Dakota, 2001-2005

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.5L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake tube
     
    Fuel injector connectors
     
    Fuel line
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Cable routing bracket
     
    Fuel supply manifold with injectors attached
     
    Fuel injectors
     

  6.  

To install:

  1. Install or connect the following:

    Fuel injectors, using new O-rings
     
    Fuel supply manifold with injectors. Tighten the bolts to 75-125 inch lbs. (8-14 Nm).
     
    Cable routing bracket
     
    Transmission cable, if equipped
     
    Cruise control cable, if equipped
     
    Accelerator cable
     
    Fuel line
     
    Fuel injector connectors
     
    Air intake tube
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

3.7L Engine

CAUTION
The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.


CAUTION
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.

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  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 air duct at throttle body air box.
  10.  
  11. Remove air box at throttle body.
  12.  
  13. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection.
  14.  
  15. Remove necessary vacuum lines at throttle body.
  16.  
  17. Disconnect electrical connectors at all 6 fuel injectors. To remove connector, push red colored slider away from injector. While pushing slider, depress tab and remove connector 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.
  18.  
  19. Disconnect electrical connectors at throttle body sensors.
  20.  
  21. Remove 6 ignition coils.
  22.  
  23. Remove 4 fuel rail mounting bolts.
  24.  
  25. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes.
  26.  
  27. Remove fuel rail (with injectors attached) from engine.
  28.  
  29. Disconnect clip(s) that retain fuel injector(s) to fuel rail.

    Click image to see an enlarged view

    Fig. Fuel rail components-3.7L engine



    Click image to see an enlarged view

    Fig. Fuel injector connector removal

  30.  

To install:

  1. Apply a small amount of clean engine oil to each fuel injector o-ring. This will help in fuel rail installation.
  2.  
  3. Install injector(s) and injector clip(s) to fuel rail.
  4.  
  5. Apply a small amount of engine oil to each fuel injector o-ring. This will help in fuel rail installation.
  6.  
  7. Position fuel rail/fuel injector assembly to machined injector openings in cylinder head.
  8.  
  9. Guide each injector into cylinder head. Be careful not to tear injector o-rings.
  10.  
  11. Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder. Push left fuel rail down until injectors have bottomed on cylinder head shoulder.
  12.  
  13. Install 4 fuel rail mounting bolts and tighten to 27 Nm (20 ft. lbs.).
  14.  
  15. Install ignition coils.
  16.  
  17. Connect electrical connectors to throttle body.
  18.  
  19. Connect electrical connectors to MAP and IAT sensors.
  20.  
  21. Connect electrical connectors at all fuel injectors. To install connector, push connector onto injector and then push and lock red colored slider. Verify connector is locked to injector by lightly tugging on connector.
  22.  
  23. Connect vacuum lines to throttle body.
  24.  
  25. Connect fuel line latch clip and fuel line to fuel rail.
  26.  
  27. Connect wiring to rear of generator.
  28.  
  29. Install air box to throttle body.
  30.  
  31. Install air duct to air box.
  32.  
  33. Connect battery cable to battery.
  34.  
  35. Start engine and check for leaks.
  36.  

3.9L And 5.9L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake tube
     
    Throttle body
     
    A/C compressor bracket
     
    Fuel injector connectors
     
    Fuel line
     
    Fuel supply manifold with injectors
     
    Fuel injectors
     

  6.  

To install:

  1. Install or connect the following:

    Fuel injectors with new O-ring seals
     
    Fuel supply manifold with injectors. Tighten the bolts to 17 ft. lbs. (23 Nm).
     
    Fuel line
     
    Fuel injector connectors
     
    A/C compressor bracket
     
    Throttle body
     
    Air intake tube
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

4.7L Engine

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.

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  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 air duct at throttle body air box.
  10.  
  11. Remove air box at throttle body.
  12.  
  13. Remove wiring at rear of generator.
  14.  
  15. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection.
  16.  
  17. Remove vacuum lines at throttle body.
  18.  
  19. Disconnect electrical connectors at all 8 fuel injectors. To remove, push red colored slider away from injector. While pushing slider, depress tab and remove connector 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 throttle body.
  22.  
  23. Disconnect electrical connectors at MAP and IAT sensors.
  24.  
  25. Remove first three ignition coils on each bank (cylinders #1, 3, 5, 2, 4 and 6).
  26.  
  27. Remove 4 fuel rail mounting bolts.
  28.  
  29. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes.
  30.  
  31. Remove fuel rail (with injectors attached) from engine.
  32.  
  33. Disconnect clip(s) that retain fuel injector(s) to fuel rail.

    Click image to see an enlarged view

    Fig. Fuel rail components-4.7L engine

  34.  

To install:

  1. Apply a small amount of clean engine oil to each fuel injector O-ring. This will help in fuel rail installation.
  2.  
  3. Install injector(s) and injector clip(s) to fuel rail.
  4.  
  5. Apply a small amount of engine oil to each fuel injector o-ring. This will help in fuel rail installation.
  6.  
  7. Position fuel rail/fuel injector assembly to machined injector openings in cylinder head.
  8.  
  9. Guide each injector into cylinder head. Be careful not to tear injector o-rings.
  10.  
  11. Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder. Push left fuel rail down until injectors have bottomed on cylinder head shoulder.
  12.  
  13. Install 4 fuel rail mounting bolts and tighten to 27 Nm (20 ft. lbs.).
  14.  
  15. Install ignition coils.
  16.  
  17. Connect electrical connectors to throttle body.
  18.  
  19. Connect electrical connectors to MAP and IAT sensors.
  20.  
  21. Connect electrical connectors at all fuel injectors. To install connector, push connector onto injector and then push and lock red colored slider. Verify connector is locked to injector by lightly tugging on connector.
  22.  
  23. Connect vacuum lines to throttle body.
  24.  
  25. Connect fuel line latch clip and fuel line to fuel rail.
  26.  
  27. Connect wiring to rear of generator.
  28.  
  29. Install air box to throttle body.
  30.  
  31. Install air duct to air box.
  32.  
  33. Connect battery cable to battery.
  34.  
  35. Start engine and check for leaks.
  36.  

 
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