Field Repair Instructions

FRI.0008 Ver. 1.0

May 26, 2022

Blue iQ® CNG OEM Fuel Gauge Conditioning Circuit Retrofit
Affected
Vehicles

Vehicles equipped with Agility® Blue iQ® compressed natural gas (CNG) fuel systems equipped
with harnesses manufactured by Kauffman Engineering between 2016 and 2020 with the
following Hexagon Agility® part numbers:
10400681

10400682

10400683

10400684

Introduction
Agility Fuel Solutions LLC, a subsidiary of Hexagon Agility Inc. (Hexagon Agility®), has identified a condition
which may result in a non-operational original equipment manufacturer (OEM) fuel gauge on certain
Blue iQ® CNG fuel systems.
While failure of the OEM fuel gauge circuit does not affect the operation of the Blue iQ® gauge, it is
inconvenient.
Blue iQ® harnesses with a molded rubber “brick” containing the OEM fuel gauge conditioning circuit may
cause an inoperative OEM fuel gauge. FIGURE I–1

1

2

FIGURE I–1. (1) OEM fuel gauge conditioning circuit “brick”; (2) Blue iQ® harness
Do not install retrofit kit if molded rubber brick is not present on Blue iQ® harness.

Hexagon Agility has released a retrofit kit, p/n 20101193, which contains a new molded conditioning circuit
(10404919), connector, terminals, and boots. This kit is designed to be used on fuel systems exhibiting an
inoperative fuel gauge which are equipped with Agility® harness with the molded rubber brick present and
which were produced by Kauffman Engineering in the period listed (see harness p/ns in “Affected Vehicles”
above).

Retrofit Kit Components
Item Description
1
2
3
4

female terminal
terminal boot
3-pin connector
OEM fuel gauge conditioning circuit module

FRI.0008 Ver. 1.0
May 26, 2022

QTY
3
3
1
1

Blue iQ® CNG OEM Fuel Gauge Conditioning Circuit Retrofit
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Warning Statements Used in this Bulletin
NOTICE is used to address practices not related to physical injury, such as best
practices or tips to help an operation or procedure go smoothly and prevent
equipment damage.
Manufacturing
Characteristic

 A product feature solely used to improve manufacturability or maintain process
control.
 A process parameter or step that has a significant effect on achieving a Critical
Characteristic of Significant Characteristic, or maintaining material
identification/traceability.

Required Tools and Materials
Item
wire cutters
wire strippers

Delphi® WeatherPack terminal crimper p/n
12014254 or equivalent

soldering iron
solder
If needed: 18 AWG TXL automotive
wire
heat gun
If needed: Raychem ES2000 adhesive
lined heat shrink tubing or equivalent
digital multimeter (DMM)
test lead kit
electrical tape

FRI.0008 Ver. 1.0
May 26, 2022

Purpose
cut existing Blue iQ® OEM fuel gauge conditioning circuit wires
prepare wires for new terminals
properly install terminals on wires
required to properly tin terminals; optional if a wire splice is necessary
required to properly tin terminals; optional if a wire splice is necessary
required for splice if existing wires are too short to complete repair
activate heat shrink adhesive
properly wire splices
test circuits
properly probe electrical connectors
Secure fuel conditioning circuit module to Blue iQ® wire harness

Blue iQ® CNG OEM Fuel Gauge Conditioning Circuit Retrofit
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Install Retrofit Kit
1. Disconnect negative battery cable. Refer to OEM procedure.
2. If necessary: open / remove FMM access panel.
3. Disconnect Blue iQ® Fuel System Control Module (FSCM) connector. Refer to DSM.0001 Blue iQ Diagnostic
Service Manual.
4. Locate existing fuel gauge conditioning circuit “brick.” The fuel gauge conditioning circuit is molded into a
rubber module which is taped to the Blue iQ® harness within 24-in of the FSCM connector. FIGURE 1–1

2

1

FIGURE 1–1. (1) OEM fuel gauge conditioning circuit brick taped to (2) Blue iQ® chassis harness

5. Remove electrical tape surrounding the molded connector and the wire loom where the fuel gauge circuit
wires enter the Blue iQ® harness. FIGURE 1–1
Use care not to cut or damage wires when removing electrical tape.

6. Pull Blue iQ® wire loom away exposing the bundle of wires inside. Remove all tape securing the fuel gauge
conditioning circuit brick. FIGURE 1–2

1

wires

wire loom

FIGURE 1–2. (1) OEM fuel gauge conditioning circuit brick separated from Blue iQ® harness

FRI.0008 Ver. 1.0
May 26, 2022

Blue iQ® CNG OEM Fuel Gauge Conditioning Circuit Retrofit
PRINTED AND DOWNLOADED COPIES ARE NOT CONTROLLED

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7. Label OEM fuel gauge conditioning circuit wires as shown in FIGURE 1–3:

1

Splice

FIGURE 1–3. (1) OEM fuel gauge conditioning circuit brick with wires labelled

8. Cut wires tagged A, B, and C flush with the OEM fuel conditioning circuit brick and recycle or discard brick
according to authority having jurisdiction or organization guidelines. FIGURES 1–3 and 1–4

(A) White wire
1
(B) White wire

(C) Black/White wire
FIGURE 1–4. Cut wires 1/4-in from (1) OEM fuel gauge conditioning circuit brick

9. Perform the following steps if necessary: (B) White wire is spliced to Blue/White wire and (B) White wire
may need to be lengthened to reach the connector that will be installed later. FIGURE 1–3
If (B) White wire is too short:
a) strip (B) white wire and new 18 AWG TXL wire as an extension
b) slip an appropriate length of adhesive lined heat shrink tubing over the wires to cover the splice
c) solder 18 AWG TXL wire extension to the existing (B) White wire
d) cover the new spice with adhesive lined heat shrink tubing.

FRI.0008 Ver. 1.0
May 26, 2022

Blue iQ® CNG OEM Fuel Gauge Conditioning Circuit Retrofit
PRINTED AND DOWNLOADED COPIES ARE NOT CONTROLLED

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10. Install wire boot from the retrofit kit over each of the wires (A), (B) and (C), pushing the seals down the wire
approximately 1-in to allow the wire to be stripped. FIGURE 1–5

wire boot

wire

FIGURE 1–5. Install wire boot before stripping the insulation from each wire

11. Strip 3/16-in of insulation from the end of each wire (A), (B), and (C). FIGURE 1–6

wire end

wire boot

FIGURE 1–6. Strip 3/16-in of insulation from each wire and slide wire boot to be flush with end of insulation

12. Position female terminal over each wire boot and wire end seal before installing using Delphi® WeatherPack
Crimper 12014254 or equivalent. FIGURE 1–7

wire boot

female
terminal

solder
FIGURE 1–7. Crimp female terminal on each wire boot and stripped wire end and tin with solder

Use solder and a soldering iron to tin female terminal to the wire. FIGURE 1–7
13. Insert each of the three wire terminals into the 3-pin connector. Verify each terminal seats properly and
close the locking tab on the connector. FIGURE 1–8

(C) Black/White wire
(B) White wire

3-pin
connector

(A) White wire

FIGURE 1–8. Three female terminals of wires (A), (B), and (C) inserted into 3-pin connector
FRI.0008 Ver. 1.0
May 26, 2022

Blue iQ® CNG OEM Fuel Gauge Conditioning Circuit Retrofit
PRINTED AND DOWNLOADED COPIES ARE NOT CONTROLLED

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14.

Use a digital multimeter (DMM) with appropriate test leads to check resistance to confirm circuit continuity
between the 3-pin connector Pin A and FSCM harness connector Pin 59. FIGURE 1–9
Pin 59
White

FIGURE 1–9. Blue iQ® FSCM harness connector end view

If resistance is 0-1 ohm, proceed to Step 15.

15.

If resistance is infinite OR resistance is greater than 1 ohms, inspect circuit repair performed in
Steps 9 through 13 and correct as necessary.
Check resistance between 3-pin connector Pin B and FSCM harness connector Pin 21. FIGURE 1–10
Pin 21
Blue / white

FIGURE 1–10. Blue iQ® FSCM harness connector end view

If resistance is 0-1 ohm, proceed to Step 16.
 If resistance is infinite OR resistance is greater than 1 ohms, inspect circuit repair performed in
Steps 9 through 13 and correct as necessary.
FRI.0008 Ver. 1.0
May 26, 2022

Blue iQ® CNG OEM Fuel Gauge Conditioning Circuit Retrofit
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16.

Check resistance between 3-pin connector Pin C and FSCM harness connector Pin 39. FIGURE 1–11

Pin 39
Black / white

FIGURE 1–11. FSCM harness connector end view

If resistance is 0-1 ohm, proceed to Step 17.
 If resistance is infinite OR resistance is greater than 1 ohms, inspect circuit repair performed in
Steps 9 through 13 and correct as necessary.
17. Disconnect Blue iQ® harness bulkhead connector and check resistance between 3-pin connector Pin B
and Blue iQ® harness bulkhead connector Pin 10. FIGURE 1–12
Pin 10
White

FIGURE 1–12. Blue iQ® harness bulkhead connector end view

If resistance is 0-1 ohm, proceed to Step 18.
 If resistance is infinite OR resistance is greater than 1 ohms, inspect circuit repair performed in
Steps 9 through 13 and correct as necessary.
18. Reconnect Blue iQ® harness bulkhead connector.

FRI.0008 Ver. 1.0
May 26, 2022

Blue iQ® CNG OEM Fuel Gauge Conditioning Circuit Retrofit
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19.

With continuity verified for each circuit, plug new OEM fuel gauge conditioning circuit module (p/n
10404919) from retrofit kit into the 3-pin connector. FIGURE 1–13

electrical tape

OEM fuel gauge
conditioning circuit
module

3-pin
connector
3 wires

wire loom
FIGURE 1–13. Blue iQ® OEM fuel gauge conditioning circuit module; 3-pin connector

20.

Reconnect Blue iQ® FSCM connector. Refer to DSM.0001 Blue iQ Diagnostic Service Manual.

Validate Repair
1. Reconnect negative battery cable. Refer to OEM procedure.
2. Verify proper OEM fuel gauge operation.
 If fuel gauge operates properly, proceed to Step 3.
 If a vehicle fuel lamp or malfunction indicator lamp illuminates, refer to OEM diagnostic manual.
 If a Blue iQ® system fault appears, refer to DSM.0001 Blue iQ Diagnostic Service Manual.
3. Use electrical tape to wrap wire loom where 3 wires exit the wire loom to prevent chafing. FIGURE 1–13
4. Reinsert excess OEM fuel gauge conditioning circuit wires into Blue iQ® chassis harness wire loom. FIGURE
1–13

5. Use electrical tape to secure retrofit circuit module to Blue iQ® harness. FIGURE 1–13
Use care in taping module and harness to avoid wrapping 3 wires too tightly to prevent excess
tension and possible wire/connector damage.
6. Close / reinstall FMM access panel.
7. Release vehicle into service.
8. Update vehicle maintenance and repair records.

Warranty Information
This procedure is covered under warranty. Standard repair time (SRT) is 0.5 hours which includes,
inspection, wire repair, component installation, and testing.

FRI.0008 Ver. 1.0
May 26, 2022

Blue iQ® CNG OEM Fuel Gauge Conditioning Circuit Retrofit
PRINTED AND DOWNLOADED COPIES ARE NOT CONTROLLED

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Hexagon Agility® Customer Care and Technical Services
Fuel system warranty or non-warranty product support may be obtained by calling or emailing Hexagon
Agility® Customer Care and Technical Services (CCTS).
Please provide your name, phone number, email address, and complete vehicle information: VIN, year,
make, model, mileage, unit number vehicle owner, and current vehicle location. A service advisor will
contact you to arrange vehicle repair or ship a part.

+1-833-4-HEX-CARE

Support
[email protected]

Parts Orders
[email protected]

Proprietary Statement
The information provided within this document is proprietary and confidential. All prior versions, including updates and revisions forwarded separately,
are proprietary. The information provided by Hexagon Agility® to its customers and clients is solely for the use of those customers and clients. No
portion of this publication may be reproduced or distributed without express written consent of Hexagon Agility®. Hexagon Agility® reserves the right
to utilize the intellectual property contained within this publication as content for any other publication produced by Hexagon Agility®.

Trademark Notice
Hexagon® is a registered trademark of Hexagon Technology AS. Agility® is a registered trademark of Agility Fuel Solutions LLC. Blue iQ® is a registered
trademark of Agility Fuel Systems, LLC. Trademarks of other manufacturers are the property of their respective companies.

Hexagon Agility®

FRI.0008 Ver. 1.0
May 26, 2022

3335 Susan Street, Suite 100 Costa Mesa, CA 92626 USA

Blue iQ® CNG OEM Fuel Gauge Conditioning Circuit Retrofit
PRINTED AND DOWNLOADED COPIES ARE NOT CONTROLLED

www.hexagonagility.com

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