NHTSA ID Number: 10214309
Manufacturer Communication Number: DSM.0052
TSB/Document Date: 2022-06-21
Summary
Service manual
for Hexagon Agility® 488LPI propane autogas (LPG) engine mechanical and fuel components.
Page 23 of 117
CAMSHAFT INSTALLATION
Lubricate Camshaft Lobes (6) and
Journals (9) with clean engine oil.
Figures 1 and 3
2. Install three (3) 8-1.25 x 100mm Bolts (3)
in Camshaft front snout (4). Figure 7
1.
11
3.
Use Bolts as a handle to carefully
install Camshaft (5). Figure 7
4. Remove Bolts from Camshaft.
5. Install Camshaft Retainer (2) with two (2)
Camshaft Retainer Bolts (1) as shown in
Figure 8. Refer to Engine Mechanical
Torque and Clearance Specifications.
6. Install Timing Chain and Sprockets.
Refer to Timing Chain and Sprocket
Replacement.
7. Install Engine Front Cover. Refer to
Engine Front Cover Replacement.
8. Install Valve Lifters. Refer to Valve Lifter
Replacement.
9. Install Pushrods. Refer to Pushrod
Inspection and Replacement.
10. Install Valve Rocker Arms. Refer to
Valve Rocker Arm Replacement.
11. Install Valve Covers. Refer to Valve
Cover Replacement.
12. Install Valley Pan. Refer to Valley Pan
Replacement.
13. Install Lower Intake Manifold. Refer to
Lower Intake Manifold Replacement.
14. Install Upper Intake Manifold. Refer to
Upper Intake Manifold Replacement.
15. Install Water Pump. Refer to Water
Pump Replacement.
16. Install Harmonic Damper. Refer to
Harmonic Damper Replacement.
17. If equipped: Install Air Compressor Belt.
Refer to Air Compressor Belt
Replacement.
18. Install Main Accessory Drive Belt. Follow
OEM procedure.
DSM.0052 Ver. 1.0 05/27/2022
12
Figure 6:
Camshaft Bearings (11).
NOTE: Exploded view shown for
illustrative purposes; bearings will still be
installed in Engine Block at position (12).
5
3
4
Figure 7:
Install Camshaft (5) using three (3) 8-1.25 x 100mm
Bolts (3) as a handle.
2
1
Figure 8:
Install Camshaft Retainer (2) and two (2)
Camshaft Retainer Bolts (1)
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 24 of 117
19. Install Cooling Pack. Follow OEM
procedure.
20. Fill engine fluids. Follow OEM procedure
and specifications in 488LPI™ Operators
Manual.
21. Verify proper operation.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 25 of 117
Crankshaft Front Oil Seal Replacement
DESCRIPTION AND OPERATION
The Crankshaft Front Oil Seal retains engine oil in the oil pan while allowing the Crankshaft to
rotate. The seal is a standalone press fit design with no bolts holding it in the engine block.
REMOVAL PROCEDURE
1. Secure vehicle.
2. Disconnect battery ground cable.
3. Verify engine has had ample cooling
time.
4. Drain engine oil.
5. Remove Main Accessory Drive Belt.
Refer to Main Accessory Drive Belt
Replacement.
6. If equipped: Remove Air Compressor
Drive Belt. Refer to Air Compressor
Drive Belt Replacement.
7. Remove Harmonic Damper (1). Figure
1. Refer to Harmonic Damper
Replacement.
8. Remove Crankshaft Front Oil Seal (2)
from Engine Front Cover (3). Figure 2
1
Figure 1:
Remove Harmonic Damper (1)
Use care not to damage Engine Front
Cover or Crankshaft sealing area
when removing Crankshaft Front Oil
Seal.
2
3
Figure 2:
Crankshaft Front Oil Seal (2) in
Engine Front Cover (3)
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 26 of 117
INSTALLATION PROCEDURE
1. Apply a very light film of oil to
Crankshaft Front Oil Seal sealing
surface.
2. Use Special Tool J 42581 to install
new Crankshaft Front Oil (2) Seal in
Engine Front Cover (3). Figure 2
3. Install Harmonic Damper (1). Figure 1
Refer to Harmonic Damper
Replacement.
4. Install Air Compressor Drive Belt.
Refer to Air Compressor Drive Belt
Replacement.
5. Install Main Accessory Drive Belt.
Refer to Main Accessory Drive Belt
Replacement. Follow OEM routing
instructions.
6. Fill engine oil. Refer to OEM
specifications.
7. Verify proper operation.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 27 of 117
Crankshaft Bearing Inspection
INSPECTION PROCEDURE
1. Drain engine oil.
Collect oil for inspection or analysis
and dispose of properly.
2. Remove Oil Pan. Refer to Oil Pan
Replacement.
3. Remove Oil Pickup Tube.
4. Remove Connecting Rod Cap Nuts.
Keep Rod Cap Nuts in order with
their respective Connecting
Rods.
5. Remove Main Bearing Cap Bolts.
Keep Cap Bolts in order with
their respective Main Bearing
Caps.
6. Inspect Connecting Rod Bearings and
Main Bearings visually for signs of
irregular wear (metal shavings, grit, etc.).
7. If wear / shavings are discovered,
remove suspect Main Bearing Cap for indepth inspection.
Figure 1 shows types of irregular wear.
8. Document any damage found.
9.
10.
11.
12.
Figure 1:
Irregular bearing wear indicators
Obtain necessary warranty approval
authorization before beginning
Engine Replacement procedure.
If no trouble is found, replace
Connecting Rod Cap Nuts. Refer to
Engine Mechanical Torque and
Clearance Specifications.
If no trouble is found, replace Main
Bearing Cap Bolts. Refer to Engine
Mechanical Torque and Clearance
Specifications.
Install Oil Pickup Tube.
Install Oil Pan. Refer to Oil Pan
Replacement.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 28 of 117
13. Replace Oil Filter.
RECOMMENDED: Install new Oil Filter.
14. Fill engine oil. Refer to OEM procedure
and 488LPI™ Operator Manual.
15. Verify proper operation.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 29 of 117
Crankshaft Rear Oil Seal Replacement
REMOVAL PROCEDURE
1. Remove Transmission. Follow OEM
procedure.
2. Remove Flywheel. Refer to Flywheel
and Transmission Adaptor
Replacement.
3. Remove Starter. Follow OEM
procedure.
4. Install Special Tool Kit J 43320 Guide
Pins (1) in two (2) opposing Crankshaft
flange (2) holes as shown in Figure 1
5. Install J 43320 (3) over Guide Pins (1).
Figures 1 and 2
6. Use a power drill with adequate torque
to insert eight (8) Self-Tapping Sheet
Metal Screws from Special Tool J
43320 into Rear Crankshaft Oil Seal in
a crisscross pattern as shown in Figure
2.
7. Thread J 43320 Center Bolt (4) into
Crankshaft to remove old Crankshaft
Rear Oil Seal and discard seal. Figure
3
8. Remove Guide Pins (1) from
Crankshaft flange (2) holes. Figure 1
2
1
Figure 1:
J 43320 Guide Pins (1) inserted in
3
Figure 2:
J 43320 (3) with Self-Tapping Screws
4
Figure 3:
J 43320 Center Bolt (4)
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 30 of 117
INSTALLATION PROCEDURE
1. Inspect Crankshaft rear chamfer (5) for
grit, loose rust, and burrs. Correct as
needed. Figure 4
2. Apply a very light film of clean engine
oil to Crankshaft sealing surface.
DO NOT apply oil to sealing
surface of engine block.
3. Install new Crankshaft Rear Oil Seal in
Special Tool J 42849 (6).
4. Position J 42849 against Crankshaft.
5. Thread J 42849 guide pins into tapped
holes in Crankshaft. Figure 4
6. Tighten J 42849 guide pins (not shown)
securely with a screwdriver to insure
Crankshaft Rear Oil Seal is installed
squarely over Crankshaft.
7. Tighten J 42849 Center Nut (7) until J
42849 bottoms. Figure 5
8. Remove Special Tool J 42849.
9. Install Starter. Follow OEM procedure.
10. Install Flywheel. Refer to Flywheel and
Transmission Adaptor Replacement.
11. Install Transmission. Follow OEM
procedure.
12. Fill engine fluids. Follow OEM
procedure and specifications in
488LPI™ Operators Manual.
13. Verify proper operation.
5
Figure 4:
Crankshaft rear chamfer (5)
6
7
Figure 5:
Special Tool J 42849 (6) and Center Nut (7)
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 31 of 117
Cylinder Head Inspection and Replacement
REMOVAL PROCEDURE
1. Drain engine coolant. Follow OEM
procedure.
2. Remove Fan. Follow OEM procedure.
3. Remove Main Accessory Drive Belt.
Follow OEM procedure.
4. Driver side Cylinder Head ONLY. If
equipped: Remove Air Compressor.
Refer to Air Compressor Replacement.
5. Remove Front End Accessory Drive
Brackets. Refer to appropriate bracket
replacement procedure.
6. Remove Upper Intake Manifold. Refer
to Upper Intake Manifold Replacement.
7. Remove Lower Intake Manifold. Refer
to Lower Intake Manifold Replacement.
8. Remove Valve Covers. Refer to Valve
Cover Replacement.
9. Remove Valve Roller Rockers. Refer
to Valve Roller Rocker Replacement.
10. Disconnect remaining electrical
connections including Ground Ring(s)
at rear of Cylinder Head(s). Move
wiring aside and secure.
11. Remove Push Rods.
Intake and Exhaust Valve Push
Rods are different lengths. Use a
divided tray to organize parts in the
order removed. Figure 2
12. Disconnect Exhaust Y-Pipe from
Exhaust Manifold of Cylinder Head to
be removed. Follow OEM procedure.
DSM.0052 Ver. 1.0 05/27/2022
7
Figure 1:
Driver side Cylinder Head (7) with Valve Rocker
Cover and Valve Rockers removed.
Figure 2:
Use an engine tear down tray to organize
valvetrain components.
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 32 of 117
13. Remove Exhaust Manifold. Refer to
Exhaust Manifold Replacement.
14. Remove Cylinder Head Bolts (1, 2, 3)
and discard. Figure 3
Three (3) different bolt sizes are
used.
15. Remove Cylinder Head (7). Figure 1
16. Remove Cylinder Head Gasket (4) and
discard. Figure 4
Figure 3:
Cylinder Head Bolts (1, 2, 3) are three (3)
different lengths and non-reusable;
discard after removal
INSPECTION PROCEDURES
Visual Inspection Procedure
4
Inspect Cylinder Head for the following
conditions:
• Damaged gasket surfaces
• Damage to threaded bolt holes
• Burnt or eroded areas in the
combustion chamber
• Cracks in exhaust ports and
combustion chambers
• External cracks in water chamber
• Restrictions in intake or exhaust
passages
• Restrictions in cooling system
passages
DSM.0052 Ver. 1.0 05/27/2022
8
Figure 4:
Cylinder Head Gasket (4) and
Engine Block Cylinder Bank Deck (8)
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 33 of 117
Flatness Measurement Procedure
1. Measure Cylinder Head (7) for
warpage with a Straight Edge (4) and
Feeler Gauge (5). Figure 5
• Cylinder Head Block Deck with
warpage > 0.050 mm (0.002 in)
within a 150.0 mm (6.0 in) area must
be repaired or replaced.
• Cylinder Head Exhaust Manifold
Deck with overall warpage >
0.102 mm (0.004 in) must be
repaired or replaced.
• Cylinder Head Intake Manifold Deck
with warpage > 0.080 mm (0.003 in)
must be repaired or replaced.
2. Engine Block Cylinder Head Deck can
be resurfaced up to 0.305 mm
(0.012 in) maximum removal.
4
5
Figure 5:
Use Straightedge (4) and Feeler Gauge (5) to
check Cylinder Head for warpage.
NOTE: Engine Block Deck mating surface shown.
Excessive Cylinder Head
resurfacing will affect
compression ratio and
emissions.
3. Cylinder Heads requiring excessive
resurfacing must be replaced.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 34 of 117
INSTALLATION PROCEDURE
Verify threaded Cylinder Head holes
in Engine Block are clean and not
damaged.
6
Clean block head and head surface
with acetone or brake cleaner and
blow surfaces dry prior to installing
head gasket.
1. Place new Cylinder Head Gasket (6) on
Engine Block Cylinder Bank Deck (8).
Figure 6
Do not use gasket sealer on
engines using composition type
gaskets.
8
Figure 6:
Cylinder Head Gasket (6) and
Engine Block Cylinder Bank Deck (8)
Align Cylinder Head Gasket
locating marks to face up. Ensure
Cylinder Head Gasket Tabs are
located over Number 1 (LH) and 2
(RH) Cylinders for correct
installation.
2. Install Cylinder Head (7). Figure 7
Do not reuse cylinder head
bolts. NEW cylinder head bolts
must be used. Cylinder head
bolts are torque-to-yield bolts and
cannot be reused. During initial
torque of the cylinder head bolt
the fastener is stretched to
achieve proper clamp load. Proper
clamp load will not be achieved if
a used bolt is torqued again. A
stretched cylinder head bolt can
also break when torqued.
Failure to replace the used
cylinder head bolts with NEW
cylinder head bolts can lead to
improper clamp loads and
extensive engine damage.
DSM.0052 Ver. 1.0 05/27/2022
7
Figure 7:
Driver Side Cylinder Head (7), Cylinder
Head Bolts (circled)
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 35 of 117
3. If not pre-applied to the new Cylinder
Head Bolts (1, 2, 3), apply sealer. Use
GM 12346004 Liquid Teflon Sealant or
equivalent.
Sealer must be applied to a
minimum of eight (8)) threads
starting at the point of the
Cylinder Head Bolt.
Figure 8:
Cylinder Head Bolt Tightening Sequence
- 3X Stronger than the leading full synthetic*
- 10X Better high stress performance**
- 20,000 miles between oil changes***
- Viscosity breakdown as measured in Kurt Orbahn test on 5W...
- As measured in Seq IX test under high load/torque conditions...
- Phosphorus Replacement Technology to help extend the life of...
- Reduces leaks, oil burnoff and power robbing deposits
- 15,000 miles between oil changes*
- Meets or exceeds the following specifications: API SP/SN...
- Or one year, whichever comes first
If the PDF is very large, it may not load in the preview below.
Some older TSBs had multiple PDFs — visit the NHTSA Website to view all PDFs.
If the TSB PDF does not show, download or view it on the NHTSA Website.
Click on the (+) Plus Sign
Then Click on Associated Document(s)
Search NHTSA Database for Recalls
Search NHTSA Database for Vehicle Investigations
View Latest Vehicle Investigations
Search NHTSA Database for Vehicle Complaints
View Latest Vehicle Complaints
TSB/Document ID: DSM.0052
Replacement Service Bulletin Number:
MFR Communication Date: 2022-05-27
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:ENGINE:HARD PARTS INTERNAL/MECHANICAL
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
- [Notice] When you receive a used device, it may be a customer return resold by Amazon without inspection. You can exchange it for a new one through Amazon. As this situation is unavoidable, we sincerely apologize. For any issues, contacting us via Amazon's "Messages" is the best way. THINKSCAN 689BT Bidirectional Scan Tool Can Be Used Immediately After It is Turned On, Without Complicated Registration Process, Which is More Convenient & Quick.
- Full Bi-Directional Control & 3000+ Active Tests: Take control and test components like actuators, fuel injectors, relays, and cooling fans in real time. You’ll quickly see if the problem is in the part itself or the control module — saving you hours of guesswork and frustrating trial-and-error.
- Advanced ECU Coding Capabilities: Handle module matching and hidden feature activation with confidence. When you replace an ECU or want to customize settings, this obd2 scanner diagnostic bi directional tool gives you the professional-level capabilities you need without the dealership price tag.
- 34+ Useful Reset and Maintenance Functions: Complete everyday service tasks smoothly with a wide range of helpful reset and maintenance functions. Whether you’re keeping up with regular upkeep or tackling a specific job, this scanner makes maintenance simpler and less stressful for both DIYers and pros.
- Comprehensive Full System Diagnostics: Diagnose every major system — Engine, Transmission, ABS, SRS, TPMS, and more — all in one place. Finally stop wondering if you’re missing something important; get the full picture and clear codes with ease.
- Top Reasons to Choose the D7S OBD2 Scanner: XTOOL D7S car scan tool, an upgrade of XTOOL D7, offers comprehensive features for automotive technicians, workshops, and DIY enthusiasts 1. Upgraded Hardware: 2+64GB memory, rear camera, intuitive interface, foldable bracket 2. Complete Diagnostics: FCA
Autoauth, OE-level all system scan, 39+ maintenance services, 4K+ bidirectional, CANFD/DoIP protocol 3. Advanced Capabilities: ECU coding, PMI functions 4. Wide Compatibility: Support 10,000+ models, covering 99% vehicle brands 5. Multi-language: Available in 22+ languages, No IP Restrictions 6. 3-Year Updates: Save 300 bucks on software updates for the latest features and optimizations - 2026 Upgraded D7S Car Scanner Features: The newly 2026 D7S V2.0 scanner for car brings exciting features for advanced vehicle diagnostics and enhanced user experience 1. FCA AutoAuth: Now supports FCA SGW module for Chrysler, for Jeep, for Dodge (2018+), for Fiat (2017+), enabling faster vehicle communication without gateway restrictions 2. PMI (Offline ECU Programming): Allows for Ford, for Lincoln, and for Mazda ECU programming for new modules 3. Optimized Diagnostic Report 2.0: Personalized reports with logos and customer info for auto shops. Note: Compatibility varies by cars, please check before order
- Cost-effective ECU Coding Scan Tool for Specific Brands: Enhance your vehicle's performance with XTOOL D7S! This obd2 scanner all systems bidirectional offers advanced capabilities at an affordable price, supports online for BMW, for Benz and offline for BENZ, for MIT, along with PMI functions for Ford, for Mazda, and for Lincoln. Ideal for technicians and DIY enthusiasts, this automotive scanner diagnostic tool optimizes vehicle performance and enhances the driving experience. Note: Not for all cars and modules, please send car VIN to check the compatibility before purchase
- OE All System Diagnostic & 8 Pids Graphing: XTOOL D7S is a comprehensive all system bi directional obd2 scanner that delivers dealer-level diagnostics, completely controlling over your vehicle’s performance and health. This automotive scan tool can read and clear DTCs, view live data and ECU information, retrieve freeze frames, and perform active tests and full obd2 functions. This bi-directional scan tool can can identify your vehicle's make, model, and year information with just one click and show up to 8 PIDs live data with options for CSV viewing, playback, and recording for in-depth analysis. It is easy-to-use for both professionals and beginners, helping pinpoint issues efficiently
- 3 Years Software Update, Value for Money: With 3 years of software updates and 22+ languages(no IP restrictions), XTOOL D7S auto scanner code scanner ensures ongoing compatibility for the latest car models and improved diagnostic functions. This all system vehicle diagnostic scanner comes with a 30-day return policy and a 24-month repair for dependable performance. XTOOL are dedicated to your satisfaction, so enjoy seamless support and lifetime expert assistance. Should you encounter any issues or concerns, don’t hesitate to reach out XTOOL. D7S with newest update with 22 languages freely transfer without authorization, check details from setting-language or from XTOOL
- 【✅Compared to BOSSCOMM IF742, IF745 Offers Full-System Diagnostics】The BOSSCOMM IF745 car diagnostic scanner is an upgraded model of IF742. In addition to supporting all OBD2 Code Reader functions and 6 reset options (ABS/EPB/SAS/BMS/Oil/Throttle), it expands diagnostics from 4 systems (Check Engine/ABS/SRS/Transmission) to vehicle All systems, including Steering, Suspension, and Body Electronics. This provides deeper, more comprehensive diagnostic capabilities.
- 【✨10 OBD2 Functions】The BOSSCOMM IF745 scan tool’s DTC Lookup instantly translates fault codes into user-friendly explanations, its I/M Readiness feature streamlines emissions testing with a single tap, and Freeze Frame lets you pinpoint the exact moment of a fault for in-depth root-cause diagnosis. Combined with a live data dashboard and advanced diagnostics (O2S, OBMon, EVAP), it delivers comprehensive insights for confident troubleshooting.
- 【✨Deep Diagnostics for All Vehicle System Modules】Beyond code reading/clearing and ECU information retrieval, our all-in-one data stream feature lets you inspect all current fault codes and their locations across the vehicle’s systems. This vehicle code reader helps you turn off dashboard warning lights and perform a comprehensive self-check of your car at home—no more back-and-forth trips to the repair shop or hefty inspection fees.
- 【✨6 Essential Resets: ABS Bleeding, Oil, EPB, SAS, Throttle, BMS】The BOSSCOMM IF745 obd2 scanner diagnostic tool swiftly purges air from brake lines to restore braking sensitivity, fine-tunes maintenance cycles to eliminate false alerts, resolves parking brake issues with one-click control, recalibrates steering sensors for stability, optimizes engine idling/acceleration for smoother performance, and deeply resets battery systems to extend lifespan and range via precise parameter adjustments.❗NOTE: Does NOT support bidirectional control, coding, or programming.
- 【✨10,000+ Car Models, AutoVIN, 13 Languages】The BOSSCOMM IF745 vehicle scanner diagnostic tool covers 73+ global car brands and offers support in 13 languages, making it perfect for DIYers, auto mechanics, or as a thoughtful gift. With a single-click AutoVIN feature, it instantly retrieves vehicle serial numbers, streamlining diagnostics for users globally. This adaptable tool balances user-friendliness with precision, catering to both personal and professional requirements.✅Unsure about compatibility? Compatibility will vary on vehicles' model and year, pls reach us via 📧 [email protected] 📧 before purchase.
This product presentation was made with AAWP plugin.