Chrysler Full-Size Trucks 1997-2000 Repair Guide

Fuel Rail Assembly

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REMOVAL & INSTALLATION




CAUTION
Whenever servicing the fuel system, always work in a well ventilated area. Do NOT allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Fuel system work is made more hazardous by a hot engine. Work on a cold engine whenever possible.


WARNING
On "V" engines, note that the left and right fuel rails are joined by a connecting hose. Do NOT attempt to separate the two rails. The hose does NOT require clamps. NEVER install any kind of clamp on this hose. Be careful NOT to bend or kink the hose. The hose is NOT serviceable. If there is damage to the hose or either rail, the entire assembly must be replaced.

2.5L Engine
  1. Remove the gas cap.
  2.  
  3. Depressurize the fuel system.
  4.  
  5. Disconnect the battery negative cable.
  6.  
  7. Remove the air tube at the top of the throttle body. Some vehicles may require removal of the air cleaner ducts at the throttle body.
  8.  
  9. Disconnect the wiring at each injector. They should be tagged by the factory, but check first and tag the leads for cylinder before disconnecting if necessary.
  10.  
  11. Disconnect the fuel supply line latch clip and fuel line at the rail.
  12.  
  13. Disconnect the throttle cable at the throttle body. Disconnect any other cables fitted, such as cruise control, transmission, etc.
  14.  
  15. Remove the cable routing bracket.
  16.  
  17. Remove the nut securing the crankshaft position sensor harness to the fuel rail-mounting stud. Remove the clamp and harness from the fuel rail-mounting stud.
  18.  
  19. Clean any dirt or debris from around the injectors on the intake manifold.
  20.  
  21. Remove the rail mounting nuts and bolts.
  22.  
  23. Gently remove the fuel rail by rocking until all the injectors are clear of the manifold.
  24.  



Click image to see an enlarged view

Fig. Fuel rail assembly-2.5L: fuel damper (1), injector (2), tag (3), rail (4), rail mounting bolts/nuts (5)

To install:

  1. Clean the injector bores.
  2.  
  3. Oil the injector O-rings.
  4.  
  5. Position the injectors over their bores and install the rail assembly.
  6.  
  7. Tighten rail mounting bolts to 100 inch lbs. (11 Nm).
  8.  
  9. The remainder of the procedure is the reverse of removal. Check for leaks before driving the vehicle.
  10.  

4.7L Engine
  1. Remove the gas cap.
  2.  
  3. Depressurize the fuel system.
  4.  
  5. Disconnect the battery negative cable.
  6.  
  7. Remove the air cleaner duct at the throttle body air box, then the air box itself.
  8.  
  9. Disconnect the wiring at the alternator.
  10.  
  11. Disconnect the wiring at each injector. They should be tagged by the factory, but check first and tag the leads for cylinder before disconnecting if necessary. To disconnect, push the red colored slider away from the injector while depressing the tab.
  12.  
  13. Disconnect the fuel supply line latch clip and fuel line at the rail.
  14.  
  15. Disconnect the throttle body vacuum lines.
  16.  
  17. Disconnect electrical connectors at the throttle body. Disconnect the TPS, MAP and IAT sensors.
  18.  
  19. Remove the first three ignition coils on each bank of cylinders.
  20.  
  21. Clean any dirt or debris from around the injectors on the intake manifold.
  22.  
  23. Remove the rail mounting bolts.
  24.  
  25. Gently remove the fuel rail by rocking until all the injectors are clear of the manifold. Free one side at a time, then remove the assembly.
  26.  



Click image to see an enlarged view

Fig. Disconnecting injector wiring-late models

To install:

  1. Clean the injector bores.
  2.  
  3. Oil the injector O-rings.
  4.  
  5. Position the injectors over their bores and install the rail assembly. Install one side at a time.
  6.  
  7. Tighten rail mounting bolts to 20 ft. lbs. (27 Nm).
  8.  
  9. The remainder of the procedure is the reverse of removal. Check for leaks before driving the vehicle.
  10.  

3.9L, 5.2L, 5.9L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove the throttle body assembly.
  8.  
  9. If equipped with A/C, remove the A-shaped A/C compressor-to-intake manifold bracket.
  10.  
  11. Disconnect the fuel line at the fuel rail.
  12.  
  13. Disconnect and label all the injector wiring harness connectors. They should be tagged by the factory, but check first and tag the leads for cylinder before disconnecting if necessary. To disconnect late models, push the red colored slider away from the injector while depressing the tab.
  14.  
  15. On the 3.9L, disconnect the IAT sensor.
  16.  
  17. Remove the fuel rail attaching bolts.
  18.  
  19. Gently rock and pull the driver's side fuel rail until the injectors unseat themselves from the intake manifold. Repeat this procedure for the passenger's side and then remove the fuel rail from the engine with the injectors attached.
  20.  

To install:

  1. Apply a small amount of engine oil to each injector O-ring.
  2.  
  3. Install the fuel rail onto intake aligning injectors into the openings. Guide the injectors into intake, taking care NOT to tear O-rings.
  4.  
  5. Push down passenger's side of fuel rail until the injectors have bottomed on injector shoulder. Repeat for the driver's side.
  6.  
  7. Install the fuel rail mounting bolts.
  8.  
  9. Plug in all the injector wiring harness connectors.
  10.  
  11. Connect the fuel line onto fuel rail.
  12.  
  13. Install the EVAP canister purge solenoid and bracket onto intake manifold.
  14.  
  15. On the 3.9L engine, plug in the IAT sensor connector.
  16.  
  17. On vehicles with A/C, install the A/C compressor support bracket.
  18.  
  19. Install the throttle body assembly.
  20.  
  21. Install the air cleaner assembly.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Start the engine and check for leaks.
  26.  



Click image to see an enlarged view

Fig. To disconnect the fuel feed line connector, compress the clip fingers and push



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Fig. Remove the latch to disconnect the fuel line



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Fig. Use a rag to catch any fuel residue in the line



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Fig. The A/C compressor support bracket must be removed to access the fuel rail on some vehicles



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Fig. Location of the fuel rail mounting bolts on 3.9L, 5.2L and 5.9L engines



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Fig. Remove the fuel rail retaining bolts



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Fig. Unplug the fuel injector connectors



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Fig. Pull straight up on the injector rail to unseat it from the intake manifold

8.0L Engine
  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. Exploded view of the fuel rail mounting-V-10 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 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. If not, tag as needed.
  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.  


NOTE
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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