NHTSA ID Number: 10200281
Manufacturer Communication Number: DSM.0001
TSB/Document Date: 2021-08-09
Summary
Blue iQ® Diagnostic Service Manual. Blue iQ system product description and operation overview including component locations and operating specifications, thermistor replacement, lists of fault code diagnostic procedures.
4
3
2
5
1
door side
4
FIGURE 2–27. Box FMM fuel fill door DAP components
1 contact switch
2 lock nut
3 washer
DSM.0001 Ver 1.0
July 20, 2021
panel side
4 cable gland
5 magnet
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panel side switch (rectangles)
door side switch (circles)
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2.6.2. Fuel receptacle cap(s)
Fuel systems not equipped with an FMM door typically use fuel receptacle caps to prevent FOD intrusion and
for DAP. A magnet in the cap aligns with a magnet on the tether to close a reed switch in the FMM panel,
completing the circuit to the FSCM. FIGURE 2–28, FIGURE 2–29, FIGURE 2–30, FIGURE 2–31
FRONT
4
3
2
6
1
5
4
5
FIGURE 2–28. Driver side ProCab® BTC FMM fuel receptacle caps and DAP components
1 FMM fuel fill panel with HP fuel gauge
2 NGV1 fuel fill receptacle
DSM.0001 Ver 1.0
July 20, 2021
3 fast fill fuel receptacle
4 magnets
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5 caps
6 tether
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4
3
FRONT
5
4
1
2
5
2
4
FIGURE 2–29. Gen 5 ProRail® side mount FMM fuel receptacle fuel cap DAP components
1 FMM fuel fill panel with HP fuel gauge
2 NGV1 fuel fill receptacle
3 fast fill fuel receptacle
4 magnets
5 fuel cap
FRONT
1
3
3
FIGURE 2–30. Gen 5 ProRail® side mount FMM cutaway
showing fuel receptacle DAP reed switch locations
1 fuel fill manifold
DSM.0001 Ver 1.0
July 20, 2021
2 reed switches
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3 fuel caps
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connector end view
connector image
reed switch assembly
FIGURE 2–31. Reed switch assembly with fuel door and fuel receptacle fuel cap connector views
Fuel door reed switch circuit pin out
Pin
Color
Circuit
A
Gray
DAP Signal
B
Black/White
DAP Return
2.6.3. Fuel receptacle kill cap(s)
“Kill” caps used on some fuel systems prevent engine starts when not installed on the fuel fill receptacle. FIGURE
2–32
1
2
4
4
5
3
5
FIGURE 2–32. Auxiliary (AUX) body side fuel fill receptacle assembly with kill cap; kill cap assemblies
1 AUX fuel fill panel
3 fuel receptacle
3 Blue iQ chassis harness
2 fuel receptacle
4 kill cap
5 kill cap connector
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July 20, 2021
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Kill caps are often used on systems with auxiliary (AUX) fuel fill receptacles separate from the FMM. These
remote fill panels are often installed on or near the front bumper but may be configured for other locations per
OEM or customer preferences on the body side or body rear.
Unlike two wire reed switch DAP circuits, the kill cap DAP circuit relies on one wire to carry the FSCM DAP 5
Signal, while the fuel fill receptacle provides ground. FIGURE 2–33
connector end view kill cap assembly
harness connector images
A
FIGURE 2–33. Fuel receptacle kill cap connector views
Fuel receptacle kill cap circuit pin out
Pin
Color
Circuit
A
Gray
DAP 5 Signal
The DAP 5 circuit is always used on auxiliary (AUX) fuel fill receptacles such as front
bumper fill or body side fill receptacles.
DSM.0001 Ver 1.0
July 20, 2021
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DAP 1 and DAP 2 circuit diagram
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Typical* DAP 3, DAP 4, and DAP 5 circuit diagram
*Basic circuit runs illustrated; harness extensions may be used on various fuel system configurations.
DSM.0001 Ver 1.0
July 20, 2021
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2.7. Blue iQ FMM Harness to Blue iQ Chassis Harness bulkhead connectors
Every Blue iQ system relies on a 31-pin bulkhead connector for the controller network. Bulkheads link the FSCM
to fuel system components, sensors, and OEM vehicle interfaces. FIGURE 2–34
connector end view
fixed bulkhead
connector image
Box FMM bulkhead harness connector (plugged in)
31-pin
bulkhead
connector
terminal
cavity
plug
FIGURE 2–34. Bulkhead harness connector end view and image
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July 20, 2021
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FMM harness bulkhead connector circuit pin out
Pin #
1
Color
Black
Description
Battery Ground
2
Red
Battery Power
3
Red / White
Ignition Switch Power
4
Red / White
Crank Request
5
Pink / White
Start Confirm
6
Red / White
External Solenoid Control
7
-
8
-
9
-
10
White
11
Gray / White
12
-
13
-
14
Blue
15
-
16
-
17
-
18
-
19
Black / Pink
20
Gray
21
Black / White
22
Gray
23
Black / White
24
Gray
25
Black / White
DAP 3,4,5 Return*
26
Black / White
Fuel Compartment Temperature Sensor 2
(Thermistor 2) Return
27
-
28
Green
J1939 CAN (+)
29
Yellow
J1939 CAN (–)
30
-
31
Pink / Black
OEM Fuel Gauge Signal
DAP Lamp (if equipped)
Fuel Compartment Temperature Sensor 2
(Thermistor 2) Signal
LP Lamp Return (if equipped)
DAP 3
DAP 3,4,5 Return*
DAP 4
DAP 3,4,5 Return*
DAP 5
LP Lamp Signal (if equipped)
*Installer choice ; consult vehicle-specific wiring manual
DSM.0001 Ver 1.0
July 20, 2021
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connector end view
harness connector
image
Gen 5 SM (rear)
Box FMM (back)
Bulkhead
connector cap
BTC (bottom rear of cabinet)F
Bulkhead connector cap
FIGURE 2–35. Bulkhead fixed connector end view and typical system bulkhead locations (circled). NOTE:
Bulkhead connector caps shown in place to protect bulkhead terminals; will be removed.
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July 20, 2021
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Chassis harness bulkhead connector circuit pin out
Pin #
1
Color
Black
Description
Battery Ground
2
Red
Battery Power
3
Red / White
Ignition Switch Power
4
Red / White
Crank Request
5
Pink / White
Start Confirm
6
Red / White
External Solenoid Control
7
-
8
-
9
-
10
White
11
Gray / White
12
-
13
-
14
Blue
15
-
16
-
17
-
18
-
19
Black / Pink
20
Gray
21
Black / White
22
Gray
23
Black / White
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TSB/Document ID: DSM.0001
Replacement Service Bulletin Number:
MFR Communication Date: 2021-07-20
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL/PROPULSION SYSTEM
MFR Component System:
MFR Component Subsystem:
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