Course Title: CNG Vehicle Conversion

Duration: 2 Weeks (10 days)

Outline: Comprehensive Technician Training (Focus on Installation & Safety)

Target Audience: Auto Mechanics, Technicians, and Engineers new to CNG.

Goal: To equip participants with the knowledge and practical skills to safely install, maintain, and troubleshoot CNG conversion kits on gasoline vehicles.

Week 1: Fundamentals & Components

• Day 1: Introduction to CNG & Automotive Basics (Theory)
  • What is CNG? Properties, advantages, disadvantages vs. Petrol/Diesel.
  • Safety protocols for handling CNG.
  • Overview of internal combustion engines (petrol focus).
  • Basic automotive electrical systems review.
• Day 2: CNG Conversion Systems & Components (Theory & Demo)
  • Types of CNG conversion kits (Venturi, Sequential Injection).
  • Detailed look at components: Cylinder, Pressure Regulator, Injectors, ECU, Piping, Filling Valve, Gauges.
  • Function and selection criteria for each component.
  • Understanding system diagrams.
• Day 3: Cylinder Installation & Safety (Theory & Practical)
  • Types of CNG cylinders and safety standards (ISO, SON).
  • Proper mounting procedures and structural considerations.
  • Valve and safety device installation (PRD, manual valve).
  • Workshop Practice: Inspecting cylinders, mounting bracket fabrication/installation.
• Day 4: High-Pressure Piping & Regulator (Theory & Practical)
  • Materials and types of high-pressure pipes and fittings.
  • Proper routing, bending, and securing of pipelines.
  • Pressure regulator installation and connection.
  • Leak detection methods (soapy water, electronic detectors).
  • Workshop Practice: Pipe bending, fitting installation, regulator mounting.

• Day 5: Low-Pressure System & Injectors (Theory & Practical)
  • Connecting the regulator to the fuel rail/injectors.
  • CNG injector types and installation (drilling intake manifold).
  • Solenoid valves and filter installation.
  • Workshop Practice: Manifold drilling (on dummy manifold), injector fitting, low-pressure hose connection.

Week 2: Electrical, Calibration & Troubleshooting

• Day 6: Electrical Wiring & ECU Installation (Theory & Practical)
  • Understanding the CNG ECU wiring harness.
  • Connecting to vehicle sensors (MAP, O2, TPS, RPM signals).
  • Injector wiring, changeover switch installation.
  • Power supply and grounding best practices.
  • Workshop Practice: Identifying sensor wires, tapping/soldering connections, ECU mounting.
• Day 7: Software Installation & Basic Calibration (Theory & Software Lab)
  • Introduction to CNG tuning software.
  • Connecting laptop to CNG ECU.
  • Reading vehicle parameters.
  • Initial setup and configuration (engine type, injector size etc.).
  • Basic map adjustment concepts.
  • Software Lab: Installing software, connecting to ECU simulator, navigating parameters.
• Day 8: Calibration & Tuning (Theory & Live Vehicle Practice)
  • Fuel trim concepts (Short Term/Long Term Fuel Trim – STFT/LTFT).
  • Calibration process: Idle tuning, part-load tuning, full-load tuning.
  • Using OBDII scanner alongside CNG software.
  • Optimizing for performance and emissions.
  • Live Vehicle Practice: Performing basic calibration on a converted vehicle under supervision.
• Day 9: System Diagnostics & Troubleshooting (Theory & Practical)
  • Common CNG system faults (leaks, electrical issues, starting problems, poor performance).
  • Using diagnostic tools (software, OBD scanner, multimeter).
  • Troubleshooting procedures.
  • Maintenance schedule for CNG systems.
  • Workshop Practice: Simulating faults, diagnosing issues on test benches/vehicles.
• Day 10: Regulations, Certification & Final Assessment
  • Nigerian regulations for CNG conversion (SON, DPR guidelines).
  • Documentation and certification process.
  • Business aspects and customer relations.
  • Final Practical Assessment: Basic installation check and calibration task.
  • Written Test & Course Review.