Subject: | Revised Fuel Inlet Pipe to Rail Connection Procedure and Torque Specification |
Attention: | General Manager, Fixed Operations Manager, Technician |
Purpose
The purpose of this bulletin is to provide an updated service procedure and
torque specification for the fuel inlet pipe to fuel rail connection. Please insert
copies of this bulletin into appropriate sections of all printed service manuals.
Service Procedure
REMOVAL
- Relieve the fuel system pressure. Refer to Fuel Pressure Relief procedure
in the 2003 Saturn ION Service Manual, Vol. 1, Engine Controls.
- Disconnect the engine fuel feed pipe from the chassis fuel flex hose.
Refer to Quick Connect Fitting(s) Service (Metal Collar) in the 2003 Saturn ION Service
Manual, Vol. 1, Engine Controls.
- Use a back up wrench on the fuel rail and disconnect
the fuel feed pipe.
- Remove the fuel feed pipe fastener located on the
engine.
- Remove the engine fuel feed pipe.
INSTALLATION
Important: Use the correct fastener in the correct location.
Replacement fasteners must be the correct part number for that application. Fasteners
requiring replacement or fasteners requiring the use of thread locking compound or
sealant are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joints unless specified. These coatings
affect fastener torque and joint clamping force and may damage fastener. Use the correct
tightening sequence and specifications when installing fasteners in order to avoid
damage to parts and systems.
- Install the fuel feed pipe to the fuel rail.
Tighten
Using a backup wrench on the fuel rail, tighten
the fuel feed pipe to 10 N·m (89 lb-in).
- Install the engine fuel feed pipe fastener located
on the engine.
Tighten
Tighten the fuel feed pipe fastener to 10 N·m
(89 lb-in).
- Connect the engine fuel feed pipe to the chassis fuel flex hose. Refer
to Quick Connect Fitting(s) Service (Metal Collar) in the 2003 Saturn ION Service
Manual, Vol. 1, Engine Controls.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect
procedure in the 2003 Saturn ION Service Manual, Vol. 1, Engine Electrical.
- Inspect for leaks using the following procedure:
5.1. | With the engine OFF, turn ON the ignition for 2 seconds. |
5.2. | Inspect for fuel leaks. |
5.3. | Turn the ignition OFF. |
5.4. | With the engine OFF, turn ON the ignition for 2 seconds. |
5.5. | Inspect for fuel leaks. |
5.6. | Turn the ignition OFF. |