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.
Verify Snap Ring (2) is fully
seated. Figure 3
Install respective Fuel Rail. Refer to
Fuel Rail Replacement. Figures 1 & 2
Pressurize fuel system to prepare for
leak check as follows:
a. Open Fuel Tank Supply and Return
Valves. Refer to OEM procedure.
b. Use a Power Probe or similar tool to
apply power to two wires of the Fuel
By-Pass Solenoid (8) Electrical
Connector (9) to pressurize fuel
system. Figure 5
Perform leak check. Refer to Fuel
System Leak Detection Procedure.
Install Upper Intake Manifold. Refer to
Upper Intake Manifold Replacement.
Verify proper operation.
3
2
Figure 3:
Fuel Injector Tube (3), Injector Tube O-Rings (4)
and Injector Tube Snap Ring (2)
7
4
Figure 4:
Fuel Injector Tube O-Ring locations (7) & (4)
8
9
Figure 5:
Fuel By-Pass Solenoid (8), Electrical Connector (9)
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 64 of 117
Fuel Rail Fitting Replacement
Fuel Line pressure can exceed 250 psi (17 bar). Exercise caution when removing Fuel
Lines.
REMOVAL PROCEDURE
FRONT
1. Secure vehicle outdoors in a safe location.
2. Bleed Fuel Lines. Refer to NFPA 58 for
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 Engine Fuel Supply Lines (1)
and Engine Fuel Return Lines (2) to Fuel
Rail Fitting to be replaced. Refer to Fuel
Supply and Fuel Return Line Replacement.
Figure 1
6. Driver side Fuel Rail only: Remove Fuel
Rail Nipple(s) (2) or (3) or Plug(s) (1) from
Fuel Rail (4). Figure 2
7. Passenger side Fuel Rail only: Remove
Fuel Rail Nipple(s) (2) or (3) or Plug(s) (1)
from Fuel Rail (5). Figure 3
1
2
Figure 1:
Rear Engine Fuel Supply (1) and
Engine Fuel Return Lines (2)
4
2
1
1
3
Figure 2:
Driver side Fuel Rail (4), Straight Fuel Supply Line
Nipple (2), 45° Fuel Return Line Nipple (3), Plugs (1)
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 65 of 117
INSTALLATION PROCEDURE
1. Install Fuel Rail Fitting(s). Refer to Fuel
System Torque and Tightening
Specifications. Figures 1, 2, & 3
2.
3.
4.
5.
6.
Do not overtighten Fittings as
damage or leaks may occur.
Connect Fuel Supply and Fuel Return
Lines to Fuel Rail Fitting being replaced.
Refer to Fuel Supply and Fuel Return
Line Replacement. Figures 1, 2, & 3
Check the fuel for fuel leaks:
a. Open fuel supply and return valves.
b. Energized supply solenoid will need to
be to allow fuel to flow and pressurize
the system. Use a Power Probe or
similar tool to apply power to the two
wires of the supply solenoid connector,
this will energize the supply solenoid
and pressurize the system.
Once the system is pressurized, perform
leak check. Refer to Fuel System Leak
Verification Procedure.
Install Upper Intake Manifold. Refer to
Upper Intake Manifold Replacement.
Verify proper operation.
DSM.0052 Ver. 1.0 05/27/2022
3
1
5
1
FRONT
2
Figure 3:
Passenger side Fuel Rail (5),
Straight Fuel Supply Line Nipple (2),
45° Fuel Return Line Nipple (3), Plugs (1)
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 66 of 117
Fuel Rail Replacement
DESCRIPTION AND OPERATION
Two (2) Fuel Rails supply liquid propane to 488LPI™ Engine and return fuel back to the Fuel
Tank(s) via Fuel Supply and Return Lines and Hoses. The Fuel Rails are designed to dissipate
heat and regulate liquid propane to the Fuel Injectors. Pressure in the Fuel Rails varies directly
with temperature: fuel pressure increases with temperature and vice versa.
Fuel Rail and Fuel Line pressure can exceed 250 psi (17 bar); exercise caution.
REMOVAL PROCEDURE
5
10
3
FRONT
1. Secure vehicle outdoors in a safe location.
2. Bleed Fuel Lines. Refer to NFPA 58 for
procedure.
3. Bring vehicle into service bay and secure.
4. Remove Upper Intake Manifold. Refer to
Upper Intake Manifold Replacement.
5. Disconnect Fuel Supply Lines (1) and Fuel
Return Lines (2) to Fuel Rail(s) (3) to be
removed. Figure 1. Refer to Fuel Supply &
Return Line Replacement.
6. Disconnect Fuel Injector Harness from
Engine Harness. Refer to Fuel Pressure/
Temperature (FPT) Sensor Replacement.
7. Disconnect Fuel Injectors from Fuel
Injector Harness Electrical Connectors
(not shown). Refer to Fuel Injector
Replacement.
8. If replacing driver side Fuel Rail only:
Remove Fuel Pressure/Temperature
(FPT) Sensor (6) from driver side Fuel
Rail. Refer to Fuel Pressure/Temperature
Sensor Replacement. Figures 2 & 5
9. If replacing passenger side Fuel Rail only:
Remove Fuel Rail Plug (9) from
passenger side Fuel Rail.
2
1
Figure 1:
Fuel Rails (3), Fuel Rail Top Brackets (5), Fuel
Injector Harness Brace (10),
Fuel Supply Lines (1), Fuel Return Lines (2)
6
FRONT
Inspect Fuel Rail Side Plug O-Ring for
damage; replace as necessary. Figure 3
Figure 2:
Fuel Pressure/Temperature (FPT) Sensor (6)
location (driver side Fuel Rail only)
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 67 of 117
9
FRONT
Figure 3:
Fuel Rail Side Plug (9) location
(passenger side Fuel Rail only)
4
FRONT
10. Remove eight (8) Fuel Rail Top Bracket
Retaining Bolts (4) and remove (2) Fuel
Rail Top Brackets (5) together with Brace
(10), and Fuel Injector Harness (not
shown). Figure 4
11. Remove four (4) Fuel Rail Side Bracket
Retaining Bolts (9) and remove Fuel Rail
Side Bracket (7) securing Rail to be
removed. Repeat for other side if removing
both Fuel Rails. Figures 5 & 6
12. Clean debris from around Fuel Injector
Delivery Tubes (not shown) using
compressed air.
13. Gently wiggle Fuel Rail (3) and lift rail from
Lower Intake Manifold. Figures 1, 5, & 6
14.
Inspect Injector Ports in Fuel Rail(s) for
damage.
15. Cover Fuel Injector Ports in Fuel Rails and
Lower Intake Manifold.
5
10
4
Figure 4:
Fuel Rail Top Bracket Retaining Bolts (4),
Fuel Rail Top Brackets (5),
Fuel Injector Harness Brace (10)
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 68 of 117
INSTALLATION PROCEDURE
1. Apply a light film of clean engine oil to
Fuel Injector Delivery Tube O-Rings.
Refer to Fuel Injector Delivery Tube
Replacement.
2. Install Fuel Rail(s) (3) in position.
Verify Fuel Injector Delivery Tubes are
orientated facing Intake Ports and ORings seat properly. Do not force Fuel
Rail into place as damage to Fuel
Injector Delivery Tubes may occur.
3. Install Fuel Rail Side Bracket (7) using
four (4) Bolts (8). Repeat for other side if
replacing both Fuel Rails. Figures 5 & 6.
Refer to Fuel System Torque and
Tightening Specifications.
4. Install two (2) Fuel Rail Top Brackets (5),
Brace (10), and Fuel Injector Harness
(not shown) as an assembly using eight
(8) Bolts (4) Figures 4 & 6. Refer to Fuel
System Torque and Tightening
Specifications.
Do not overtighten Bolts as
damage may occur.
5. If replacing driver side Fuel Rail only:
Install FPT Sensor (6) in driver side Fuel
Rail. Refer to Fuel Pressure/Temperature
(FPT) Sensor Replacement. Figures 2 &
5
6. If replacing passenger side Fuel Rail
only: Install Fuel Rail Side Plug (9) in
driver side Fuel Rail. Figure 3
Apply a light film of clean engine
oil to Fuel Rail Side Plug O-Ring
(not shown).
7. Install Fuel Supply Lines (1) and Fuel
Return Lines (2). Figure 1
DSM.0052 Ver. 1.0 05/27/2022
6
7
8
Figure 5:
FPT Sensor (6), Fuel Rail Side Bracket (7),
Fuel Rail Side Bracket Retaining Bolts (8).
NOTE: Driver side shown; passenger side similar.
Ignition Coil omitted for clarity; no need to remove.
5
4
3
FRONT
10
4
8
5
Figure 6:
Fuel Rails (3), Fuel Rail Top Brackets (5), Brace (10),
Fuel Rail Top Bracket Retaining Bolts (4),
Side Fuel Rail Bracket Bolts (8).
NOTE: Passenger side shown; driver side similar.
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 69 of 117
8. Pressurize fuel system to prepare for leak
check as follows:
a. Open Fuel Tank Supply and Return
Valves. Refer to OEM procedure.
b. Use a Power Probe or similar tool to
apply power to two wires of the Fuel
By-Pass Solenoid (11) Electrical
Connector (12) to pressurize fuel
system. Figure 7
9. Perform leak check. Refer to Fuel System
Leak Verification Procedure.
10. Install Upper Intake Manifold. Refer to
Upper Intake Manifold Replacement.
11. Verify proper operation.
DSM.0052 Ver. 1.0 05/27/2022
12
11
Figure 7:
Fuel By-Pass Solenoid (11), Electrical Connector (12)
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 70 of 117
Fuel Rail Supply/Return Lines Replacement
DESCRIPTION AND OPERATION
Fuel Rail Supply and Return Lines on the 488LPI engine carry liquid propane from the Fuel
Distribution Blocks via two Fuel Supply Lines to the Fuel Rails. Fuel Return Line Fittings circulate
fuel from the Fuel Rails to the Fuel Distribution Blocks. The passenger side Fuel Distribution
Blocks houses the Fuel By-Pass Solenoid which allows liquid fuel and vapor to be returned to the
fuel storage system.
REMOVAL PROCEDURE
1. Perform fuel line bleed procedure.
Refer to NFPA 58 Fuel Line Bleed
Procedure.
2. Tow or push vehicle into service bay.
FRONT
5
3. Remove Upper Intake Manifold.
Follow Upper Intake Manifold
Replacement procedure.
4. Disconnect stainless steel Fuel Supply
Fittings and/or Return Line Fittings (2)
for the respective side being serviced.
Figure 1
5. Remove line(s) being serviced from the
vehicle.
1
3
4
6
2
Figure 1:
Rear of engine with Upper Intake Manifold
removed. Fuel Supply Line Fittings (1),
Fuel Distribution Block (3), Fuel Rails (5),
Fuel Return Line Fittings (2), Fuel Return
Block (4), Fuel By-Pass Solenoid (6).
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 71 of 117
INSTALLATION PROCEDURE
1. Install stainless steel Supply/Return
Line being serviced. Figure 1. Refer to
Fuel System Torque and Tightening
Specifications.
2. If removed: connect Fuel Storage
System Fuel Supply Hose and/or Fuel
Return Hose (both not shown) to the
driver side Fuel Distribution Block (3)
and/or passenger Fuel Distribution
Block (4) 90-degree elbow fittings.
Figure 1
3. Pressurize fuel system to prepare for
leak check as follows:
a. Open Fuel Tank Supply and Return
Valves. Refer to OEM procedure.
b. Use a Power Probe or similar tool to
apply power to two wires of the Fuel
By-Pass Solenoid (6) Electrical
Connector (7) to pressurize fuel
system. Figure 2
4. Perform leak check. Refer to Fuel
System Leak Verification Procedure.
5. Install Upper Intake Manifold. Refer to
Upper Intake Manifold Replacement.
6. Verify proper operation.
DSM.0052 Ver. 1.0 05/27/2022
7
6
Figure 2:
Fuel By-Pass Solenoid (6), Electrical Connector (7)
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 72 of 117
Harmonic Damper Replacement
REMOVAL PROCEDURE
1.
2.
3.
4.
Secure vehicle on an approved hoist.
Verify engine is off and cool.
Raise vehicle.
Remove Transmission Adapter.
Refer to Flexplate & Transmission
Adapter Replacement.
5. Attach Flywheel Holding Tool to
Starter bolt holes. Figure 1
6.
7.
8.
9.
Verify holding tool teeth fully
engage Flywheel.
Lower vehicle.
Remove Cooling Pack. Follow OEM
procedure.
Remove Main Accessory Belt. Follow
OEM procedure.
If equipped: Remove Air Compressor
Belt. Refer to Air Compressor Belt
Replacement.
Figure 1:
Flywheel Holding Tool
2
1
Figure 2:
Harmonic Damper Flanged Bolt (1)
3
Figure 3:
Fit special tool (3) over
Crankshaft snout
DSM.0052 Ver. 1.0 05/27/2022
488LPI Propane Autogas Engine Mechanical
and Fuel Components Service Manual
Page 73 of 117
10. If equipped: Remove Dual A/C Drive
Pulley. Refer to Front End Accessory
Drive Components Replacement.
11. Remove Harmonic Damper Flanged
Bolt (1) from Harmonic Damper (2).
Figure 2
12. Install removal tool (3) over
Crankshaft snout (6). Figures 3 & 5.
13. Install special tool (4) on Harmonic
Damper (5). Figure 4
14. Tighten special tool center screw to
pull Harmonic Damper off
Crankshaft.
15. Remove Harmonic Damper (5),
taking care not to lose the Alignment
Key (not shown).
16. Remove special tool from Harmonic
Damper (5). Figure 4
17. Clean and inspect Harmonic
Damper.
- 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...
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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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