Fuel System - Revised Fuel Pipe Connection Procedure

File in Section: 06 - Engine/Propulsion System

Bulletin No.: 03-06-04-022

Issue Date: March, 2003

Subject:
Revised Fuel Inlet Pipe to Rail Connection Procedure and Torque Specification

Models Affected:
2003 Saturn ION Vehicles

Attention:
General Manager, Fixed Operations Manager, Technician

Purpose

The purpose of this bulletin is to provide an updated service procedure and torque specification for the fuel inlet pipe to fuel rail connection. Please insert copies of this bulletin into appropriate sections of all printed service manuals.

Service Procedure

REMOVAL

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief procedure in the 2003 Saturn ION Service Manual, Vol. 1, Engine Controls.

2. Disconnect the engine fuel feed pipe from the chassis fuel flex hose. Refer to Quick Connect Fitting(s) Service (Metal Collar) in the 2003 Saturn ION Service Manual, Vol. 1, Engine Controls.





3. Use a back up wrench on the fuel rail and disconnect the fuel feed pipe.





4. Remove the fuel feed pipe fastener located on the engine.

5. Remove the engine fuel feed pipe.

INSTALLATION





Important:
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joints unless specified. These coatings affect fastener torque and joint clamping force and may damage fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.





1. Install the fuel feed pipe to the fuel rail.

Tighten

Using a backup wrench on the fuel rail, tighten the fuel feed pipe to 10 N.m (89 lb-in).

2. Install the engine fuel feed pipe fastener located on the engine.

Tighten

Tighten the fuel feed pipe fastener to 10 N.m (89 lb-in).

3. Connect the engine fuel feed pipe to the chassis fuel flex hose. Refer to Quick Connect Fitting(s) Service (Metal Collar) in the 2003 Saturn ION Service Manual, Vol.1, Engine Controls.

4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect procedure in the 2003 Saturn ION Service Manual, Vol.1, Engine Electrical.

5. Inspect for leaks using the following procedure:

5.1. With the engine OFF, turn ON the ignition for 2 seconds.

5.2. Inspect for fuel leaks.

5.3. Turn the ignition OFF.

5.4. With the engine OFF, turn ON the ignition for 2 seconds.

5.5. Inspect for fuel leaks.

5.6. Turn the ignition OFF.





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