Chrysler Full-Size Trucks 1989-1996 Repair Guide

Fuel Rail

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REMOVAL & INSTALLATION



2.5L Engine
  1. Remove the fuel tank filler cap
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Perform the fuel system pressure release procedure.
  6.  
  7. Remove the air cleaner housing.
  8.  
  9. Disconnect the throttle cable.
  10.  
  11. Remove the fuel injector harness connectors. These may be numerically tagged from the factory, but if they are not, tag them accordingly to facilitate installation.
  12.  
  13. Disconnect the fuel supply line from the fuel rail. Remove the fuel rail mounting bolts
  14.  
  15. Remove the fuel rail by gently rocking until the four injectors are out of the manifold.
  16.  

To install:
  1. Apply a small amount of engine oil to each fuel injector O-ring.
  2.  
  3. With the injectors installed to the rail, position the injector tips into their respective bores in the intake manifold.
  4.  
  5. Being careful not to tear the O-rings, seat the injectors into the bores.
  6.  
  7. Tighten the fuel rail mounting bolts to 20 ft. lbs. (27 Nm).
  8.  
  9. Connect the injector harness in the correct order (as tagged).
  10.  
  11. Connect the fuel line to the rail.
  12.  
  13. Install the protective cap to the test port fitting, if still removed.
  14.  
  15. Install the fuel tank cap.
  16.  
  17. Connect the throttle cable.
  18.  
  19. Install the air cleaner housing.
  20.  
  21. Start the engine and check for leaks.
  22.  

V6 and V8 Engines

See Figures 1, 2, 3 and 4

WARNING

The fuel rail connecting hose is not meant to come off. Do not remove it or attempt to clamp it. The left and right fuel rails must be removed and installed as an assembly.



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Fig. Fig. 1: A common fuel rail-V6 and V8 engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner tube and housing.
  4.  



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Fig. Fig. 2: Remove the A/C compressor support bracket to access the fuel rail-V6 and V8 engines

  1. Release the fuel system pressure.
  2.  
  3. Remove the throttle body from the intake manifold.
  4.  



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Fig. Fig. 3: A common design of injector connectors-V6 and V8 engines

  1. If equipped with air conditioning, remove the A/C compressor-to-intake manifold support bracket.
  2.  



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Fig. Fig. 4: Remove the fuel line at the fuel rail-V6 and V8 engines

  1. Unplug the electrical connectors at all of the injectors. The factory harness should already be numerically tagged (INJ 1, INJ 2, etc.) to ease reconnection.
  2.  
  3. On the V6 engine, unplug the connector at the intake manifold air temperature sensor. Do not remove the sensor.
  4.  
  5. Remove the evaporative emissions (EVAP) purge solenoid/bracket assembly.
  6.  
  7. Disconnect the main fuel line at the side of the fuel rail.
  8.  
  9. Remove the remaining fuel rail mounting bolts.
  10.  
  11. Gently rock and pull the LEFT fuel rail until the injectors just start to clear the intake manifold. Then do the same for the right. Alternate each side progressively until all left and right injectors have cleared the intake manifold.
  12.  
  13. With the injectors attached, remove the fuel rail.
  14.  

To install:
  1. Apply a small amount of engine oil to each fuel injector O-ring.
  2.  
  3. With the injectors attached, position the fuel rail/fuel injector assembly to the injector openings on the intake manifold.
  4.  
  5. Guide each injector into the manifold. Be careful not to tear any O-rings.
  6.  
  7. Push the RIGHT fuel rail down until the injectors bottom on the injector shoulder. Then do the same for the left side injectors.
  8.  
  9. Install the fuel rail mounting bolts.
  10.  
  11. Connect all removed wires. Install the A/C bracket, if applicable.
  12.  
  13. Install the throttle body.
  14.  
  15. Install the main fuel line at the fuel rail.
  16.  
  17. Install the air cleaner tube and housing.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Start the engine and check for leaks. If any are detected, shut the engine off immediately and correct.
  22.  

V10 Engine

See Figure 5

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner tube and housing.
  4.  
  5. Release the fuel system pressure.
  6.  



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the fuel rail mounting-V10 engine

  1. Remove the throttle body from the intake manifold.
  2.  
  3. Remove the ignition coil pack and bracket assembly at the intake manifold and right cylinder head (valve) cover.
  4.  
  5. Remove the upper half of the intake manifold.
  6.  
  7. Unplug the electrical connectors at all of the injectors. The factory harness should already be numerically tagged (INJ 1, INJ 2, etc.) to facilitate reconnection.
  8.  
  9. Disconnect the main fuel line at the rear of the engine.
  10.  
  11. Remove the six fuel rail mounting bolts from the lower half of the intake manifold.
  12.  
  13. Gently rock and pull the LEFT fuel rail until the injectors just start to clear the intake manifold. Then do the same for the right. Alternate each side progressively until all left and right injectors have cleared the intake manifold.
  14.  
  15. With the injectors attached, remove the fuel rail.
  16.  

To install:
  1. Apply a small amount of engine oil to each fuel injector O-ring.
  2.  
  3. With the injectors attached, position the fuel rail/fuel injector assembly to the injector openings on the intake manifold.
  4.  
  5. Guide each injector into the manifold. Be careful not to tear any O-rings.
  6.  
  7. Push the RIGHT fuel rail down until the injectors bottom on the injector shoulder. Then do the same for the left side injectors.
  8.  

The fuel injector electrical connectors on all 10 injectors should be facing to the right (passenger) side of the vehicle.

  1. Install the six fuel rail mounting bolts. Tighten them to 136 inch lbs. (15 Nm).
  2.  
  3. Connect all removed wires.
  4.  
  5. Install the upper half of the intake manifold.
  6.  
  7. Install the ignition coil pack.
  8.  
  9. Install the throttle body and the throttle linkage.
  10.  
  11. Install the main fuel line at the fuel rail.
  12.  
  13. Install the air cleaner tube and housing.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the engine and check for leaks. If any are detected, shut the engine off immediately and correct.
  18.  

 
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