Fuel - Mandatory Assembly Sequence For Fuel Rail

Number 85-6(Gasoline)-23 Date 4/85

Subject: MANDATORY ASSEMBLY SEQUENCE FOR FUEL RAIL ASSEMBLY OF 1.8L TURBOCHARGED (VIN J-LA5) ENGINE

Intake Manifold And Fuel Rail Assembly:

The purpose of this bulletin is to establish a mandatory assembly sequence for the Fuel Rail Assembly of the 1.8L Turbocharged (VIN J-LA5) Engine.

DISASSEMBLY:

1. Relieve fuel system pressure, as specified in Section 6C of Service Manual.

2. Disconnect negative battery cable.

3. Disconnect injector control harness connectors at injectors.

4. Disconnect fuel feed line and brackets at throttle body end of fuel rail.

5. Disconnect fuel return at pressure regulator.

6. Disconnect fuel return pipe 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.

2. Loosely assemble fuel pressure regulator (10028562) and bracket to intake manifold.

3. Loosely assemble fuel return pipe assembly.
4. Line up hole on fuel rail return end tab with center hole on pressure regulator bracket and install fastener 6 N-m (4.5 ft. lbs.).

5. Loosely assemble throttle control bracket (10036070) and fuel line bracket with fuel rail.

6. Install fuel injector clips (4) (10041029).

7. Loosely assemble fuel feed (10041027) and return lines (10041030). Be sure new "O" rings are in place.

8. Install clamp (10041028) - fuel return line to fuel line bracket - 6 N-m. (4.5 ft.lbs.).

9. Tighten mounting bolts on pressure regulator - 27 N-m (20 ft. lbs.).

10. Tighten nuts on fuel feed and return lines - 27 N-m. (20 ft. lbs.). Use a click ID torque wrench and a backup wrench.

11. Tighten bolts holding fuel rail brackets to Siamese injector housings - 27 N-m (20 ft.lbs.).

12. Hand tighten fuel return pipe nuts A and B.

13. Tighten nut A to 27 N-m (20 ft.lbs.) using a click ID torque wrench and a backup wrench.

14. Tighten nut B to 27 N-m (20 ft.lbs.) in a similar manner.

15. Connect injector control harness connectors at injectors.

16. Connect negative battery cable.