Chrysler Voyager 2020-present Fuel System Bolt Torque Specifications & Line Fittings
Chrysler Voyager 2020-present

Chrysler Voyager 2020-present Fuel System Bolt Torque Specifications

Detailed torque specifications for fuel system bolts on the 2020-Present Chrysler Voyager, including fuel rail, fuel line, and fuel pump mounting bolts.

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 section covers the torque specifications for the fuel rail, injectors, and related mounting hardware. Proper torque is essential for preventing fuel leaks and ensuring proper fuel delivery.

1

Fuel Rail Mounting Bolts

M6 x 1.0
Torque Value
3.3 ft-lbs (4.5 N·m)
Important Notes
Ensure bolts are tightened evenly. If the fuel rail mounts to a plastic manifold, verify the torque does not exceed the manifold specifications. These are usually low torque values.
2

Fuel Injector Mounting Bolts

M6 x 1.0
Torque Value
17 ft-lbs (23 N·m)
Important Notes
Ensure injectors are properly seated before tightening. Over-tightening can damage the injector or its seals.
3

Fuel Injector Rail Mounting Bolts (Secondary)

M8 x 1.25
Torque Value
20 ft-lbs (27 N·m)
Important Notes
Some fuel rails may have multiple mounting points. Ensure all mounting bolts are tightened to spec.
4

Fuel Line Fitting to Fuel Rail/Injector

M12 x 1.5 (Banjo Bolt)
Torque Value
18 ft-lbs (24 N·m)
Important Notes
This is an estimated torque value; refer to specific fitting manufacturer specifications when available. Always use new sealing washers. Ensure the fitting is properly aligned before tightening. Overtightening can cause damage.

Fuel Pump

This section contains the torque specifications for the fuel pump mounting components within the fuel tank. Correct torque prevents leaks and maintains proper pump operation.

1

Fuel Pump Mounting Bolts

M8 x 1.25
Torque Value
30 ft-lbs (41 N·m)
Important Notes
Ensure the pump assembly is properly seated against the tank before tightening. Avoid damaging the fuel tank seal.
2

Fuel Tank Sending Unit Retaining Ring Bolts

M6 x 1.0
Torque Value
18 ft-lbs (24 N·m)
Important Notes
This is an estimated torque value, if a retention ring is used, consult service manual. If this component utilizes a plastic threaded retention ring, follow special torque and procedure specifications from the manufacturer for that retention ring.

Fuel Tank

This section specifies the torque for fuel tank-related components such as the filler neck and drain plug. Proper torque prevents leaks and ensures secure connections.

1

Fuel Filler Neck Mounting Bolts

M6 x 1.0
Torque Value
15 ft-lbs (20 N·m)
Important Notes
Ensure the filler neck is correctly aligned with the tank and body panels. Avoid over-tightening to prevent damage to the body or neck.
2

Fuel Tank Drain Plug

M14 x 1.5
Torque Value
23 ft-lbs (31 N·m)
Important Notes
This is an estimated torque value; refer to the specific service manual. Always use a new sealing washer and ensure the sealing surface is clean.

Fuel Filter

This section specifies the torque for the fuel filter mounting hardware. Proper torque ensures secure and leak-free mounting of the fuel filter.

1

Fuel Filter Mounting Bolt/Nut

M8 x 1.25
Torque Value
30 ft-lbs (41 N·m)
Important Notes
Ensure the filter is securely mounted and that the fuel lines are not stressed. Avoid over-tightening the bolt/nut, as it could damage the housing or bracket.

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 a fuel line bolt?

Overtightening fuel line bolts can crush the sealing washers or deform the fittings, leading to fuel leaks. This is a significant safety hazard, and can also cause damage to the threads. Always use a calibrated torque wrench and adhere to the specified torque value.

Q2

What happens if I undertighten a fuel line bolt?

Undertightening fuel line bolts won't provide sufficient clamping force to maintain a leak-free seal. This will also result in fuel leaks, and can potentially result in a dangerous situation. Always use a calibrated torque wrench and adhere to the specified torque value.

Q3

Should I use thread locker on fuel system bolts?

Generally, thread locker is NOT recommended for most fuel system bolts unless specifically called for in the Chrysler service manual. Using the wrong thread locker can compromise the fuel system's sealing properties and introduce contaminants. Always consult the service manual before applying any thread locker to fuel system components.

Q4

How often should I inspect fuel line connections?

It's a good practice to inspect fuel line connections during routine maintenance, such as oil changes or tire rotations. Look for signs of fuel leaks, dampness, or corrosion around the fittings. Addressing potential issues early can prevent more serious problems down the road.

Q5

Are there different torque specs for different fuel system components on the 2020+ Chrysler Voyager?

Yes, there are. Fuel rails, lines, injectors, and pump fittings can have very different torque specifications. Always consult the specific repair manual for the correct torque value for the exact bolt and location you're working on. Do not assume bolts of the same size have the same torque.

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 (1/4" Drive)

A precision tool used to apply a specific amount of torque to fasteners.

  • Measures torque in inch-pounds or Newton-meters
  • Click-type or digital readout
Learn more

Torque Wrench (3/8" Drive)

A tool used for larger torque applications.

  • Measures torque in foot-pounds or Newton-meters
  • Click-type or digital readout
Learn more

Socket Set (Metric)

A set of sockets in various metric sizes to fit the fuel system fasteners.

  • Various sizes to fit fuel system bolts and fittings
  • 6-point design
Learn more

Extension Bars

Used to access fasteners in hard-to-reach areas.

  • Different lengths
  • Various drive sizes to match your torque wrench
Learn more
Service Procedures

Fuel Rail Bolt Torque Procedure

This procedure outlines the proper steps to torque the fuel rail bolts.

  • Locate the fuel rail bolts.
  • Refer to the appropriate torque specification (typically 15-20 Nm for M6 bolts).
  • Using the correct metric socket and torque wrench, set the torque wrench to the specified value.
  • Tighten each bolt to the specified torque in a cross pattern to ensure even pressure.
  • Double-check each bolt with the torque wrench to verify correct torque.
View full procedure

Fuel Line Fitting Torque Procedure

This procedure outlines the proper steps to torque the fuel line fittings.

  • Locate the fuel line fittings.
  • Refer to the appropriate torque specification (typically 15-20 Nm for most fittings).
  • Use the correct size wrench or crowfoot adapter, and set the torque wrench to the specified value.
  • Tighten each fitting to the specified torque. Be very careful not to overtighten.
  • Double-check each fitting with the torque wrench to verify correct torque.
View full procedure

Fuel Tank Strap Bolt Torque Procedure

This procedure outlines the proper steps to torque the fuel tank strap bolts.

  • Locate the fuel tank strap bolts.
  • Refer to the appropriate torque specification (typically 30-40 Nm for M10 bolts).
  • Using the correct metric socket and torque wrench, set the torque wrench to the specified value.
  • Tighten each bolt to the specified torque. Ensure equal tension across both straps.
  • Double-check each bolt with the torque wrench to verify correct torque.
View full procedure
Technical Service Bulletins

Fuel Leak from Rail Connection

2021-05-15

Some 2020-2021 Voyager models have experienced fuel leaks due to improper fuel rail bolt torque at the factory.

2020-2021

Resolution: Inspect and retorque all fuel rail bolts to the specified torque of 18 Nm. Replace bolts if damaged or stretched.

Fuel Line Fitting O-Ring Damage

2022-08-20

Reports of fuel leaks at fuel line fittings on 2021-2022 Voyager models are often due to damaged O-rings. Overtorquing can lead to premature O-ring failure.

2021-2022

Resolution: Inspect O-rings for damage, replace if necessary. Retorque to 17 Nm. Avoid overtightening.

Fuel Tank Strap Bolt Corrosion

2023-01-10

2020-2023 Voyagers in regions with heavy road salt usage have exhibited corrosion of fuel tank strap bolts, leading to incorrect torque readings.

2020-2023

Resolution: Inspect all tank strap bolts for corrosion. Clean or replace as needed. Retorque to 35 Nm. Apply anti-seize to prevent future corrosion.

About the Author

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Alan Montanye - Automotive Technical Specialist
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Alan Montanye

Automotive Technical Specialist

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