Chrysler Voyager 1984-1990

Chrysler Voyager 1984-1990 Fuel System Bolt Torque Specifications

This page provides detailed torque specifications for fuel system bolts on 1984-1990 Chrysler Voyager vehicles. Includes torque values for various fuel system components.

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 Tank And Mounting

Specifications for the fuel tank, its mounting hardware, and related components such as the fuel pump and sending unit. These are critical for the secure and safe operation of the fuel system.

1

Fuel Pump Mounting Bolts (Tank Mounted)

M8 x 1.25
Torque Value
11 ft-lbs (15 N·m)
Important Notes
Secures the fuel pump module to the fuel tank. Proper torque prevents leaks and ensures correct pump submersion. Estimated value.
2

Fuel Sending Unit Retaining Ring

N/A
Torque Value
23 ft-lbs (31 N·m)
Important Notes
Secures the fuel sending unit and fuel pump assembly into the tank. Proper torque prevents fuel leaks. Estimated value.
3

Fuel Tank Strap Mounting Bolts

M12 x 1.75
Torque Value
30 ft-lbs (41 N·m)
Important Notes
These bolts are critical for safety and must be torqued correctly to prevent the tank from shifting. Estimated value.

Fuel Filtration And Lines

Specifications for components related to fuel filtration and delivery lines, including the fuel filter, its bracket, and line retaining clamps. Proper torque is essential to prevent leaks and ensure component stability.

1

Fuel Filter Bracket Bolts (to Body/Frame)

M8 x 1.25
Torque Value
18 ft-lbs (24 N·m)
Important Notes
Secures the fuel filter bracket to the vehicle's body or frame. Estimated value.
2

Fuel Filter Inlet and Outlet Fittings (Banjo Bolts or Threaded Fittings)

M12 x 1.5
Torque Value
20 ft-lbs (27 N·m)
Important Notes
These fittings must be torqued properly to avoid fuel leaks. Always replace crush washers with each removal. Estimated value.
3

Fuel Line Retaining Clamps (to Body/Frame)

M6 x 1.0
Torque Value
9 ft-lbs (12 N·m)
Important Notes
These bolts secure the clamps holding fuel lines in place. Estimated value.

Fuel Injection System

Specifications for fuel injection system components, including the fuel pressure regulator, fuel injectors, fuel rail, and throttle body (if applicable). Proper torque ensures correct component function and prevents leaks.

1

Fuel Pressure Regulator Mounting Bolts

M6 x 1.0
Torque Value
8 ft-lbs (11 N·m)
Important Notes
Secures the fuel pressure regulator to the fuel rail or intake manifold. Estimated value.
2

Fuel Injector Hold-Down Bolts

M5 x 0.8
Torque Value
6 ft-lbs (8 N·m)
Important Notes
Fastens fuel injectors to the intake manifold or fuel rail. Tighten evenly in sequence to prevent damage to o-rings. Estimated value.
3

Fuel Rail Mounting Bolts

M8 x 1.25
Torque Value
12 ft-lbs (16 N·m)
Important Notes
Secures the fuel rail to the intake manifold. A tightening sequence is usually followed to ensure even pressure. Estimated value.
4

Throttle Body Mounting Bolts

M8 x 1.25
Torque Value
18 ft-lbs (24 N·m)
Important Notes
Secures the throttle body to the intake manifold. Even torque is critical. A tightening sequence is often required. Estimated value.

Carburetion System

Specifications for components related to the carburetion system, including carburetor mounting. Proper torque ensures correct component function and prevents leaks.

1

Carburetor Mounting Studs/Bolts

M8 x 1.25
Torque Value
15 ft-lbs (20 N·m)
Important Notes
Secures the carburetor to the intake manifold. Even torque is essential for a leak-free connection. Estimated value.

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 fuel system bolts?

Overtightening can damage threads, crush gaskets, and distort fuel system components. This can lead to fuel leaks, which are a significant fire hazard. For example, overtightening the fuel rail bolts can cause the rail to crack or warp, resulting in fuel spraying into the engine compartment.

Q2

What happens if I undertighten fuel system bolts?

Undertightening can cause fuel leaks due to insufficient pressure on sealing surfaces. This can lead to fuel smells, poor engine performance, and potential fire hazards. An example is an undertightened fuel filter banjo bolt, which can seep fuel.

Q3

Do I need to use new gaskets or seals when working on the fuel system?

Yes, always use new gaskets, O-rings, and seals when reassembling any fuel system components. Old seals can be brittle and fail to create a proper seal, leading to fuel leaks. For instance, reusing an old injector O-ring is almost guaranteed to cause a leak.

Q4

What should I do if I don't have a torque wrench?

While a torque wrench is highly recommended for proper fuel system work, if one isn't available you should be VERY careful. Tighten fuel bolts by hand, feeling the resistance, and then go a small amount further, using an equal tightening method as if following torque. However this process should never substitute for a proper torque spec.

Q5

How often should I inspect the fuel system?

It's good practice to visually inspect fuel lines, connections, and fuel system components during routine maintenance, such as oil changes. Look for signs of leaks, cracks, or corrosion. Addressing issues early prevents more significant problems. A common example is spotting a fuel line crack before it causes a major leak.

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 (3/8" drive)

A calibrated torque wrench is essential for accurately tightening fuel system bolts to the manufacturer's specifications.

  • Click-type or digital
  • Inch-pound or Newton-meter scale
  • Range suitable for specified torque values (typically 5-30 ft-lbs)
Learn more

Socket Set (3/8" drive)

A set of sockets with various sizes to match the fuel system bolt heads.

  • Standard and/or metric sizes
  • 6-point sockets for a secure grip
  • Shallow and deep sockets to accommodate different bolt lengths
Learn more

Extension Bars (3/8" drive)

Extension bars assist in reaching bolts located in confined spaces.

  • Various lengths available
  • Allows for flexible access
  • Secure connection to sockets and wrench
Learn more
Service Procedures

Fuel Rail Bolt Torque Procedure

This procedure details the correct torque application for the fuel rail mounting bolts.

  • Locate the fuel rail mounting bolts.
  • Consult the manufacturer's service manual for the specific torque value. Typically 10-12 ft-lbs for M6 bolts.
  • Using the correct socket and torque wrench, tighten the bolts to the specified torque value in a cross-tightening pattern (if multiple bolts).
  • Do not overtighten.
View full procedure

Fuel Injector Mounting Bolt Torque Procedure

This procedure details the correct torque application for the fuel injector mounting bolts.

  • Locate the fuel injector mounting bolts.
  • Consult the manufacturer's service manual for the specific torque value. Typically 8-10 ft-lbs for M5 bolts.
  • Using the correct socket and torque wrench, tighten the bolts to the specified torque value.
  • Do not overtighten.
View full procedure

Fuel Line Fitting Torque Procedure

This procedure details the correct torque application for fuel line fittings.

  • Locate the fuel line fittings.
  • Consult the manufacturer's service manual for the specific torque value. Typically 15-20 ft-lbs for banjo fittings and 10-12 ft-lbs for smaller threaded fittings. Refer to spec sheet of the part.
  • Using the correct wrench (flare wrench recommended), tighten the fittings to the specified torque value.
  • Do not overtighten.
View full procedure
Technical Service Bulletins

Fuel Leakage at Fuel Rail Bolts

1987-04-15

Some 1984-1987 Chrysler Voyagers may exhibit fuel leakage at the fuel rail mounting bolts due to improper tightening during assembly. Check the torque specs.

1984-1987

Resolution: Verify correct torque of 10-12 ft-lbs on the fuel rail bolts. Replace seals if damaged. Retighten to spec.

Fuel Injector O-ring Damage and Torque Specs

1988-08-22

Improper installation of fuel injectors and incorrect torque on the mounting bolts can damage the O-rings. Re torque all fittings after any work to the fuel system. O-ring failures can cause fuel leaks.

1984-1990

Resolution: Replace damaged O-rings and ensure the fuel injector mounting bolts are torqued to the manufacturer's specification of 8-10 ft-lbs.

Fuel Line Fitting Leakage

1990-01-10

Fuel line fitting leaks are often the result of improper installation and /or torquing. Verify the fittings are tightened to the correct torque.

1984-1990

Resolution: Verify the correct torque specifications for all fuel line fittings which typically are 15-20 ft-lbs for banjo fittings and 10-12 ft-lbs for smaller threaded fittings. Replace seals and damaged parts.

About the Author

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Alan Montanye - Automotive Technical Specialist
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Alan Montanye

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