Chrysler 200 2015-2017 Fuel System Bolt Torque Specifications & Line Fittings
Chrysler 200 2015-2017

Chrysler 200 2015-2017 Fuel System Bolt Torque Specifications

Detailed torque specifications for all fuel system bolts on the 2015-2017 Chrysler 200, including fuel rail, fuel pump, and fuel line connections. Includes units in both foot-pounds (ft-lbs) and Newton-meters (Nm).

Updated

Important Information

Safety guidelines and reference information for proper torque application

Quick Reference Guide
ft-lbs → Nm
× 1.356
ft-lbs → kg-m
× 0.138
Nm → ft-lbs
× 0.738
in-lbs → ft-lbs
× 0.083

Common Torque Patterns

Star Pattern

Used for wheels and other circular bolt patterns

Star Pattern torque pattern diagram showing proper bolt tightening sequence
Cross Pattern

Used for gaskets and cover plates

Cross Pattern torque pattern diagram showing proper bolt tightening sequence
Sequential Pattern

Used for head bolts and other critical components

Sequential Pattern torque pattern diagram showing proper bolt tightening sequence

Common Mistakes to Avoid

Over-tightening

Exceeding the specified torque value can stretch or break fasteners, damage threads, or crack components.

Prevention:

Always use a calibrated torque wrench and follow specifications exactly.

Incorrect Torque Sequence

Tightening bolts in the wrong order can cause uneven pressure distribution and potential leaks or damage.

Prevention:

Follow the manufacturer's specified torque sequence pattern.

Dirty Threads

Dirt, rust, or old thread locker can affect torque readings and proper fastener tension.

Prevention:

Clean and inspect all threads before assembly. Use new thread locker if specified.

Reusing TTY Bolts

Torque-to-yield bolts are designed to stretch and must not be reused.

Prevention:

Always replace TTY bolts with new ones. They are single-use only.

Dry vs. Lubricated

Not accounting for whether torque specs are for dry or lubricated fasteners can lead to incorrect tension.

Prevention:

Check if specs are for dry or lubricated threads. Use specified lubricant when required.

Recommended Tools

Torque Wrench (1/4" Drive)

Range: 2-25 ft-lbs
Small fasteners, delicate components

Torque Wrench (3/8" Drive)

Range: 10-100 ft-lbs
Most common automotive fasteners

Torque Wrench (1/2" Drive)

Range: 30-250 ft-lbs
Large fasteners, wheels

Angle Gauge

Torque-to-yield (TTY) bolts

Torque Wrench Care

  • Calibrate annually or after 5,000 clicks
  • Store at lowest setting
  • Keep clean and lubricated

Search Specifications

Search by component name, bolt size, or description

Torque Calculator

Convert between different torque units

Fuel Rail

This subsystem includes the fuel rail, injectors, and related mounting hardware. Proper torque is critical to maintain a leak-free seal and ensure proper fuel delivery.

1

Fuel Rail Mounting Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (11.9 N·m)
Important Notes
Torque bolts in a criss-cross pattern to ensure even pressure distribution. Ensure fuel rail is properly seated before final tightening.
2

Fuel Injector Mounting Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (11.9 N·m)
Important Notes
Ensure injector O-rings are properly lubricated before installation. Some injectors may be held in with a clip rather than a bolt.
3

Fuel Injector Rail Mounting Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (11.9 N·m)
Important Notes
This may be the same bolt as the Fuel Rail Mounting Bolts. Confirm bolt location in the vehicle's repair manual.

Fuel Pump

This subsystem includes the fuel pump, fuel filter, fuel tank, straps, and filler neck. Proper torque ensures no leaks and a secure mounting of all parts.

1

Fuel Pump Mounting Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (11.9 N·m)
Important Notes
Use a criss-cross pattern if multiple bolts are present. Ensure fuel pump seal is properly seated prior to final tightening
2

Fuel Filter Mounting Bolt/Nut

M8 x 1.25
Torque Value
13 ft-lbs (17 N·m)
Important Notes
Ensure filter is properly seated before final tightening. Check for leaks after installation.
3

Fuel Tank Strap Bolts

M10 x 1.5
Torque Value
35 ft-lbs (47 N·m)
Important Notes
Tighten both straps evenly to ensure proper support. Ensure no pinching or binding of straps.
4

Fuel Filler Neck Bolts

M8 x 1.25
Torque Value
35 ft-lbs (47 N·m)
Important Notes
Check alignment of filler neck to tank before tightening.
5

Fuel Tank Sending Unit/Module Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (11.9 N·m)
Important Notes
Tighten in a criss-cross pattern to ensure even pressure on the seal. Confirm proper installation before final torque.

Fuel Lines And Fittings

This subsystem includes all fuel line connections, both banjo and threaded fittings. Proper torque ensures a leak-free seal under pressure.

1

Fuel Line Banjo Fitting Bolt

M12 x 1.5
Important Notes
Torque to the first value then tighten an additional 45 degrees. Ensure sealing washers are installed correctly on either side of the banjo fitting.
2

Threaded Fuel Line Fitting

Varies by application
Torque Value
15 ft-lbs (20 N·m)
Important Notes
This is an estimated value, torque spec may vary by application. Ensure proper sealing material (e.g. PTFE tape or sealant) is used. This applies to a fitting size of approximately M10-M14, use a service manual for more precise specifications.

Evaporative Emissions

This subsystem covers the EVAP components, including the canister, purge valve, and associated lines. Proper torque on these components is critical for preventing vapor leaks and ensuring system functionality.

1

EVAP Canister Mounting Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (11.9 N·m)
Important Notes
Ensure the canister is properly seated before final tightening.
2

EVAP Purge Valve Mounting Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (11.9 N·m)
Important Notes
Confirm the purge valve is properly seated before final tightening.
3

EVAP Vapor Line Connection Fittings

Varies by application
Torque Value
8.75 ft-lbs (11.9 N·m)
Important Notes
This is an estimated value. May have a quick connect, in which case it does not require torque. Inspect lines for leaks after assembly. Refer to manufacturer's manual for specific fitting types and torque values.

Fuel Pressure Regulation

This subsystem relates to the fuel pressure regulator and its associated mounting bolts. Proper torque is crucial to ensure accurate pressure regulation and prevent fuel leaks.

1

Fuel Pressure Regulator Mounting Bolts/Screws

M6 x 1.0
Torque Value
8.75 ft-lbs (11.9 N·m)
Important Notes
Ensure the regulator is properly seated against its mounting surface before applying final torque.

Troubleshooting Guide

Common issues, diagnostic steps, and prevention guidelines

Common Issues

Bolt stretching, stripped threads, uneven torque patterns

Loose Components

Symptoms:
  • Rattling or vibration noises
  • Visible movement in components
  • Uneven panel gaps
Solutions:
  • Clean threads and mounting surfaces
  • Replace damaged fasteners
  • Apply proper torque in sequence
  • Use thread locker if specified

Stripped Fasteners

Symptoms:
  • Unable to achieve proper torque
  • Fastener spins freely
  • Visible thread damage
Solutions:
  • Use thread repair kit if appropriate
  • Install thread insert (HeliCoil)
  • Replace component if threaded hole is damaged
  • Upgrade to higher grade fastener if recommended

Overtightened Components

Symptoms:
  • Cracked or deformed parts
  • Broken fasteners
  • Compressed gaskets or seals
Solutions:
  • Replace damaged components
  • Use new fasteners
  • Follow proper torque sequence
  • Verify correct torque specifications

Diagnostic Steps

Visual inspection, torque verification, thread assessment

1

Visual Inspection

Inspect the affected area for any visible signs of damage or wear

  • Check for cracks or deformation
  • Look for signs of excessive wear
  • Verify proper fastener installation
2

Torque Verification

Verify the torque applied to the fasteners

  • Check the torque wrench calibration
  • Verify the torque specification
  • Compare the applied torque to the specification
3

Thread Assessment

Assess the condition of the threads

  • Check for signs of thread damage
  • Verify the thread type and size
  • Check for proper thread engagement

Prevention Guidelines

Best practices, maintenance tips, tool care

Best Practices

  • Always follow the recommended torque specification
  • Use the correct type and size of fasteners
  • Verify the torque wrench calibration regularly

Maintenance Tips

  • Regularly inspect the affected area for signs of wear or damage
  • Replace damaged or worn-out components promptly
  • Keep the work area clean and organized

Tool Care

  • Regularly clean and maintain the torque wrench
  • Store the torque wrench in a dry and secure location
  • Verify the torque wrench calibration before each use

Frequently Asked Questions

Find answers to common questions about torque specifications

Q1

Why is it crucial to torque fuel system bolts to the correct specification?

Proper torque ensures a leak-free seal and prevents damage to components. Under-torquing can lead to fuel leaks, creating a fire hazard. Over-torquing can strip threads, crack housings, or distort sealing surfaces, also resulting in leaks. Consistent, accurate torque is vital for fuel system safety and reliability.

Q2

What happens if I overtighten a fuel system bolt?

Overtightening can damage the bolt, the threaded hole it screws into, and the component it's holding. For example, over-torquing a fuel rail bolt could crack the rail or strip the threads, requiring replacement of the entire rail assembly and potentially leading to a fuel leak. This can result in costly repairs and a significant safety risk.

Q3

Can I reuse fuel system bolts after removal?

It's generally recommended to replace fuel system bolts, especially those that are torque-to-yield (TTY). TTY bolts are designed to stretch upon tightening and may not achieve the correct clamping force if reused. Reusing standard bolts is sometimes acceptable *if* they are in perfect condition, but it is generally recommended to replace them for peace of mind and to ensure proper sealing.

Q4

What tools do I need for accurate torqueing of fuel system bolts?

You will need a properly calibrated torque wrench with the correct range for the bolt specifications (often in inch-pounds or Newton-meters). It's essential to use a reliable tool and to regularly check its calibration. Using an incorrect or uncalibrated torque wrench is dangerous and could result in an improperly tightened bolt, leading to a fuel leak and/or component damage.

Q5

How do I find the correct torque specification for a specific fuel system bolt?

The correct torque specification can be found in the vehicle's repair manual or a reliable online database specific to your vehicle year and model. Always consult the proper documentation and never rely on guesswork or generic torque values, as these can vary significantly even within the same vehicle.

Environmental Considerations

Temperature, humidity, and seasonal effects on torque specifications

Temperature Effects

Includes: High Heat, Cold Weather, Thermal Cycling

Temperature can significantly impact torque values and fastener behavior

Cold Weather

Effects:
  • Increased material brittleness
  • Higher torque required due to thread contraction
  • Reduced thread lubricant effectiveness
Recommendations:
  • Allow components to warm to room temperature when possible
  • Consider using winter-grade thread lubricants
  • Check torque values more frequently during winter months

Hot Weather

Effects:
  • Thermal expansion of components
  • Decreased friction in threads
  • Accelerated lubricant breakdown
Recommendations:
  • Check torque when components are at normal operating temperature
  • Use temperature-resistant thread lockers
  • Consider re-torquing after heat cycles

Humidity and Corrosion

Covers: Rust Prevention, Salt Exposure, Moisture Control

Moisture and corrosion can affect fastener integrity and torque values

High Humidity

Effects:
  • Accelerated corrosion formation
  • Reduced friction coefficient
  • Potential thread seizing
Prevention:
  • Use corrosion-resistant fasteners
  • Apply appropriate anti-seize compounds
  • Maintain proper protective coatings

Salt Exposure

Effects:
  • Rapid corrosion development
  • Thread damage
  • Seized fasteners
Prevention:
  • Regular underbody washing
  • Use of sacrificial anodes where appropriate
  • Application of protective coatings

Seasonal Maintenance

Spring, Summer, Fall, and Winter maintenance schedules

Spring

  • Inspect for winter damage
  • Clean and protect exposed fasteners
  • Check torque on critical components

Summer

  • Monitor heat-affected components
  • Check expansion-related loosening
  • Inspect cooling system mounts

Fall

  • Prepare for winter conditions
  • Apply corrosion protection
  • Verify all fasteners are properly torqued

Winter

  • More frequent inspection of critical fasteners
  • Check for salt damage
  • Monitor suspension component torque

Related Resources

Tools, service procedures, and technical bulletins

Recommended Tools

Torque Wrench

A calibrated torque wrench is essential for tightening fuel system bolts to the correct specifications. Using a torque wrench ensures proper sealing and prevents leaks.

  • Accurate torque settings
  • Various torque ranges available
Learn more

Socket Set

A standard socket set with the correct sizes for the fuel line connections and fuel pump access.

  • Variety of sizes
  • Usually comes with extensions
Learn more

Line Wrench

A line wrench (also known as a flare nut wrench) can help avoid damaging the fuel line fittings during removal or tightening.

  • Grip on multiple sides
  • Less chance of rounding nuts
Learn more
Service Procedures

Fuel Rail Bolt Torque Procedure

Instructions for properly torquing the bolts that secure the fuel rail to the engine. Incorrect torque can lead to fuel leaks or damage to components.

  • Locate the fuel rail bolts.
  • Refer to the specific torque specification chart for your vehicle and engine type.
  • Using a calibrated torque wrench, tighten the bolts to the specified torque in a proper sequence (usually a criss-cross pattern).
  • Double-check the tightness using a torque wrench
View full procedure

Fuel Pump Module Access & Torque Procedure

Instructions for properly removing/installing and tightening the fuel pump module within the fuel tank access panel. Incorrect torque can lead to fuel leaks or damage to components.

  • Safely remove the access panel to the fuel pump.
  • Refer to the specific torque specification chart for your vehicle and fuel pump module type.
  • Using a calibrated torque wrench, tighten the bolts to the specified torque in a proper sequence.
  • Double-check the tightness using a torque wrench
View full procedure

Fuel Line Connection Torque Procedure

Instructions for properly tightening the fuel line connection bolts and fittings. Incorrect torque can lead to fuel leaks or damage to components.

  • Refer to the specific torque specification chart for your vehicle and fuel line type.
  • Using a line wrench, carefully tighten the fuel line fittings to the specified torque.
  • Double-check the tightness using a torque wrench
View full procedure
Technical Service Bulletins

Fuel Leak Diagnosis and Repair

2016-05-12

This bulletin provides guidance on diagnosing and repairing fuel leaks on the Chrysler 200, emphasizing proper torque specifications for all fuel system connections.

2015-2017 Chrysler 200

Resolution: Always use a calibrated torque wrench and refer to the vehicle specific service manual for all torque specifications

Fuel System Component Replacement Procedures

2017-02-01

Detailed procedures for replacing various fuel system components, including the fuel rail, fuel pump, and fuel lines, stressing the importance of proper torque to prevent leaks and ensure safety.

2015-2017 Chrysler 200

Resolution: Always use the manufacturer's specific replacement parts and torque specifications during installation of any new fuel components

About the Author

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Alan Montanye - Automotive Technical Specialist
ASE

Alan Montanye

Automotive Technical Specialist

ASE Master Certified Technician with over a decade of hands-on experience in automotive repair and diagnostics.

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