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Hexagon 488LPI Service Manual

Propane autogas engine electrical and sensors
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Propane Autogas
Engine Electrical and Sensors
Service Manual
DSM.0053 Ver. 1.0
May 26, 2022
P
D
C
U
RINTED AND
OWNLOADED
OPIES ARE
NCONTROLLED

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Summary of Contents for Hexagon 488LPI

  • Page 1 Propane Autogas Engine Electrical and Sensors Service Manual DSM.0053 Ver. 1.0 May 26, 2022 RINTED AND OWNLOADED OPIES ARE NCONTROLLED...
  • Page 2 Hexagon Agility Inc. Copyright ©2022. All Rights Reserved. DSM.0053 Ver. 1.0 05/26/2022 Page 2 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 3 ® Freightliner Custom Chassis Corporation or Thomas Built Buses. Fuel system warranty or non-warranty product support may be obtained by calling or emailing Hexagon Agility ® Customer Care and Technical Services (CCTS). Please provide your name, phone number, email address, and complete vehicle information: VIN, year, make, model, mileage, unit number, vehicle owner, and current vehicle location.
  • Page 4 Mass Air Flow (MAF) Sensor Spark Plug Inspection Spark Plug Wire Inspection Torque Security Module (TSM) References Electrical Component and Sensor Torque Specifications Ignition System Specifications DSM.0053 Ver. 1.0 05/26/2022 Page 4 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 5 EVAP evaporative emissions fuel pressure/temperature sensor liquid propane gas Liquid Propane Injection manifold absolute pressure sensor mass air flow sensor torque security module DSM.0053 Ver. 1.0 05/26/2022 Page 5 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 6 Individuals who are not trained are not permitted to service, maintain, test, or inspect a system. LPG used for automotive applications is often referred to as “propane autogas.” DSM.0053 Ver. 1.0 05/26/2022 Page 6 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 7 C19d C19b C19a Ignition Ignition Ignition Ignition Coil 8 Coil 6 Coil 4 Coil 2 Crankshaft Position Compressor Sensor Clutch 1 Compressor Clutch 2 DSM.0053 Ver. 1.0 05/26/2022 Page 7 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 8 Repair Procedures FRONT DSM.0053 Ver. 1.0 05/26/2022 Page 8 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 9 Electrical Component & Sensor Torque Specifications. 4. Connect CMP Sensor Electrical Connector (2) to Engine Harness (3). Figure 1 5. Lower vehicle. 6. Verify proper operation. DSM.0053 Ver. 1.0 05/26/2022 Page 9 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 10 CKP Sensor must be replaced if O- Figure 1: ring is damaged. Camshaft (CKP) Sensor Electrical Connector location (2), Engine Front Cover (1), Engine Harness (3) DSM.0053 Ver. 1.0 05/26/2022 Page 10 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 11 Electrical Component & Sensor Torque Specifications. 4. Connect CMP Sensor Electrical Connector (2) to Engine Harness (3). Figure 1 5. Lower vehicle. 6. Verify proper operation. DSM.0053 Ver. 1.0 05/26/2022 Page 11 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 12 Engine Harness via three (3) electrical connectors and attaches to the Upper Intake Manifold using three (3) bolts. ECMs are unique to each vehicle and must be programmed according to Vehicle Equipment Programming Stations (VEPS). Please contact Hexagon Agility ® REMOVAL PROCEDURE 1.
  • Page 13 Figure 2: ECT Sensor (3), ECT Sensor Pigtail Electrical procedure. Connector (2), ECT Sensor Threads (4) 5. Clean any spilled fluids. 6. Verify proper operation. DSM.0053 Ver. 1.0 05/26/2022 Page 13 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 14 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 Page 14 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 15 Cylinder Heads. Figure 11 13. Lower vehicle. 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 Page 15 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 16 8. If equipped: Connect C26 and C27 Air Conditioner Compressor Clutch Connector(s) (not shown). Figure 9: Engine Harness Cap Stud Retaining Bolt (15) locations DSM.0053 Ver. 1.0 05/26/2022 Page 16 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 17 Electrical Component and Sensor Torque Specifications. 18. Lower vehicle. 19. Reconnect negative (–) Battery Cable. 20. Verify proper operation. Figure 13: C28 Bulkhead Connector (22) location DSM.0053 Ver. 1.0 05/26/2022 Page 17 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 18 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 Page 18 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 19 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 Page 19 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 20 Fuel Rail (2) using a deep well socket and extension. Figures 1 & 2 Inspect FPT Sensor O-ring for damage; replace O-ring as necessary. DSM.0053 Ver. 1.0 05/26/2022 Page 20 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 21 5. Reinstall Fuel Supply and Fuel Return detailing FPT Sensor (1) and FPT Sensor Lines. Refer to Fuel Line Bleed Electrical Connector (3) Procedure. 6. Verify proper operation. DSM.0053 Ver. 1.0 05/26/2022 Page 21 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...

  • Page 22: Connector (3). Figure

    NOTE: Driver side shown; passenger side similar. Rocker Cover Mounting Bosses (5). Figure 3 Figure 2: Ignition Coil Harness Connectors (3). NOTE: Driver side shown; passenger side similar. DSM.0053 Ver. 1.0 05/26/2022 Page 22 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 23 Driver side Ignition Coils #1, #3 and #7 (1). NOTE: Ignition Coil #5 removed to show Valve Cover Coil Mount Bosses (5) and Coil Mounting Bolt (4). DSM.0053 Ver. 1.0 05/26/2022 Page 23 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 24 Upper Intake Manifold (4) Figure 2: Manifold Absolute Pressure (MAP) Sensor (1), MAP Sensor O-Ring Seal (5), MAP Sensor Electrical Connector (6) DSM.0053 Ver. 1.0 05/26/2022 Page 24 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 25 Component & Sensor Torque Specifications. 4. Connect MAP Sensor Electrical Connector (6) to Engine Harness Connector (2). Figures 1 & 2 5. Verify proper operation. DSM.0053 Ver. 1.0 05/26/2022 Page 25 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...

  • Page 26: Electrical Connector

    Electrical Connector (6) 5. Connect MAF (1) to Engine Harness Electrical Connector (2) at MAF Connector (6). Figures 1 & 2 6. Verify proper operation. DSM.0053 Ver. 1.0 05/26/2022 Page 26 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 27 An excessively wide gap can cause engine misfires and poor vehicle operation. Figure 3: Spark Plug with crack (6) in porcelain Insulator DSM.0053 Ver. 1.0 05/26/2022 Page 27 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 28 Boots from Terminal Connectors. 2. If any of the above conditions are found, replace damaged Spark Plug Wire and any component connected to it. DSM.0053 Ver. 1.0 05/26/2022 Page 28 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 29 TSM Mounting Bolt (4), TSM Mounting Bracket (6), Upper Intake Manifold (7) Verify connector security locks are firmly in place. 4. Verify proper operation. DSM.0053 Ver. 1.0 05/26/2022 Page 29 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 30 23  ft-lbs Throttle Body Bolt 15 Nm 11 ft-lbs Torque Security Module Bracket Bolts 15 Nm 11 ft-lbs *F.S.N.S. = Fully Seated, Not Stripped DSM.0053 Ver. 1.0 05/26/2022 Page 30 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...
  • Page 31 Plugs should be installed as boxed (dry). Do not mix different types of spark plugs. Driver Passenger side side Firing order 1–8–7–2–6–5–4–3 DSM.0053 Ver. 1.0 05/26/2022 Page 31 of 31 488LPI Propane Autogas Engine Electrical and Sensors Manual...