Fuel - Mandatory Assembly Sequence For Fuel Rail
Bulletin 85-6C-14Date Apr.. '85
Ref. No. 85-214-6C
SUBJECT: MANDATORY ASSEMBLY SEQUENCE FOR FUEL RAIL ASSEMBLY
MODELS AFFECTED: ALL MODELS EQUIPPED WITH THE 1.8L TURBOCHARGED ENGINE (VIN CODE J)
The purpose of this bulletin is to establish a mandatory assembly sequence for the Fuel Rail Assembly of the 1.8L Turbocharged engine (VIN Code J).
DISASSEMBLY:
1. Relieve fuel system pressure, as described in Section 6C of the Chassis Service Manual.
2. Disconnect the negative battery cable.
3. Disconnect the injector control harness connectors at injectors.
4. Disconnect the fuel feed line and brackets at throttle body end of fuel rail.
5. Disconnect the fuel return pipe at pressure regulator.
6. Disconnect fuel return pipe at fuel rail assembly.
7. Disconnect fuel rail at pressure regulator bracket.
8. Disconnect fuel rail at Siamese injector housings.
9. Remove fuel rail and injectors.
10. Disconnect pressure regulator and bracket from intake manifold.
MANDATORY ASSEMBLY SEQUENCE:
1. Loosely assemble fuel rail and injectors to Siamese injector housings.
FUEL RAIL ASSEMBLY:
2. Loosely assemble fuel pressure regulator (item 5) and bracket to intake manifold.
3. Loosely assemble fuel return pipe assembly.
4. Line up hole on fuel rail return end tab (item 14) with center hole on pressure regulator bracket and torque fastener to 6 N-m (4.5 lb.ft.).
5. Loosely assemble throttle control bracket (item 4) and fuel line bracket (item 3) with fuel rail.
6. Install four (4) fuel injector clips (item 10).
7. Loosely assemble fuel feed line (item 8) and return lines (item 7). Be sure new "O" rings are in place.
8. Install clamp (item 13) - fuel return line to fuel line bracket - 6 N-m (4.5 lb.ft.).
9. Tighten mounting bolts on pressure regulator - 27 N-m (20 lb.ft.).
10. Tighten nuts on fuel feed and return lines - 27 N-m (20 lb.ft.). Use a torque wrench and a backup wrench.
11. Tighten bolts holding fuel rail brackets to Siamese injector housings - 27 N-m (20 lb.ft.)
12. Hand tighten fuel return pipe fittings.
13. Torque fittings to 27 N-m (20 lb.ft.) using a torque wrench and a backup wrench.
14. Connect injector control harness connectors at injectors.
15. Connect negative battery cable.