NHTSA ID Number: 10082015
Manufacturer Communication Number: ENP-371
TSB/Document Date: 2016-10-11
Summary
SERVICE BULLETIN WITH INSTRUCTIONS TO REMOVE AND INSULATE UN-NEEDED WIRES FROM THE INSTALLATION WIRE HARNESS ENDS AND PLUG EMPTY HOLES IN THE CONNECTOR HOUSING.
Field Service Bulletin
Kenworth
BTC UPS
CNG Fuel Gauge Wiring Repair
ENP-371
March 17, 2015
1. Introduction
New 160 DGE BTC systems released from the Kelowna plant from 1/1/15 to 3/16/15 have a
potential ECU programming error and an improper wire harness modification.
Figure 1 Two wires in the three-pin connector between the ECU and the dashboard fuel
gauge must be removed (red arrows) to enable proper fuel gauge operation
2. Affected Units
This procedure applies to 45 vehicles. A list of VINs is included at the end of this bulletin.
3. Corrective Action
Remove and insulate un-needed wires from the installation wire harness ends and plug the empty
holes in the connector housings. The wiring harness inside the fuel management module is NOT
affected and should not be modified.
4. Parts, Materials and Tools Required
QTY
2
2
PART NUMBER
10400032
10400100
DESCRIPTION
MOLEX CAVITY PLUG
WEATHERPACK GREEN CAVITY PLUG
Molex pin removal tool (Note: A paper clip can be used to retract the pin from the connector
housing.)
WeatherPack pin removal tool
5. Procedure
CAUTION
Make sure to insulate and protect wires with adhesive-lined heat shrink tubing and
the proper plugs to prevent corrosion.
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1. Leave tractor in key off position to ensure no electrical power is going to ECU.
2. Verify Agility Fuel Systems harness part number 10400221 “Rev B” or “Rev New” as shown
in Figure 2.
Wire harness part
number and Rev
Chassis connection
– green and blue
harness wires
Chassis harness
connection, white
signal wire to in-dash
fuel gauge
Clipped wires, replace with
cavity plug
White wire connecting to left
side connector in photo
Figure 2 Wire harness identification and wire colors
3. Refer to Figure 2. Identify and separate three wires (pink, gray, white) from the wire loom
for the fuel level gauge. The three wires should connect to an extension harness with one
white wire in a 2-pin connector with one blue and one green wire.
4. Make sure the 3-pin Weatherpak connector has one white wire with the other two pin
positions filled with green cavity plugs. Any wires that are cut in this area must be removed
to prevent a corrosion path from developing.
5. Check the other side of this 3-pin connection to make sure there are matching green cavity
plugs and a white wire.
6. See Figure 4 and the Reference section. Remove the pink (pin 13, solenoid valve power)
and gray (pin 9, gauge ground) wires from the 16-pin connector. Note: The pink wire at pin
5 is NOT removed.
7. NOTE: The white section of the 16 pin connector (terminal position assurance - TPA) must
be popped out to enable pin removal, see Reference section.
8. Install plugs at locations 13 and 9 to retain weatherproofing.
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Figure 3 Remove the pink wire (pin 13) and gray wire (pin 9) from the 16-pin connector and
replace them with insulating plugs
9. Check the 2 pin connector that connects to the dashboard fuel gauge to make sure unused
pins have cavity plugs. The chassis side should include a blue and green wire. The blue
wire should receive the fuel gauge signal (white wire).
10. Install the correct ECU with the correct calibration file and firmware version:
Kenworth02.gau calibration and Firmware 5.0, part number 20102105
6. Warranty Statement
This procedure is covered under warranty. Standard repair time (SRT) is 0.5 hours. Refer to
warranty reimbursement procedures in the Warranty Manual, ENP-067.
Contact Agility Fuel Systems Product Support at 949-267-7745 or [email protected] for more
information.
Agility Fuel Systems
1815 Carnegie Ave
Santa Ana, CA 92705 USA
Product Support
949-267-7745
[email protected]
Proprietary Statement
ENP-371 Kenworth UPS BTC Fuel Gauge Wiring Repair
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The information provided within this document is proprietary and confidential. All prior versions of
this document, including updates and revisions forwarded separately, are proprietary. The
information provided by Agility Fuel Systems to its customers and clients is solely for the use of
those customers and clients. No portion of this manual may be reproduced or distributed without
express written consent of Agility Fuel Systems. Agility Fuel Systems reserves the right to utilize
the intellectual property contained within this publication as content for any other publication
produced by Agility Fuel Systems.
Warning Message Used in this Bulletin
CAUTION
Damage to equipment, fuel system or vehicle is possible if instructions are not
followed
Revision
Description
Author
Approved By
Date
--
Initial Release
W. Yoshida
M. Gustafson
3/16/15
7. Reference
Molex Connector Pin Extraction Instructions:
http://www.molex.com/pdm_docs/ats/ATS-638131500.pdf
WeatherPack Pin Removal:
http://www.weatherpackkits.com/how-to-remove-weatherpack-terminals-from-housings/
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Kenworth UPS - CNG VIN List of Affected Vehicles
477498
1NKYA38X0GJ477498
276125
New Orleans, LA
477499
1NKYA38X2GJ477499
276126
New Orleans, LA
477500
1NKYA38X5GJ477500
276127
New Orleans, LA
477501
1NKYA38X7GJ477501
276128
New Orleans, LA
477502
1NKYA38X9GJ477502
276129
New Orleans, LA
477503
1NKYA38X0GJ477503
276130
New Orleans, LA
477504
1NKYA38X2GJ477504
276131
New Orleans, LA
477505
1NKYA38X4GJ477505
276132
New Orleans, LA
477506
1NKYA38X6GJ477506
276133
New Orleans, LA
477507
1NKYA38X8GJ477507
276134
New Orleans, LA
477508
1NKYA38XXGJ477508
276135
New Orleans, LA
477509
1NKYA38X1GJ477509
276136
New Orleans, LA
477510
1NKYA38X8GJ477510
276137
New Orleans, LA
477511
1NKYA38XXGJ477511
276138
New Orleans, LA
477512
1NKYA38X1GJ477512
276139
New Orleans, LA
477513
1NKYA38X3GJ477513
276140
Oklahoma City, OK
477514
1NKYA38X5GJ477514
276141
Oklahoma City, OK
477515
1NKYA38X7GJ477515
276142
Oklahoma City, OK
477516
1NKYA38X9GJ477516
276143
Oklahoma City, OK
477517
1NKYA38X0GJ477517
276144
Oklahoma City, OK
477518
1NKYA38X2GJ477518
276145
Oklahoma City, OK
477519
1NKYA38X4GJ477519
276146
Oklahoma City, OK
477520
1NKYA38X0GJ477520
276147
Oklahoma City, OK
477521
1NKYA38X2GJ477521
276148
Oklahoma City, OK
477522
1NKYA38X4GJ477522
276149
Oklahoma City, OK
477523
1NKYA38X6GJ477523
276150
Oklahoma City, OK
477524
1NKYA38X8GJ477524
276151
Oklahoma City, OK
ENP-371 Kenworth UPS BTC Fuel Gauge Wiring Repair
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477525
1NKYA38XXGJ477525
276152
Oklahoma City, OK
477526
1NKYA38X1GJ477526
276153
Oklahoma City, OK
477527
1NKYA38X3GJ477527
276154
Oklahoma City, OK
477528
1NKYA38X5GJ477528
276155
Oklahoma City, OK
477529
1NKYA38X7GJ477529
276156
Oklahoma City, OK
477530
1NKYA38X3GJ477530
276157
Oklahoma City, OK
477531
1NKYA38X5GJ477531
276158
Oklahoma City, OK
477532
1NKYA38X7GJ477532
276159
Oklahoma City, OK
477533
1NKYA38X9GJ477533
276160
Oklahoma City, OK
477534
1NKYA38X0GJ477534
276161
Oklahoma City, OK
477535
1NKYA38X2GJ477535
276162
Oklahoma City, OK
477536
1NKYA38X4GJ477536
276163
Oklahoma City, OK
477537
1NKYA38X6GJ477537
276164
Oklahoma City, OK
477538
1NKYA38X8GJ477538
276165
ATLANTA, GA
477539
1NKYA38XXGJ477539
276166
ATLANTA, GA
477540
1NKYA38X6GJ477540
276167
ATLANTA, GA
477541
1NKYA38X8GJ477541
276168
ATLANTA, GA
477542
1NKYA38XXGJ477542
276169
ATLANTA, GA
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TSB/Document ID: ENP-371
Replacement Service Bulletin Number:
MFR Communication Date: 2015-03-17
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, OTHER:STORAGE:FUEL GAUGE SYSTEM
MFR Component System:
MFR Component Subsystem:
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