NHTSA ID Number: 10214310
Manufacturer Communication Number: DSM.0054
TSB/Document Date: 2022-06-21
Summary
Service manual
for Hexagon Agility® 488LPI propane autogas (LPG) fuel storage system and evaporative emissions system components.
leak detection solution. Refer to Fuel
System Leak Check Procedure.
11. Verify proper operation.
DSM.0054 Ver. 1.0 05/27/2022
488LPI Propane Autogas
Fuel Storage and EVAP System
Page 12 of 35
Fuel System Leak Detection Procedure
DESCRIPTION AND OPERATION
Safe and effective 488LPI™ Engine and Fuel System operation, maintenance and repairs require
the system be free of propane leaks. Use the following procedure to check the Fuel System for
leaks.
Fuel Line pressure can exceed 250 psi (17 bar). Caution must be exercised.
PROCEDURE
1. Secure vehicle outdoors in a safe location.
2. If removed: Connect and tighten Fuel Supply
and Fuel Return Lines at Fuel Distribution
Blocks. Refer to Fuel and Supply Return Line
Replacement and Fuel System Torque &
Tightening Specifications.
3. If removed: Connect and tighten Fuel Supply
and Fuel Return Lines at Fuel Supply (1) and
Fuel Return (2) Manual Shutoff Valves. Refer
to Fuel and Supply Return Line Replacement
and Fuel System Torque & Tightening
Specifications. Figures 1 & 2
4. Slowly turn Fuel Supply Manual Shutoff Valve
(1) and Fuel Return (2) Manual Shutoff Valve
knobs counterclockwise to open. Figures 1 &
2
1
2
3
Figure 1:
Tank End Fuel Supply Manual Shutoff Valve (1),
Fuel Return Manual Shutoff Valve (2),
Fuel Supply Solenoid (3)
3
Knobs must be opened slowly or Excess
Flow Protection Valve will trigger and stop
fuel flow.
5. Disconnect Fuel Supply Solenoid (3) Electrical
Connector. Figures 1 & 2
Energize Fuel Supply Solenoid (3) with
twelve (12) volts using a Power Probe® or
similar tool. Figures 1 & 2. NOTE: An
audible “click” should be heard indicating
the solenoid has opened.
If an audible click is not heard, check 12 V
power supply for a good connection.
Re-energize the Fuel Supply Manual
Shutoff Valve Solenoid and listen again for
an audible click.
DSM.0054 Ver. 1.0 05/27/2022
2
1
Figure 2:
Tank Side Fuel Supply Manual Shutoff Valve (1)
and Fuel Supply Solenoid (3) with
Tank End Fuel Return Manual Shutoff Valve (2)
488LPI Propane Autogas
Fuel Storage and EVAP System
Page 13 of 35
Once energized, the Fuel Supply Manual
Shutoff Valve Solenoid allows fuel to flow
and pressurizes the fuel system.
6. When fuel system is pressurized, spray each
Line Fitting with an approved LPG leak
detection solution and look for any bubbling
around the connections.
Retighten any loose fittings. Follow Fuel
System Torque & Tightening
Specifications.
Spray leak source again with leak
detection solution
Depressurize fuel system before
replacing damaged fittings, lines,
seals, or components.
7. Connect Fuel Supply Solenoid (3) Electrical
Connector. Figures 1 & 2
DSM.0054 Ver. 1.0 05/27/2022
488LPI Propane Autogas
Fuel Storage and EVAP System
Page 14 of 35
Fuel Tank Drain Procedure
DESCRIPTION AND OPERATION
The 488LPI™ Fuel Tank stores liquid propane and houses the Fuel Pump which supplies fuel to
the engine and returns fuel back to the Tank for storage. When performing fuel system repairs
and maintenance, it is sometimes necessary to drain propane from the Fuel Tank.
Fuel Line pressure can exceed 250 psi (17 bar).
REMOVAL PROCEDURE
1. Secure vehicle outdoors in a safe location.
2. Bleed Fuel Lines per NFPA 58 and any
organizational or AHJ regulations.
3. Remove Fuel Drain Valve Cap (2) from Fuel
Drain Valve (1). Figure 1
4. Connect Fuel Transfer Hose (not shown) to
Fuel Drain Valve (1). Figure 1
5. Connect other end of Transfer Hose to Fill
Receptacle (not shown) of LPI® Fuel Recovery
Tank. Figure 4
6. Perform Static Fuel Discharge per NFPA 58
and any organizational or AHJ regulations.
Verify that you and any equipment used are
properly grounded.
7. Repeat Step 6 until no fuel pressure remains in
both hoses.
5
3
4
1
2
Figure 1:
Fuel Tank (5), Fuel Drain Valve (1),
Fuel Drain Valve Cap (2),
Fuel Return Manual Shutoff Valve (3),
Fuel Fill Hose 90° Elbow Nipple (4)
Both Fuel Supply and Fuel Return Lines
must be drained to ensure all pressure is
removed from Fuel Rails.
8. Disconnect Fuel Supply Hose from Fuel Supply
Manual Shutoff Valve (6) and Fuel Return Hose
from Fuel Return Manual Shutoff Valve (7).
Figures 2 & 3
Cover Fuel Hose openings to moisture or
FOD intrusion.
DSM.0054 Ver. 1.0 05/27/2022
488LPI Propane Autogas
Fuel Storage and EVAP System
Page 15 of 35
INSTALLATION PROCEDURE
1. Install Fuel Supply Line on Fuel Supply
Manual Shutoff Valve (6) and Fuel Return
Line on Fuel Return Manual Shutoff Valve
(7). Refer to Fuel Hose Replacement.
Figures 2 & 3
2. Slowly open Fuel Supply and Return
Manual Shutoff Valves (6) and (7) by
turning knobs counterclockwise. Figures 2
&3
3.
6
7
Figure 2:
Tank End Fuel Supply Manual Shutoff Valve (7) and
Fuel Return Manual Shutoff Valve (6) locations
Check for fuel leaks. Refer to Fuel
System Leak Detection Procedure.
4. Verify proper operation.
7
6
Figure 3:
Tank Side Fuel Supply Manual Shutoff Valve (6)
and Tank End Fuel Return Manual Shutoff Valve (7)
locations
Figure 4:
LPI® Fuel Recovery Tank, Special Tool 69000235
DSM.0054 Ver. 1.0 05/27/2022
488LPI Propane Autogas
Fuel Storage and EVAP System
Page 16 of 35
Fuel Tank Pass-Through Wiring Harness
Replacement
DESCRIPTION AND OPERATION
A Fuel Tank Pass-Through Wiring Harness provides the 488LPI™ Fuel Pump with battery power
and ground to operate. Fuel Tank Pass-Through Wiring is designed to withstand tank pressure
while maintaining proper seal.
If the Fuel Tank Pass-Through Wiring Harness is damaged or otherwise defective it must
be replaced.
Fuel Line pressure can exceed 250 psi (17 bar). Exercise caution when performing fuel
system service.
REMOVAL PROCEDURE
1. Secure vehicle outdoors in a safe location.
2. Bleed Fuel Lines per NFPA 58 and any
organizational or AHJ regulations.
3. Drain Fuel Tank (8). Refer to Fuel Tank Drain
Procedure. Figure 1
4. Remove Fuel Tank (8) Access Cover (1)
Retaining Bolts. Figure 1
5. Remove Fuel Tank Access Cover (1). Figure 1
6. Remove Fuel Tank Access Cover (1) O-ring (3).
Figure 1
7. Disconnect Fuel Pump Electrical Connector (6).
Figure 2
8. Remove Fuel Tank Pass-Through Wiring (9) from
Tank (8) through Access Opening (4).
Figures 1 & 2
DSM.0054 Ver. 1.0 05/27/2022
4
3
1
8
2
Figure 1:
Fuel Tank (8), Access Cover (1), Access Cover
Retaining Bolts (2), Access Cover O-ring (3),
Access Opening (4)
488LPI Propane Autogas
Fuel Storage and EVAP System
Page 17 of 35
INSTALLATION PROCEDURE
1. Install new Fuel Tank Pass-Through Wiring
Harness (9) into Fuel Tank (8). Figure 2
2. Connect Fuel Pump Electrical Connector
(6). Figure 2
3. Install new Fuel Tank Access Cover O-ring
(3). Figure 1
4. Install Fuel Tank Access Cover (1). Figure
1
5. Install Fuel Tank Access Cover Retaining
Bolts (2).
Tighten Bolts using a star pattern.
Refer to Fuel System Torque and
Tightening Specifications. Figure 1
6. Connect Fuel Tank Pass-Through Wiring
Harness Connector to Chassis Harness
7. Fill Fuel Tank with propane removed
during Fuel Tank Drain Procedure.
8. Install Fuel Supply and Fuel Return Lines.
Refer to Fuel Line Replacement.
9.
8
5
6
7
9
4
Figure 2:
Cutaway of Fuel Tank (8) showing Access
Opening (4), Fuel Pump Retaining Bolts (5),
Fuel Pump Electrical Connector (6),
Fuel Supply Line Quick Connect Adaptor (7);
Fuel Tank Pass-Through Wiring Harness (9)
Check for leaks with an approved LPG
leak detection solution. Refer to Fuel
System Leak Check Procedure.
10. Verify proper operation.
DSM.0054 Ver. 1.0 05/27/2022
488LPI Propane Autogas
Fuel Storage and EVAP System
Page 18 of 35
Evaporative (EVAP) Emissions System
Overview & Schematic
DESCRIPTION AND OPERATION
The 488LPI™ engine evaporative (EVAP) emissions system is essential for optimum performance
with minimal emissions. The EVAP system relies upon three line types to circulate various gases:
EVAP Purge Lines convey traces of propane in gaseous form, PCV Lines recirculate engine blowby products, and a Make-Up Air Line supplies air necessary for positive crankcase ventilation. A
leak from a broken line or improperly connected fitting can trigger the engine control module
(ECM) to generate a range of diagnostic trouble codes (DTCs).
EVAP system lines run from the passenger side Valve Cover and rear of the Upper Intake
Manifold to the chassis mounted EVAP Module Box and EVAP Canister on the passenger side
frame rail.
EVAP system lines are as follows:
1. EVAP Purge Line, engine intake mounted
2. EVAP Purge Line, engine to EVAP canister
3. PCV Line, engine to EVAP pump
4. PCV Line, EVAP pump to EVAP canister
5. Make-Up Air Line, engine to EVAP canister
EVAP System Schematic
DSM.0054 Ver. 1.0 05/27/2022
488LPI Propane Autogas
Fuel Storage and EVAP System
Page 19 of 35
EVAP System Component Locations
intake manifold
EVAP purge solenoid
quick
disconnect
fittings
intake
air
tube
EVAP
purge
line
passenger
side valve
cover
make-up air line
PVC line
passenger
chassis
frame
EVAP purge line
quick
disconnect
fittings
EVAP canister
EVAP pump module
DSM.0054 Ver. 1.0 05/27/2022
488LPI Propane Autogas
Fuel Storage and EVAP System
Page 20 of 35
EVAP System Line & Tube Replacement
DESCRIPTION AND OPERATION
EVAP system lines run from the passenger side valve cover and rear of the intake manifold to the
chassis mounted EVAP module box and EVAP canister on the passenger side frame rail.
EVAP system lines and corresponding repair procedures are as follows:
A.
B.
C.
D.
E.
F.
EVAP purge line, intake mounted
EVAP purge line, engine to EVAP canister
PCV line, engine to EVAP pump module
PCV line, EVAP pump module to EVAP canister
Make-up air line, engine to EVAP canister
PCV lines, EVAP pump module box top to EVAP pump
QUICK CONNECT REMOVAL PROCEDURE
1. Secure vehicle on an approved hoist.
2. Raise vehicle.
Depending upon the line being
serviced, it may be necessary to open
the hood for engine bay access and/or
remove the EVAP module box cover.
3. To safely release quick connect fittings
for all line types: Firmly but gently
squeeze quick connect fitting (1) tab (2)
and twist fitting counterclockwise. Pull
fitting straight off nipple (3). Figure 1
Gently decouple and remove lines and
fittings to avoid cracking the tubing or
weakening the connections.
1
3
2
Figure 1: Quick connect fitting (1),
release tab (2), nipple (3).
Use wire as needed to temporarily
support long lines.
DSM.0054 Ver. 1.0 05/27/2022
488LPI Propane Autogas
Fuel Storage and EVAP System
Page 21 of 35
REMOVAL PROCEDURES
A. EVAP purge line, intake mounted
1. Remove intake mounted EVAP purge
line (5) from EVAP purge solenoid (4)
and from purge line fitting (6) on intake
manifold (7). Figure 2
7
4
5
6
Figure 2: EVAP purge solenoid (4), intake
mounted EVAP purge line (5), EVAP purge line
fitting (6), intake manifold (7).
NOTE: Intake air tube not shown for clarity.
DSM.0054 Ver. 1.0 05/27/2022
488LPI Propane Autogas
Fuel Storage and EVAP System
Page 22 of 35
B. EVAP purge line, EVAP purge solenoid
to EVAP canister
1. Remove engine to EVAP canister EVAP
purge line (not visible) from EVAP purge
solenoid (4) fitting (8) on intake manifold
(7). Figure 3
2. Remove engine to EVAP purge solenoid
to EVAP canister line (14) from quick
connect fitting (1) on EVAP module (12).
Figure 4
3. Loosen P-clamps (20) to release EVAP
purge line (14). Figure 4 Refer to OEM
procedure.
8
4
7
Figure 3: EVAP purge solenoid (4), fitting (8),
intake manifold (7).
NOTE: Intake air tube not shown for clarity.
20
14
1
12
Figure 4: EVAP purge solenoid to EVAP cannister
line (14), P-clamps (20), quick connect fitting (1),
EVAP cannister (13).
DSM.0054 Ver. 1.0 05/27/2022
488LPI Propane Autogas
Fuel Storage and EVAP System
Page 23 of 35
C. PCV line, engine to EVAP pump module
1. Remove engine to EVAP module PCV
line (not shown) from PCV valve (10) on
passenger side valve cover and PCV line
fitting (9) on rear of intake manifold (7).
Figure 2
2. Remove engine to EVAP pump module
box PCV line (16) from quick connect
fitting (1) on EVAP pump module (12).
Figure 4
3. Loosen P-clamps (20) to release line
engine to EVAP Pump module PCV line
(16). Figure 6 Refer to OEM procedure.
7
9
10
Figure 5: PCV line fitting (9), PCV valve (10),
intake manifold (7).
NOTE: Intake air tube not shown for clarity.
20
16
1
12
Figure 6: engine to EVAP pump module PCV
line (16), EVAP pump module (12); quick
disconnect fitting (1), P-clamps (20).
DSM.0054 Ver. 1.0 05/27/2022
488LPI Propane Autogas
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TSB/Document ID: DSM.0054
Replacement Service Bulletin Number:
MFR Communication Date: 2022-05-27
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
MFR Component System:
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