300, Magnum, 2005

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.7L & 3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
    CAUTION
    The fuel system is under constant pressure even with engine off. Before servicing fuel injector(s), fuel system pressure must be released.

  2.  
  3. Release fuel system pressure.
  4.  
  5. Disconnect negative cable to battery.
  6.  
  7. Remove intake manifold plenum.
  8.  
  9. Lift Plenum up off of engine. Cover intake manifold to prevent foreign material from entering engine.
  10.  
  11. Disconnect fuel supply tube quick connect fittings at the rear of intake manifold.
    NOTE
    If the injector connectors are not tagged with their cylinder number, tag them to identify the correct cylinder.



    Click image to see an enlarged view

    Fig. Quick disconnect fittings

  12.  
  13. Disconnect electrical connectors at fuel injectors. Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
  14.  
  15. Remove fuel rail mounting bolts.
  16.  
  17. Lift fuel rail straight up off of the cylinder head.
  18.  
  19. Remove retaining clips from fuel injectors at fuel rail.
  20.  
  21. Remove fuel injectors.
  22.  
  23. Repeat for remaining injectors.
  24.  
  25. Check injector O-ring for damage. If O-ring is damaged, it must be replaced. Replace the injector clip if it is damaged.
  26.  

To install:

  1. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil.
  2.  
  3. Install retaining clips on fuel injectors.
  4.  
  5. Push injectors into fuel injector rail until clips are in the correct position.
  6.  
  7. Position fuel rail over cylinder head, and push rail into place. Tighten fuel rail mounting bolts to 100 inch lbs. (11 Nm) torque.
  8.  
  9. Connect fuel supply tube quick connect fittings at the rear of intake manifold.
  10.  
  11. Connect electrical connectors to fuel injectors.
  12.  
  13. Install intake manifold plenum.
  14.  
  15. Connect negative cable to battery.
  16.  
  17. Use a scan tool to pressurize the fuel system. Check for leaks.
  18.  

5.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
    CAUTION
    The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.


    WARNING
    The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tube. Due to design of tube, it does not use any clamps. Never attempt to install a clamping device of any kind to tube. When removing fuel rail assembly for any reason, be careful not to bend or kink tube.

  2.  
  3. Remove fuel tank filler tube cap.
  4.  
  5. Perform fuel system pressure release procedure.
  6.  
  7. Remove negative battery cable at battery.
  8.  
  9. Remove flex tube (air cleaner housing to engine).
  10.  
  11. Remove air resonator box at throttle body.
  12.  
  13. Disconnect all spark plug cables from all spark plugs and ignition coils. Do not remove cables from cable routing tray. Note original cable positions while removing.
  14.  
  15. Remove spark plug cable tray from engine by releasing 4 retaining clips. Remove tray and cables from engine as an assembly.
    NOTE
    Before removing or disconnecting any spark plug cables, note their original position. Remove cables one-at-a-time. To prevent ignition crossfire, spark plug cables must be placed in cable tray (routing loom) into their original position.



    Click image to see an enlarged view

    Fig. Ignition coil (1), bolt (2), spark plug boot (3)-5.7L engine

  16.  

An individual ignition coil is used at each cylinder. The coil mounts to the top of the valve cover with two bolts. The bottom of the coil is equipped with a rubber boot to seal the spark plug to the coil. Inside each rubber boot is a spring. The spring is used for a mechanical contact between the coil and the top of the spark plug.

  1. Depending on which coil is being removed, the throttle body air intake tube or intake box may need to be removed to gain access to coil.
  2.  
  3. Unlock electrical connector by moving slide lock first. Press on release lock while pulling electrical connector from coil.
  4.  
  5. Disconnect secondary high-voltage cable from coil with a twisting action.
  6.  
  7. Clean area at base of coil with compressed air before removal.
  8.  
  9. Remove two mounting bolts (note that mounting bolts are retained to coil).
  10.  
  11. Carefully pull up coil from cylinder head opening with a slight twisting action.
  12.  
  13. Remove coil from vehicle.
  14.  
  15. Before installing spark plug cables to either the spark plugs or coils, or before installing a coil to a spark plug, apply dielectric grease to inside of boots.
  16.  
  17. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection.
  18.  
  19. Disconnect electrical connectors at all 8 fuel injectors. Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
  20.  
  21. Disconnect electrical connectors at all throttle body sensors.

    Click image to see an enlarged view

    Fig. Fuel rail (2) with injectors (4) attached by clips (3)-5.7L engine

  22.  
  23. Remove four fuel rail mounting bolts and hold-down clamps.
  24.  
  25. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in intake manifold. Gently rock and pull right side of rail until injectors just start to clear intake manifold head holes. Repeat this procedure (left/right) until all injectors have cleared machined holes.
  26.  
  27. Remove fuel rail (with injectors attached) from engine.
  28.  
  29. Remove clip(s) retaining injector(s) to fuel rail.
  30.  
  31. Remove injector(s) from fuel rail.
  32.  

To install:

  1. Clean out fuel injector machined bores in intake manifold.
  2.  
  3. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation.
  4.  
  5. Position fuel rail/fuel injector assembly to machined injector openings in intake manifold.
  6.  
  7. Guide each injector into intake manifold. Be careful not to tear injector O-rings.
  8.  
  9. Push right side of fuel rail down until fuel injectors have bottomed on shoulders. Push left fuel rail down until injectors have bottomed on shoulders.
  10.  
  11. Install 4 fuel rail hold-down clamps and 4 mounting bolts and. Torque to 100 inch lbs. (11 Nm).
  12.  
  13. Position spark plug cable tray (7) and cable assembly to intake manifold. Snap 4 cable tray retaining clips into intake manifold.
  14.  
  15. Install all cables to spark plugs and ignition coils.
  16.  
  17. Connect electrical connector to throttle body.
  18.  
  19. Using compressed air, blow out any dirt or contaminants from around top of spark plug.
  20.  
  21. Before installing spark plug cables to either the spark plugs or coils, or before installing a coil to a spark plug, apply dielectric grease to inside of boots.
  22.  
  23. Position ignition coil into cylinder head opening and push boot onto spark plug. Twist coil into position.
  24.  
  25. Install two coil mounting bolts and tighten to 105 inch lbs. (12 Nm).
  26.  
  27. Connect electrical connector to coil and lock connector.
  28.  
  29. Install spark plug cables to coils. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position. See the Specifications section of this chapter, following the Tune-up Chart, for correct wiring.
  30.  
  31. If necessary, install throttle body air tube.
  32.  
  33. Connect electrical connector to throttle body.
  34.  
  35. Connect electrical connectors at all fuel injectors. Push connector onto injector and then push and lock red colored slider. Verify connector is locked to injector by lightly tugging on connector.
  36.  
  37. Connect fuel line latch clip and fuel line to fuel rail.
  38.  
  39. Install air resonator to throttle body (2 bolts).
  40.  
  41. Install flexible air duct to air box.
  42.  
  43. Connect battery cable to battery.
  44.  
  45. Start engine and check for leaks.
  46.  

 
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