GAS PORTS GAS INJECTOR WITH RING “1”
BLACK
E1
WHITE/BLUE I
4 3
2 1
DO NOT
CONNECT
L
YELLOW/BLACK INJECTORS
(LINEA CAN -) PIN 14
“JET”
CONNECTOR
OBD
BANK 1 OXYGEN
SENSOR FITTING
VIOLET
H
RED RING
24
DO NOT CONNECT GREY 2M
5 6 7 8
VIOLET/BLACK
BANK 2 OXYGEN N
SENSOR FITTING CUT INJECTOR
DO NOT CONNECT GREY/BLACK WIRING
BANK 2
WARNING!
RPM SIGNAL THE CONNECTOR WITH RING “5”
+ - BROWN 2I
Q
RPM
RED/WHITE
+ 12 V 8 7
COIL RED RING 6
5
TO EXTERNAL L
ORANGE/WHITE DO NOT
SPARK TIMING
ADVANCER CONNECT
ORANGE
BLACK
G INJECTORS
SENSOR REDUCER GAS AND
PRESSURE
TEMPERATURE
SENSOR
SOLENOID VALVES
WHITE RED P
BLUE BLACK
BLACK GROUND
VAPORIZER/
F A
REDUCER
“META” RED/BLACK
BATTERY
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LEGENDA:
RIDUTTORE
INIETTORE - INJECTORES - INYECTOR META/S
INGRESSO
SENSORE MAP - MAP SENSOR - SENSOR MAP ACQUA
INGRESSO ACQUA - WATER INLET - AGUA DE ENTRADA ELETTROVALVOLA
NEW BORA ECU

SENSORE MAP
800DE802060
INIETTORI
JET SENSORE TEMPERATURA
PRESSIONE 3201000
800DE525001 5
25
10
495002
400.FILTER
FILTRO
5
495002 MAX 150 mm
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ZAVOLI srl ISG-KNWB-5CSPNV-CNG-003.01 Del 18/11/2013

MELTABLE RELAY
FUSE 15A
GAS CONTROL UNIT D

CONNECTOR
C
O
B
STANDARD SENSORS
WHITE
E 1 2 3 4
WHITE
BLACK M
BLACK
RED CUT INJECTORS
WIRING BANK 1
DO NOT
WARNING!CONNECT
POSTERIOR SOLENOID
VALVE AND
GAS PORTS I
BLACK 4 3
E1 2 1
WHITE/BLUE DO NOT
CONNECT
L
INJECTORS
“JET”
CONNECTOR
EOBD
VIOLET
26
SENSOR FITTING H
DO NOT CONNECT 2M
GREY
BANK 2 OXYGEN
SENSOR FITTING N
GREY/BLACK WIRING
BANK 2
RPM SIGNAL WARNING!

+ -
2I
RPM
+ 12 V
COIL RED/WHITE
8 7
RED RING 6
5
TO EXTERNAL L DO NOT
ORANGE/WHITE
SPARK TIMING CONNECT
ADVANCER
ORANGE
BLACK G INJECTORS
SENSOR REDUCER
GAS AND
PRESSURE
TEMPERATURE
SENSOR
WHITE RED P
BLUE BLACK
F A
“ZETA”
RED/BLACK
SOLENOID VALVES
BATTERY
ZAVOLI srl ISG-6C-NWBNLPG-PNV-004.02-E Del 06/04/2016
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LEGENDA:
ELETTROVALVOLA - SOLENOID VALVES - ELETROVALVULA SENSORE MAP
RIDUTTORE - REDUCER - RIDUTOR 800DE802060
SENSORE TEMPERATURE PRESSIONE - GAS AND PRESSURE TEMPERATURE SENSOR - SENSOR TEMPERATURA Y PRESION 5
SENSORE TEMPERATURA INIETTORI 495002

PRESSIONE JET
800DE525001
NEW BORA ECU
10
27
5
495002
MAX 150 mm
INGRESSO
ACQUA
RIDUTTORE
100ZETA
3201000
400.FILTER 400.FILTER ELETTROVALVOLA
FILTRO FILTRO
10
www.zavoli.com
MELTABLE RELAY
FUSE 15A
GAS CONTROL UNIT D

CONNECTOR
C
O
B
BLA C K BLACK
1 2 3 4
E
WHITE WHITE M
CUT INJECTORS
DO NOT
WARNING!CONNECT
BLACK
E1
WHITE/BLUE I
4 3
2 1
DO NOT
CONNECT
L
YELLOW/BLACK INJECTORS
“JET”
CONNECTOR
OBD
28
VIOLET
BANK 1 OXYGEN
RED RING
SENSOR FITTING H
DO NOT CONNECT GREY
2M
5 6 7 8
VIOLET/BLACK
BANK 2 OXYGEN
SENSOR FITTING N
DO NOT CONNECT GREY/BLACK CUT INJECTOR
WIRING
BANK 2
RPM SIGNAL WARNING!

BROWN GAS INJECTOR WITH RING “5”
Q
+ -
2I
RPM
RED/WHITE
+ 12 V
COIL 8 7
RED RING 6
5
DO NOT
CONNECT
TO EXTERNAL L
ORANGE/WHITE
SPARK TIMING
ADVANCER
ORANGE
BLACK
G
INJECTORS
PRESSURE
TEMPERATURE
SENSOR
SOLENOID VALVES
WHITE RED P
BLUE BLACK
BLACK GROUND
VAPORIZER/
F A
REDUCER
BATTERY
www.zavoli.com
LEGENDA:
ELETTROVALVOLA - SOLENOID VALVES - ELETROVALVULA SENSORE MAP
RIDUTTORE - REDUCER - RIDUTOR 800DE802060
SENSORE TEMPERATURE PRESSIONE - GAS AND PRESSURE TEMPERATURE SENSOR - SENSOR TEMPERATURA Y PRESION
5
SENSORE TEMPERATURA INIETTORI 495002

PRESSIONE JET
800DE525001
NEW BORA ECU
10
29
5
495002
MAX 150 mm
RIDUTTORE
META/S
INGRESSO
ACQUA
400.FILTER 400.FILTER
FILTRO FILTRO
ELETTROVALVOLA
10
ZAVOLI srl ISG-KNWB-6CSPNV-CNG-004.01 Del 18/11/2013 www.zavoli.com
MELTABLE RELAY
FUSE 15A
GAS CONTROL UNIT D

CONNECTOR
C
O
B
STANDARD SENSORS
WHITE
E 1 2 3 4
WHITE
BLACK M
BLACK
RED CUT INJECTORS
WIRING BANK 1
WARNING!
POSTERIOR SOLENOID
VALVE AND
GAS PORTS I
BLACK 4 3
E1 2 1
WHITE/BLUE
L INJECTORS
“JET”

CONNECTOR
EOBD
VIOLET
30
SENSOR FITTING H
DO NOT CONNECT 2M
GREY
BANK 2 OXYGEN
SENSOR FITTING N
GREY/BLACK WIRING
BANK 2
RPM SIGNAL WARNING!
2I
+ -
RPM
+ 12 V
RED/WHITE
COIL 8 7
RED RING 6
5
TO EXTERNAL L
ORANGE/WHITE
SPARK TIMING
ADVANCER
INJECTORS
ORANGE “JET”
BLACK G
GAS TEMPERATURE
SENSOR REDUCER
GAS AND
PRESSURE
TEMPERATURE
SENSOR
WHITE RED P
BLUE BLACK
F A
“ZETA”
RED/BLACK
SOLENOID VALVES
BATTERY
ZAVOLI srl ISG-8C-NWBNLPG-PNV-005.02-I Del 06/04/2016
www.zavoli.com
SENSORE MAP
800DE802060
NEW BORA ECU
5
10
5
MAX 150 mm
495002
495002
INIETTORE
INIETTORE 495002 JET
JET
31
SENSORE
TEMPERATURA
PRESSIONE
800DE525001
3201000
400.FILTER 400.FILTER INGRESSO
LEGENDA: FILTRO FILTRO ACQUA
INIETTORE - INJECTORES - INYECTOR 10
FILTRO - FILTER - FILTRO RIDUTTORE
INGRESSO ACQUA - WATER INLET - AGUA DE ENTRADA 100ZETA
ELETTROVALVOLA

www.zavoli.com
MELTABLE RELAY
FUSE 15A
GAS CONTROL UNIT D

CONNECTOR
C
O
B
BLA C K BLACK
1 2 3 4
E
WHITE WHITE M
CUT INJECTORS
WARNING!
BLACK
E1
WHITE/BLUE I
4 3
2 1

L
INJECTORS
YELLOW/BLACK
“JET”
CONNECTOR
OBD
32
VIOLET
SENSOR FITTING H
DO NOT CONNECT GREY
2M
5 6 7 8
VIOLET/BLACK
BANK 2 OXYGEN
SENSOR FITTING N
DO NOT CONNECT GREY/BLACK CUT INJECTOR
WIRING
BANK 2
RPM SIGNAL WARNING!

BROWN GAS INJECTOR WITH RING “5”
Q 2I
+ -
RPM
RED/WHITE
+ 12 V
COIL 8 7
RED RING 6
5
TO EXTERNAL L
ORANGE/WHITE
SPARK TIMING
ADVANCER
ORANGE
INJECTORS
BLACK
G “JET”
GAS TEMPERATURE
PRESSURE
TEMPERATURE
SENSOR
SOLENOID VALVES
WHITE RED P
BLUE BLACK
BLACK GROUND
VAPORIZER/
F A
REDUCER
BATTERY
www.zavoli.com
SENSORE MAP
800DE802060
NEW BORA ECU
5
10
5
MAX 150 mm
495002
495002
INIETTORE
INIETTORE 495002 JET
JET
33
SENSORE
TEMPERATURA
PRESSIONE
800DE525001
RIDUTTORE
META/S
INGRESSO
ACQUA
400.FILTER 400.FILTER
LEGENDA: FILTRO FILTRO
FILTRO - FILTER - FILTRO 10
SENSORE TEMPERATURE PRESSIONE - GAS AND PRESSURE TEMPERATURE SENSOR - SENSORTEMPERATURA Y PRESION ELETTROVALVOLA
ZAVOLI srl ISG-KNWB-8CSPNV-CNG-005.01 Del 18/11/2013

www.zavoli.com
Standard Errors Codes Bora
ERROR
DESCRIPTION
CODE
P0006 Rear Fuel Cut-Off Solenoid Valve Control Circuit Low
P0007 Rear Fuel Cut-Off Solenoid Valve Control Circuit High
P01A5 Alternative fuel rail pressure circuit low voltage
P01A6 Alternative fuel rail pressure circuit high voltage
P01B5 Alternative fuel rail temperature, circuit performance
P01B6 Alternative fuel rail temperature circuit low voltage
P01B7 Alternative fuel rail temperature high voltage
P2146 Alternative fuel actuators supply voltage
P16B4 Sensors supply voltage low
P22DA Cylinder 1 alternative fuel injector circuit low
P22DB Cylinder 1 alternative fuel injector circuit high
P22DE Cylinder 2 alternative fuel injector circuit low
P22DF Cylinder 2 alternative fuel injector circuit high
P22E2 Cylinder 3 alternative fuel injector circuit low
P22E3 Cylinder 3 alternative fuel injector circuit high
P22E6 Cylinder 4 alternative fuel injector circuit low
34
P22E7 Cylinder 4 alternative fuel injector circuit high
P22EA Cylinder 5 alternative fuel injector circuit low
P22EB Cylinder 5 alternative fuel injector circuit high
P22EE Cylinder 6 alternative fuel injector circuit low
P22EF Cylinder 6 alternative fuel injector circuit high
P22F2 Cylinder 7 alternative fuel injector circuit low
P22F3 Cylinder 7 alternative fuel injector circuit high
P22F6 Cylinder 8 alternative fuel injector circuit low
P22F7 Cylinder 8 alternative fuel injector circuit high
P2666 High Pressure cut-off solenoid valve in front, control circuit low
P2667 High Pressure cut-off solenoid valve in front, control circuit high
P15AE System voltage low voltage
P15AF System voltage high voltage
P2115 Water temperature sensor signal not plausible
www.zavoli.com
Program Errors Codes Bora
ERROR
CAUSE
CODE
0 No error
1 Generic error
2 Framework.Net 4.0 Extended not installed
3 SQL Server Compact 4.0 not installed
The language set for the application is not valid (it does not exist in the DB, or it exists
4
but the resource file is missing)
5 License File error
6 Error in the chart settings File
100 Error in the Database Opening
101 Error in the retrieval of the SQL command
102 Error in the retrieval of the SQL parameter
103 Error in the retrieval of the languages
104 Error in the retrieval of the skin info (id_group and group code)
105 Error in the retrieval in the enabling of user functions
106 Error in the retrieval of the list of the variables based on the skin and language
Error in the retrieval of the info relating to the ecu and software (ECU and ECU_DERIVA-
107
TIVES and SOFTWARE and Enabling of Functions - GetEcuDetails)
108 ECU not present in the DB (GetEcuDetails) 35
109 ECU sw not present in the DB (GetEcuDetails)
200 Error in the initialisation of the communication library (oEcuLib.InitLibrary)
201 Error in the opening of the connection (oEcuLib.OpenConnection)
202 The request for info to the library returned FALSE
203 The control unit returned a negative reply to the request
205 The data that has returned from the control unit is not in the correct format (DATA_KO)
206 Error in the procedure management of the info (OnGetEcuInfo)
There is no feature to read the Flag in RAM or failure in the read request (Share-
207
dRamwithPC)
The Ecu has an ID that is not complete, and the user is not enabled to connect to Ecu
300
with an incomplete ID
301 The Ecu was programmed by a toll of a group different from the user's license
302 Ecu not associated to the SKIN group
303 File A2L does not exist
304 Error in the loading of the A2L file
305 Error in the reading of the calibration from the ECU
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Fitting Instructions Bora System

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Fitting Instructions Bora System

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Available Formats

Fitting Instructions

3 Cylinders Fitting Schemes 10

2 CYLINDERS 3 CYLINDERS 4 CYLINDERS 5 CYLINDERS 6 CYLINDERS 8 CYLINDERS

FOR CARS 4 CYLINDERS 3 2

CABLE ECU GAS

CUT INJECTOR PETROL INJECTORS

Standard: Leave the Map sensor always connected.

OEM: Connect the White wire of the gas Ecu to

Software Setting (example setting values map oem)

PETROL INJECTORS CONNECTOR

CUT INJECTORS PETROL INJECTORS

ZAVOLI srl ISG-3C-BS32-OBD-ZTJ-LPG-010.00-E Del 05/04/2016

ZAVOLI srl ISG-KNWB-3CPNV-GPL-002.01 Del 18/11/2013 www.zavoli.com

STA NDARD SENSO RS C NG

POSTERIOR SOLENOID GAS AND 13

PETROL INJECTORS CONNECTOR

STA NDARD SENSO RS C NG P

POSTERIOR SOLENOID GAS AND 14

CUT INJECTORS PETROL INJECTORS

ZAVOLI srl ISG-3C-BS32-OBD-MTJ-CNG-010.00-E Del 06/04/2016

NEW BORA ECU

POSTERIOR SOLENOID INJECTORS

PETROL INJECTORS CONNECTOR

WHITE (LINEA K) PIN 7

ZAVOLI srl ISG-4C-BS32-OBD-ZTJ-LPG-011.00-I Del 05/04/2016

INIETTORI 495002 SENSORE TEMPERATURA

STA NDARD SENSO RS C NG

PETROL INJECTORS CONNECTOR

POSTERIOR SOLENOID GAS AND 20

SOLENOID VALVES WHITE (LINEA K) PIN 7

ZAVOLI srl ISG-4C-BS32-OBD-MTJ-CNG-011.00-E Del 06/04/2016

GAS CONTROL UNIT D

YELLOW/BLACK (LINEA CAN -) PIN 14 INJECTORS

SENSORE MAP INGRESSO

GAS CONTROL UNIT D

LEVEL SENSO R STANDA RD C NG

NEW BORA ECU

ZAVOLI srl ISG-KNWB-5CSPNV-CNG-003.01 Del 18/11/2013

GAS CONTROL UNIT D

RPM SIGNAL WARNING!

SENSORE TEMPERATURA INIETTORI 495002

GAS CONTROL UNIT D

LEVEL SENSO R STANDA RD C NG

RPM SIGNAL WARNING!

SENSORE TEMPERATURA INIETTORI 495002

GAS CONTROL UNIT D

YELLOW/BLACK (LINEA CAN -) PIN 14

ZAVOLI srl ISG-KNWB-8CPNV-GPL-005.01 Del 18/11/2013

GAS CONTROL UNIT D

LEVEL SENSO R STANDA RD C NG

YELLOW (LINEA CAN +) PIN 6

RPM SIGNAL WARNING!

ZAVOLI srl ISG-KNWB-8CSPNV-CNG-005.01 Del 18/11/2013

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