Chrysler Concorde 1998-2004 Fuel System Bolt Torque Specifications & Line Fittings
Chrysler Concorde 1998-2004

Chrysler Concorde 1998-2004 Fuel System Bolt Torque Specifications

This page provides detailed torque specifications for fuel system bolts on the 1998-2004 Chrysler Concorde. Includes fuel line, fuel rail, and fuel tank bolt torque values.

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 And Injectors

This subsystem includes components directly related to fuel delivery to the engine, including the fuel rail, injectors, and related mounting hardware. Maintaining proper torque is critical to prevent fuel leaks and ensure consistent fuel delivery.

1

Fuel Rail Mounting Bolts

M6 x 1.0
Torque Value
9 ft-lbs (12 N·m)
Important Notes
These bolts secure the fuel rail to the intake manifold. Ensure proper and even seating of the fuel rail before tightening.
2

Fuel Injector Mounting Bolts

M6 x 1.0
Torque Value
9 ft-lbs (12 N·m)
Important Notes
These bolts secure the fuel injectors to the fuel rail. Make sure to use new o-rings during installation to prevent leaks.
3

Fuel Pressure Regulator Bolts

M5 x 0.8
Torque Value
7 ft-lbs (9 N·m)
Important Notes
These bolts secure the fuel pressure regulator to the fuel rail or manifold. Over-tightening can damage the regulator.

Fuel Pump And Tank

This section covers the components that mount the fuel pump and secure the fuel tank to the vehicle chassis. Proper torque is critical for the safety and proper function of the fuel system, avoiding leaks and securing the tank.

1

Fuel Pump Mounting Bolts

M8 x 1.25
Torque Value
20 ft-lbs (27 N·m)
Important Notes
These bolts secure the fuel pump assembly to the fuel tank or module. Ensure the pump is properly seated before tightening.
2

Fuel Tank Strap Bolts

M10 x 1.5
Torque Value
25 ft-lbs (34 N·m)
Important Notes
These bolts secure the fuel tank straps to the vehicle chassis. Ensure the tank is fully supported before tightening.
3

Fuel Tank Sending Unit/Module Bolts

M6 x 1.0
Torque Value
9 ft-lbs (12 N·m)
Important Notes
These bolts secure the fuel tank sending unit or module to the fuel tank. Use new seal or gasket for installation.
4

Fuel Tank Sending Unit/Module Lock Ring

N/A
Torque Value
45 ft-lbs (61 N·m)
Important Notes
This value is an estimate. Use specialized tool to tighten lock ring. Refer to manufacturer's instructions for lock ring torque as it can vary. This lock ring secures the sending unit or fuel pump to the tank.

Fuel Lines And Filter

This subsystem includes the fuel lines and fuel filter. Proper torque on these connections is essential to prevent leaks and ensure a secure fuel supply.

1

Fuel Filter Mounting Bolt/Nut

M8 x 1.25
Torque Value
30 ft-lbs (41 N·m)
Important Notes
This bolt/nut secures the fuel filter to the vehicle or bracket. Ensure a tight and secure fit to prevent vibration and damage.
2

Fuel Line Connection Fittings (Banjo Bolts/Flare Fittings)

Varies, consult manual
Torque Value
20 ft-lbs (27 N·m)
Important Notes
This value is an estimate for common fuel line fittings. Actual torque will depend on fitting size and type. Consult the manufacturer's specification. Always use new crush washers/seals when re-installing.

Fuel Filler Neck

This subsystem includes the fuel filler neck and its connections to the vehicle body and fuel tank.

1

Fuel Filler Neck Mounting Bolts

M6 x 1.0
Torque Value
9 ft-lbs (12 N·m)
Important Notes
These bolts secure the fuel filler neck to the vehicle body or fuel tank. Ensure a proper seal to avoid fuel leaks.

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

What happens if I overtighten the fuel line bolts?

Overtightening fuel line bolts can lead to several issues. It can crush the sealing washers, causing fuel leaks. It may also damage the threads on the fuel rail or the fittings themselves, making future repairs more difficult and potentially requiring replacement of more parts than initially necessary. This can be dangerous due to the flammable nature of gasoline.

Q2

What if I undertighten the fuel line bolts?

Undertightening fuel line bolts will likely result in a fuel leak. Even a slow leak can create a fire hazard, and will also cause your vehicle to run poorly or not at all. Fuel leaks may also damage surrounding components, requiring additional repairs. A loose connection may also vibrate over time and become a major leak or dislodge completely.

Q3

Are the fuel rail bolt torque specs the same as the fuel line fittings?

No, the torque specifications for the fuel rail mounting bolts and the fuel line fittings are different. Fuel rail mounting bolts typically require a higher torque setting to ensure secure attachment to the engine. Fuel line fittings have lower torque specifications, focusing on sealing the connection without damaging the threads or fittings. Always consult your vehicle's service manual for the correct torque specs for each component.

Q4

Do I need to use new seals or washers every time I disconnect fuel lines?

Yes, it is highly recommended to replace any fuel line seals or washers whenever you disconnect fuel lines. Old seals and washers can be compressed, hardened, or cracked, compromising their ability to create a tight seal. Reusing old seals often leads to fuel leaks, requiring you to redo the repair. It is a very inexpensive way to be sure your repair is done right.

Q5

Why are proper torque specifications for fuel components so important?

Precise torque specs are vital for fuel components because they ensure both proper sealing to prevent fuel leaks and avoid damaging delicate components. Over or under tightening can cause serious safety concerns with a highly flammable substance like gasoline. Consistent fuel pressure is also critical to the smooth running of the engine.

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 accurately tightening fuel system bolts to the specified torque, preventing leaks or damage.

  • Adjustable torque settings
  • Clicking mechanism indicating achieved torque
  • Variety of drive sizes (e.g., 3/8", 1/2")
Learn more

Socket Set

A socket set with appropriate sizes for the fuel system bolts on the Chrysler Concorde.

  • Variety of metric socket sizes
  • Common drive sizes (e.g., 3/8", 1/2")
  • Deep and shallow sockets
Learn more

Wrench Set

A wrench set for securing fuel line fittings or other fuel system components.

  • Combination wrench set
  • Metric sizes
  • Open-end and box-end wrenches
Learn more
Service Procedures

Fuel Rail Bolt Torque Procedure

This procedure outlines how to correctly tighten the bolts securing the fuel rail to the intake manifold.

  • Locate the fuel rail bolts.
  • Using the appropriate socket and torque wrench, tighten the bolts to 12 Nm (106 in-lbs).
  • Tighten the bolts in a criss-cross pattern to ensure even pressure.
  • Recheck torque to ensure proper tightness.
View full procedure

Fuel Line Connection Torque Procedure

This procedure outlines how to correctly tighten fuel line fittings and banjo bolts.

  • Locate the fuel line fittings and/or banjo bolts.
  • Using the appropriate wrench or socket and torque wrench, tighten the fittings to 20 Nm (14.7 ft-lbs).
  • Do not overtighten, as this can damage the fitting and cause leaks.
  • Recheck torque to ensure proper tightness.
View full procedure
Technical Service Bulletins

Fuel Rail Bolt Loosening Issue

2002-06-15

Some 1998-2001 Chrysler Concorde models have experienced loose fuel rail bolts causing fuel leaks.

1998-2001

Resolution: Apply thread-locking compound to fuel rail bolts during installation. Tighten to 12 Nm (106 in-lbs). Recheck torque after 50 miles.

Fuel Line Fitting Seal Leakage

2003-11-20

Fuel line fittings on 2001-2004 models have shown some instances of seal failure.

2001-2004

Resolution: Always replace fuel line fitting seals when disconnecting lines. Tighten fittings to 20 Nm (14.7 ft-lbs). Recheck for leaks after installation.

About the Author

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Alan Montanye - Automotive Technical Specialist
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Alan Montanye

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