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.
4. Install cylinder head bolts. Figure 8
a. Tighten cylinder head bolts first
pass in sequence to 50nm
(37 lb ft).
b. Final pass: Tighten the cylinder
head bolts #1, 2, 3, 6, 7, 8, 9, 12,
14 and 15 an additional 75 degrees
using a torque/angle meter.
c. Tighten cylinder head bolts #13
and 16 an additional 70 degrees
using a torque/angle meter.
d. Tighten cylinder head bolts #4, 5,
10 and 11 an additional 50 degrees
using a torque/angle meter.
5. Install Exhaust Manifold. Refer to
Exhaust Manifold Replacement.
6. Connect Exhaust “Y” Pipe to Exhaust
Manifold. Follow OEM procedure.
7. Install Push Rods. Refer to Push Rod
Inspection and Replacement.
Intake and Exhaust Valve Push
Rods are different lengths.
Ensure push rod installation
order matches order removed.
8. Route Engine Harness and connect
electrical connections including
Ground Ring(s) at rear of Cylinder
Head(s).
9. Install Valve Roller Rockers and set
lash. Refer to Valve Roller Rocker
Replacement and Valve Lash
Adjustment.
10. Install Fan. Refer to OEM procedure.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 36 of 117
11. Install Main Accessory Drive Belt.
Follow OEM procedure.
12. Install Valve Covers. Refer to Valve
Cover Replacement.
13. Install Lower Intake Manifold. Refer
to Lower Intake Manifold
Replacement.
14. Install the Upper Intake Manifold.
Refer to Upper Intake Manifold
Replacement.
15. Install Front End Accessory Drive
Bracket. Refer to Front End
Accessory Drive Bracket
Replacement.
16. Driver Side Cylinder Head ONLY. If
removed: Install Air Compressor.
Refer to Air Compressor
Replacement.
17. Fill engine fluids. Follow OEM
procedure and specifications in
488LPI™ Operators Manual.
18. Clean engine with engine degreaser.
19. Start Engine and bring up to
operating temperature.
20. Verify proper operation.
21. Check for leaks.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 37 of 117
Dual A/C Drive Bracket Replacement
REMOVAL PROCEDURE
1. Secure vehicle.
2. Verify engine is off and cool.
3. Using a 3/8” drive breaker bar, relieve
tension on Dual A/C Drive Belt using
Socket (5) on Dual A/C Tensioner (4).
Figure 1
4. Remove Dual A/C Drive Belt. Follow OEM
Procedure.
5. Remove two (2) A/C Compressors (not
shown from locations (2). Follow OEM
procedure. Figure 1
6. Remove three (3) Dual A/C Bracket
Retaining Bolts (1) and Washers (6).
Figure 1
7. Remove Dual A/C Bracket (3) from
passenger side Cylinder Head (7).
7
2
3
6
1
4
5
Figure 1:
Dual A/C Bracket (3), A/C Compressor locations (2),
Dual A/C Tensioner (4), ½” Drive Socket location (5),
Dual A/C Bracket Retaining Bolts (1) and Washers (6),
passenger side Cylinder Head
Bracket is heavy and has accessory
drive Pulleys attached. Please take
precautions when removing to avoid
personal injury or damage to
components.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 38 of 117
INSTALLATION PROCEDURE
2
A/C Bracket is heavy and has accessory
7
3
drive Pulleys attached. Please take
precautions when removing to avoid
personal injury or damage to
6
components.
1. Thread one (1) Dual A/C Bracket
Retaining Bolt (1) and Washer (6) through
Dual A/C Bracket into passenger side
1
Cylinder Head (7). Figure 2. NOTE: This
helps distribute bracket weight and eases
alignment.
2. Align Dual A/C Bracket (2) mounting holes
with Cylinder Head (7) holes. Figure 2
Figure 2:
Install and thread one (1) Bolt (1) and Washer (6) to hold
3. Install two (2) remaining Retaining Bolts
and align Dual A/C Bracket (3) to Cylinder Head (7)
(1) and Washers (6) and torque all (3)
before installing and tightening remaining two (2) Bolts
Bolts (1). Refer to Front End Accessory
(1) and Washers (6)
Drive Torque Specifications. Figure 2
4. Install two (2) A/C Compressors (not
shown) at locations (2) on Dual A/C
Bracket (3). Figure 2. Follow OEM
procedure.
5. Install Dual A/C Drive Belt. Follow OEM
procedure.
6. Verify proper operation.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 39 of 117
Engine Front Cover and
Front Crankshaft Oil Seal Replacement
REMOVAL PROCEDURE
1. Secure vehicle.
2. Confirm engine is has cooled.
3. Remove Cooling Pack. Follow OEM
procedure.
4. Remove Accessory Belt. Follow OEM
procedure.
5. If equipped: Remove Air Compressor
Belt. Refer to Air Compressor Belt
Replacement.
6. Remove Water Pump. Refer to Water
Pump Replacement.
7. Remove Harmonic Damper. Refer to
Harmonic Damper Replacement.
8. Remove Camshaft Position Sensor
Retaining Bolt (3) and Camshaft
Position Sensor (4). Figure 1
9. Inspect Camshaft Position Sensor Oring (5) for cuts, cracks, tears and
damage. Figure 1
5
4
3
Figure 1:
Camshaft Position Sensor (4), Sensor
Retaining Bolt (3), and Sensor O-ring (5)
2
1
Replace O-ring as needed.
10. Drain engine oil.
11. Loosen Oil Pan Bolts.
Only loosen bolts enough to relieve
tension on the bottom edge of
Engine Front Cover as its base is
sealed by the Oil Pan Gasket. Refer to
Oil Pan Replacement.
12. Remove six (6) Engine Front Cover
Retaining Bolts (2). Figure 2
13. Remove Engine Front Cover (1) and
inspect. Figure 2
Figure 2:
Engine Front Cover (1) and Retaining Bolts (2)
Engine Front Cover Gasket is
reusable.
14. Remove Front Crankshaft Oil Seal (not
shown) from Engine Front Cover.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 40 of 117
3
INSTALLATION PROCEDURE
1. Install new Front Crankshaft Oil Seal
using special tool J 42851 (Front Cover
Oil Seal Installer).
2. Lubricate sealing surface of Front
Crankshaft Seal with clean engine oil.
3. Apply 2.0 mm (0.08 in) of sealant to two
(2) locations (3) on the Engine Block
where the Engine Front Cover meets the
Oil Pan. Figures 3 and 4.
Engine Front Cover must be
installed and fasteners tightened
while sealant is still wet.
4. Install Front Engine Cover Gasket (not
shown) into the Front Engine Cover.
Use care not to push sealant out.
5. Install the Engine Front Cover as shown
in Figure 4 as follows:
a. Hold Engine Front Cover (1) up to
Crankshaft nose (2).
b. Lift Engine Front Cover (1) while
sliding cover over Crankshaft (2).
c. Slide Engine Front Cover towards
the Engine Block surface (5) while
keeping cover raised.
d. Lower Engine Front Cover down
over the Dowel Pin (4), allowing the
cover to rest on the sealant (3).
6. Install and tighten six (6) Engine Front
Cover Bolts using Figure 5 sequence.
Refer to Engine Mechanical Torque and
Clearance Specifications for torque
values.
↓UP↓
3
Figure 3:
Apply sealant to Engine Block (5) at locations (3)
Figure 4:
Proper Engine Front Cover Alignment
and Installation Sequence (side view)
Figure 5:
Engine Front Cover Bolt Tightening
Sequence
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 41 of 117
7. Install Camshaft Position Sensor (4)
using Camshaft Position Sensor
Retaining Bolt (3). Figure 1
Inspect Camshaft Position
Sensor O-ring; replace if
damaged.
8. Install Harmonic Damper. Refer to
Harmonic Damper Replacement.
9. Install Water Pump. Refer to Water
Pump Replacement.
10. If equipped: Install Air Compressor
Belt. Refer to Air Compressor Belt
Replacement.
11. Install Main Accessory Belt. Follow
OEM procedure.
12. Install Cooling Pack. Follow OEM
procedure.
13. Fill engine fluids. Follow OEM
procedure and specifications in
488LPI™ Operators Manual.
14. Verify engine operation: bring up to
operating temperature and check for
leaks.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 42 of 117
Engine Removal and Replacement
Always obtain warranty service approval before beginning engine repair.
Prior to starting work on removing the engine the fuel lines must be drained. Follow
Fuel Line Drain Procedure.
Purge fuel lines only in a properly ventilated area.
Never purge propane near a drain or in a low area such as a service pit.
REMOVAL PROCEDURE
1. Secure vehicle outdoors in a safe
location away from any source of
ignition.
2. Close LPI® fuel supply and fuel return
Manual Shutoff Valves on Fuel
Tank(s).
3. Disconnect Battery. Follow OEM
procedure.
4. Remove vehicle Hood. Follow OEM
procedure.
5. Remove vehicle Cooling Pack. Follow
OEM procedure.
6. Remove Oil Dipstick Tube. Follow
OEM procedure.
7. Remove Air Cleaner Assembly. Follow
OEM procedure.
8. Remove Air Intake Tube. Refer to Air
Intake Tube Replacement.
9. Remove Main Accessory Drive Belt.
Refer to OEM procedure.
10. Remove Alternator. Follow OEM
procedure.
11. If equipped: Remove Air Compressor.
Refer to Air Compressor Replacement.
12. If equipped: Remove Air Conditioning
Compressor(s). Follow OEM
procedure.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 43 of 117
13. Remove Air Conditioning Compressor
Bracket. Refer to Single- or Dual-A/C
Drive Bracket Replacement.
14. Remove Spark Plug Wires with their
respective Ignition Coils attached; set
aside in order removed. Refer to Spark
Plug Wire Replacement and Ignition
Coil Replacement.
15. Disconnect Engine Harness from
Engine and engine accessory
attachment points. Refer to Engine
Harness Replacement.
16. Remove Upper Intake Manifold. Refer
to Upper Intake Manifold Replacement.
17. Remove Fuel Rails. Refer to Fuel Rail
Replacement.
Secure Fuel Supply and Fuel Return
Lines out of way in engine
compartment.
18. Secure vehicle on approved hoist and
raise vehicle.
19. Remove three (3) Nuts (2) securing
each of the Y-Pipe Assemblies (3) to
Exhaust Manifolds (1). Figure 1
20. Remove Y-Pipe Gaskets (4) and
discard. Figure 1
3
23. Remove Transmission. Follow OEM
procedure.
4
2
21. Loosen Y-Pipe Hanger (not shown) at
Transmission. Follow OEM procedure.
22. Remove Starter. Follow OEM
procedure.
1
5
Figure 1:
Y-Pipe Assembly (3), Y-Pipe Gasket (4),
Exhaust Manifold Heat Shield (5),
Exhaust Manifold (1), and Nut (2)
24. Disconnect Post-catalyst Heated
Exhaust Gas Oxygen (HEGO) sensors
from Engine Harness. Refer to OEM
procedure.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 44 of 117
25.
Confirm Engine Harness Ground
Rings at rear of each Cylinder Head
have been disconnected. Refer to
Step 14 and Engine Harness
Replacement.
26. Lower vehicle.
7
27. Unbolt Front Engine Mount from
vehicle frame. Refer to Front Engine
Mount Replacement.
28. Use approved hoist and proper lifting
hardware to remove Engine using Main
Accessory Drive Bracket (7) Lift Point
(6). Figure 2
Avoid damage to engine
components and peripheral items.
Place Engine on approved engine
stand before removing dress
components for reuse.
29. Remove Main Accessory Drive
Bracket. Refer to Main Accessory Drive
Bracket Replacement.
6
Figure 2:
Engine Lift Point (7) on
Main Accessory Drive Bracket (6)
30. Remove Water Pump. Refer to Water
Pump Replacement.
31. Remove Lower Intake Manifold. Refer
to Lower Intake Manifold Replacement.
32. Remove Flexplate and Transmission
Adapter. Refer to Flexplate and
Transmission Adapter Replacement.
33. Remove Exhaust Manifolds. Refer to
Exhaust Manifold Replacement.
34. If equipped: Remove Engine Block
Heater. Refer to Engine Block Heater
Replacement.
35. Remove Front Engine Mount from
Engine. Refer to Front Engine Mount
Replacement.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 45 of 117
INSPECTION PROCEDURE
Before installing previously used engine
components check for the following
conditions:
Broken electrical connectors or frayed
wires
Damaged seals and gasket surfaces
External cracks on metal and composite
parts
Damage to threaded bolt holes
Cracks inside intake and exhaust
manifold ports
Warped or worn flywheel or damaged
flywheel teeth
Replace any suspect components or wear
items including non-reusable gaskets,
seals, belts, spark plugs, spark plug
wires, thermostats, etc.
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 46 of 117
INSTALLATION PROCEDURE
1. Remove Valve Covers from
replacement Engine; recycle or
dispose of Valve Covers.
2. Install Valve Rocker Covers from
vehicle engine on replacement
Engine. Follow Valve Cover
Replacement Procedure.
3. If equipped: Install Engine Block
Heater. Refer to Engine Block Heater
Replacement.
4. Install Water Pump. Refer to Water
Pump Replacement.
5. Install Front Engine Mount on Engine.
Refer to Front Engine Mount
Replacement.
1.
6. Install Exhaust Manifolds. Refer to
Exhaust Manifold Replacement.
7.
7. Install Spark Plug Wires and Ignition
Coils. Refer to Spark Plug Wire
Replacement and Ignition Coil
Replacement.
8.
8. Install Fuel Rails. Refer to Fuel Rail
Replacement.
9.
9. Install Main Accessory Drive Bracket.
Refer to Main Accessory Drive Bracket
Replacement.
10.
- 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
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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:
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