NHTSA ID Number: 10214308
Manufacturer Communication Number: DSM.0053
TSB/Document Date: 2022-06-21
Summary
Service manual
for Hexagon Agility® 488LPI propane autogas (LPG) engine electrical components and sensors.
Specifications.
3. Connect ECT Sensor Pigtail Electrical
Connector (2) to Engine Harness (5).
Figure 1
4. Fill cooling system. Follow OEM
procedure.
5. Clean any spilled fluids.
2
4
3
Figure 2:
ECT Sensor (3), ECT Sensor Pigtail Electrical
Connector (2), ECT Sensor Threads (4)
6. Verify proper operation.
DSM.0053 Ver. 1.0 05/26/2022
488LPI Propane Autogas Engine
Electrical and Sensors Manual
Page 13 of 31
Engine Harness Replacement
DESCRIPTION AND OPERATION
The Engine Harness connects the Electronic Control Module (ECM) to various electronic
components including engine sensors, ignition coils, fuel injectors, and relays. Additionally, the
Engine Harness connects to OEM vehicle wiring via the C28 Bulkhead Connector.
When making many engine repairs it may be necessary to partially or completely remove
the Engine Harness. This may require removing wire harness clips and retainers; always
replace any retaining devices to prevent harness contact with hot surfaces or rotating
parts and minimize rubbing and chafing of the harness.
When removing connectors, never pull on the wire harness; only pull on the connect
REMOVAL PROCEDURE
1. Secure vehicle.
2. Verify engine is cool.
3. Disconnect negative (–) Battery
Cable.
4. Disconnect Engine Harness from the
following passenger side engine
electrical components shown in
Figure 1:
3
1
a) C7 Manifold Absolute Pressure
(MAP) Sensor (1)
b) C30 EVAP Purge Solenoid (2)
c) C32 Fuel By-Pass Solenoid (3)
d) C9 Electronic Throttle Control
(ETC) (4)
e) C6 Mass Air Flow (MAF) Sensor
(5)
2
4
5
Figure 1:
Manifold Absolute Pressure (MAP) Sensor (1)
EVAP Purge Solenoid (2), Fuel By-Bass Solenoid (3),
Electronic Throttle Control (ETC) (4), and
Mass Air Flow (MAF) Sensor (5) connector locations
DSM.0053 Ver. 1.0 05/26/2022
488LPI Propane Autogas Engine
Electrical and Sensors Manual
Page 14 of 31
5. Disconnect C19 Connectors (6) from
Ignition Coils 2, 4, 6, 8. Figure 2
6. If equipped: Disconnect C26 and
C27 Air Conditioner Compressor
Clutch Connector(s) (not shown).
7. Disconnect Engine Harness from
driver side component connectors as
follows:
a. C17 Connectors (7) from Ignition
Coils 1, 3, 5, 7. Figure 3
b. C22 Fuel Rail Pressure/
Temperature (FTP) Sensor (8).
Figure 4
c. C14 Engine Coolant Temperature
(ECT) Sensor connector (9).
Figure 5
d. C16 Fuel Injector Harness
Connector (10). Figure 5
e. C31 Fuel Supply Solenoid
connector (11) at rear of manifold.
Figure 6
8. Raise vehicle.
9. Disconnect Engine Harness
connector from the following front
engine sensors:
a) C11 Crankshaft (CKP) Sensor (12).
Figure 7
b) C12 Camshaft (CMP) Sensor (13).
Figure 8
c) C10 Oil Pressure Sensor (14).
Figure 8
10. Remove Engine Harness Stud Cap
Retaining Bolts (15). Figure 9
11. Disconnect C15B LH and C15A RH
Pre-Catalyst Heated Exhaust Gas
Oxygen (HEGO) Sensor connectors
(16) & (17). Figure 10
12. Remove Retaining Bolts (18) securing
Engine Harness Ground Connector
Rings C20 and C21 (from rear of
Cylinder Heads. Figure 11
13. Lower vehicle.
6
FRONT
4
Figure 2:
Passenger side Ignition Coil connector (6) locations.
NOTE: Intake Air Tube not shown for clarity.
7
FRONT
Figure 3:
Driver side Ignition Coil connector (7) locations
FRONT
8
Figure 4:
Fuel Rail Pressure/Temperature (FTP) Sensor (8)
location
FRONT
9
10
Figure 5:
Engine Coolant Temperature (ECT) Sensor
connector (9) and C16 Fuel Injector Harness connector
(10) locations
DSM.0053 Ver. 1.0 05/26/2022
488LPI Propane Autogas Engine
Electrical and Sensors Manual
Page 15 of 31
14. Disconnect C4 TSM Connector (20)
and J1-A, J1-B and J1-C ECM
Connectors (21). Figure 12
15. Disconnect C28 Bulkhead Connector
(22). Figure 13
16. Remove Zip Tie Stud Fastener
securing Engine Harness to Upper
Intake Manifold (not shown).
17. Remove all Nylon Push Fasteners AKA
“Christmas tree pins” and Zip Ties
securing Engine Harness carefully.
FRONT
11
Figure 6:
Fuel Supply Solenoid connector (11) location
Inspect fasteners for damage and
save for Engine Harness
Installation.
18. Carefully remove Engine Harness.
Inspect Engine Harness for
damage.
INSTALLATION PROCEDURE
Apply dielectric grease to all
connectors and verify connector
security locks are firmly in place.
1. Connect C28 Bulkhead Connector
(22). Figure 13
2. Connect C4 Torque Security Module
(TSM) connector (20) and J1-A, J1-B
and J1-C ECM connectors (21).
Figure 12
3. Connect C31 Fuel Supply Solenoid
(11). Figure 6
4. Connect C16 Fuel Injector Harness
Connector (10). Figure 5
5. Connect C14 ECT Sensor connector
(9). Figure 5
6. Connect C22 FTP Sensor (8). Figure 4
7. Connect C17 Connectors (7) to
Ignition Coils 1, 3, 5, 7. Figure 3
8. If equipped: Connect C26 and C27
Air Conditioner Compressor Clutch
Connector(s) (not shown).
DSM.0053 Ver. 1.0 05/26/2022
FRONT
12
Figure 7:
Crankshaft Position (CKP) Sensor connector (12)
13
14
Figure 8:
Camshaft Position (CMP) Sensor connector (13) and
Oil Pressure Sensor (14) locations
15
Figure 9:
Engine Harness Cap Stud Retaining Bolt (15) locations
488LPI Propane Autogas Engine
Electrical and Sensors Manual
Page 16 of 31
9. Connect C19 Connectors (6) to
Ignition Coils 2, 4, 6, 8. Figure 2
10. Connect the following components
shown in Figure 1 to the Engine
Harness:
a) C7 MAP Sensor (1)
b) C30 EVAP Purge Solenoid (2)
c) C32 Fuel By-Pass Solenoid (3)
d) C9 ETC Sensor (4)
e) C6 MAF Sensor (5)
11. Raise vehicle.
12. Connect the following engine front
sensors to the Engine Harness:
a) C11 CKP Sensor (12). Figure 7
b) C12 CMP Sensor (13). Figure 8
c) C10 Oil Pressure Sensor (14).
Figure 8
13. Install Engine Harness Stud Cap
Bolts (15). Figure 9
14. Install Zip Tie Stud Fastener to
secure Engine Harness to Upper
Intake Manifold (not shown).
15. Install all Nylon Push Fasteners AKA
“Christmas tree pins” and Zip Ties to
secure Engine Harness.
Replace any missing/damaged
fasteners.
16. Connect C15B LH and C15A RH
HEGO Sensor connectors (16) &
(17). Figure 10
17. Install Engine Harness Ground
Connector Ring C20 and C21
Retaining Bolts (18) on rear of
Cylinder Heads. Figure 11. Refer to
Electrical Component and Sensor
Torque Specifications.
18. Lower vehicle.
19. Reconnect negative (–) Battery
Cable.
20. Verify proper operation.
DSM.0053 Ver. 1.0 05/26/2022
16
17
Figure 10:
LH and RH Pre-Cat Heated Exhaust Gas Oxygen
(HEGO) Sensor connectors (16) & (17)
DS cylinder head
18
LS cylinder head
Figure 11:
C20 & C21 Ground Ring Retaining Bolt (18) locations.
21
20
Figure 12:
ECM Connector J1-A, J1-B & J-1C (21) and C4 Torque
Security Module (TSM) connector (20) locations
22
Figure 13:
C28 Bulkhead Connector (22) location
488LPI Propane Autogas Engine
Electrical and Sensors Manual
Page 17 of 31
EVAP Purge Solenoid Replacement
DESCRIPTION AND OPERATION
The EVAP Purge Solenoid connects to the EVAP Emissions Cannister via a hose connection and
is also plumbed into the Upper Intake Manifold to consume any fuel system propane vapor.
The EVAP Purge Solenoid attaches to the Engine Harness using an electrical connector and is
mounted on a bracket on passenger side of the Upper Intake Manifold. Two Upper Intake Manifold
Retaining Nuts secure the EVAP Purge Solenoid Bracket to the Upper Intake Manifold.
REMOVAL PROCEDURE
1. Secure vehicle and verify engine is off.
2. Disconnect EVAP Purge Solenoid
Electrical Connector (2) from Engine
Harness. Figure 1
3. Disconnect EVAP Purge Hose (not
shown) from EVAP Purge Solenoid
(5) at Hose Connector (4). Figure 1
4. Disconnect EVAP Purge Solenoid to
Intake Line Fitting (6) from EVAP
Purge Solenoid (5). Figure 1
5. Remove EVAP Purge Solenoid (5)
from EVAP Purge Solenoid Bracket
Clip (7). Figure 1
5
7
6
1
4
2
Figure 1:
EVAP Purge Solenoid (5), Electrical Connector (2),
Hose Connector (4), Solenoid to Intake Line Fitting
(6), Bracket Clip (7), Upper Intake Manifold (1)
INSTALLATION PROCEDURE
1. Install EVAP Purge Solenoid (5) on
Solenoid Bracket Clip (7). Figure 1
2. Connect EVAP Purge Solenoid to
Intake Line Fitting (6) to EVAP Purge
Solenoid (5). Figure 1
3. Connect EVAP Purge Hose (not
shown) to EVAP Purge Solenoid (5)
at Hose Connector (4). Figure 1
Apply dielectric grease to electrical
connector.
4. Connect EVAP Purge Solenoid
Electrical Connector (2) to Engine
Harness Connector (1). Figure 1
5. Verify proper operation.
DSM.0053 Ver. 1.0 05/26/2022
488LPI Propane Autogas Engine
Electrical and Sensors Manual
Page 18 of 31
Fuel By-Pass Solenoid Replacement
REMOVAL PROCEDURE
1. Secure vehicle outdoors in a safe location.
2. Bleed Fuel Lines. Refer to Fuel Line Bleed
Procedure.
3. Bring vehicle into service area and secure.
4. Remove Upper Intake Manifold. Refer to
Upper Intake Manifold Replacement.
5. Disconnect Fuel By-pass Solenoid (1)
Electrical Connector (3). Figure 1
6. Remove Fuel By-pass Solenoid Connector
Retaining Clip from the Fuel Distribution
Block Mounting Bracket.
7. Remove Fuel By-pass Solenoid Retaining
Nut (2). Figure 1
8. Slide Fuel By-pass Solenoid (3) off
Pressure Regulator on passenger side
Fuel Distribution Block (4). Figure 1
1
4
2
3
2
Figure 1:
Fuel By-pass Solenoid (1) with Electrical
Connector (3) and Retaining Nut (2);
Passenger side Fuel Distribution Block (4)
INSTALLATION PROCEDURE
1. Install Fuel By-pass Solenoid (1) on
Pressure Regulator on passenger side
Fuel Distribution Block (4). Figure 1
2. Install Fuel By-pass Solenoid Retaining
Nut (2). Figure 1. Refer to Fuel System
Torque and Tightening Specifications.
3. Install Fuel By-pass Solenoid Connector
Retaining Clip on Fuel Distribution Block
Mounting Bracket.
4. Connect Fuel By-pass Solenoid (1)
Electrical Connector (3). Figure 1
5. Install Upper Intake Manifold. Refer to
Upper Intake Manifold Replacement.
6. Verify proper operation.
DSM.0053 Ver. 1.0 05/26/2022
488LPI Propane Autogas Engine
Electrical and Sensors Manual
Page 19 of 31
Fuel Pressure/Temperature (FTP) Sensor
Replacement
DESCRIPTION AND OPERATION
The Fuel Pressure/Temperature (FPT) Sensor provides critical real time fuel temperature and fuel
pressure readings to the Electronic Control Module (ECM). An ECM algorithm uses FPT data to
adjust base fuel calculation.
A malfunctioning FPT Sensor could result in incorrect fuel delivery to the engine. This can lead to
a rough running engine along with possible Check Engine Light or other Malfunction Indicator
Light illumination.
REMOVAL PROCEDURE
1. Secure vehicle outdoors in a safe
location.
2. Bleed Fuel Lines. Refer to Fuel Line
Bleed Procedure.
3. Bring vehicle into service bay and
secure.
4. Using a trim removal tool, walk Fuel
Injector Harness Connector Clip (not
shown) off its bracket.
5. Disconnect C16 Fuel Injector Harness
Connector and secure out of the way.
Refer to Engine Harness Schematic
and Connector End Views.
6. Disconnect Fuel Pressure/Temperature
(FPT) Sensor Electrical Connector (3).
Figure 2
7. Remove FPT Sensor (1) from driver
side Fuel Rail (2) using a deep well
socket and extension. Figures 1 & 2
FRONT
1
Figure 1:
Fuel Pressure/Temperature (FTP) Sensor (1) location
on driver side fuel rail
Inspect FPT Sensor O-ring for
damage; replace O-ring as
necessary.
DSM.0053 Ver. 1.0 05/26/2022
488LPI Propane Autogas Engine
Electrical and Sensors Manual
Page 20 of 31
INSTALLATION PROCEDURE
1. Install FPT Sensor (1) in driver side
Fuel Rail (2) using a deep well socket
and extension. Figure 1. Refer to
Electrical Components & Sensors
Torque Specifications.
2. Connect FPT Sensor Electrical
Connector (3). Figure 2
3. Connect C16 Fuel Injector Harness
Connector.
4. Connect Fuel Injector Harness
Connector Clip to its bracket.
5. Reinstall Fuel Supply and Fuel Return
Lines. Refer to Fuel Line Bleed
Procedure.
6. Verify proper operation.
DSM.0053 Ver. 1.0 05/26/2022
2
1
3
Figure 2:
Driver side Fuel Rail (2) shown off Engine
detailing FPT Sensor (1) and FPT Sensor
Electrical Connector (3)
488LPI Propane Autogas Engine
Electrical and Sensors Manual
Page 21 of 31
Ignition Coil Replacement
DESCRIPTION AND OPERATION
Eight (8) individual Ignition Coils deliver high voltage to each of the Spark Plugs via short Spark
Plug Wires.
REMOVAL PROCEDURE
1
1. Secure vehicle.
2. Disconnect Spark Plug Wire(s) (2) at
Ignition Coil(s) (1) using a Spark Plug
Removal Tool. Figure 1. Refer to
Spark Plug Wire Replacement.
Use caution to avoid damage to
Spark Plug Wire or Boot
Connector.
3. Disconnect Ignition Coil Harness
Connector(s) (3). Figure 2
4. Remove two (2) Ignition Coil Mounting
Bolts (4) from each Ignition Coil (1).
Figure 3
5. Remove Ignition Coil(s) (1) from Valve
Rocker Cover Mounting Bosses (5).
Figure 3
2
Figure 1:
Ignition Coils (1) and Spark Plug Wires (2).
NOTE: Driver side shown; passenger side similar.
3
Figure 2:
Ignition Coil Harness Connectors (3).
NOTE: Driver side shown; passenger side similar.
DSM.0053 Ver. 1.0 05/26/2022
488LPI Propane Autogas Engine
Electrical and Sensors Manual
Page 22 of 31
INSTALLATION PROCEDURE
1. Install Ignition Coil(s) (1) on Valve
Rocker Cover Coil Mount Bosses (5).
Figure 2
2. Install two (2) Ignition Coil Mounting
Bolts (4) per Ignition Coil (1) and
tighten. Figure 3. Refer to Electrical
Component & Sensor Torque
Specifications.
3. Connect Ignition Coil Electrical
Connector(s) (9). Figure 2
4. Connect Spark Plug Wire(s) (2) to
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TSB/Document ID: DSM.0053
Replacement Service Bulletin Number:
MFR Communication Date: 2022-05-26
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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