Ram B1500, B2500, B3500, 1999-2003

Fuel Rail (Supply Manifold) & Injectors

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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.  

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.


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

  1. Remove fuel tank filler tube cap.
  2.  
  3. Properly relieve the fuel system pressure, as outlined in this section.
  4.  
  5. Remove negative battery cable at battery.
  6.  
  7. Remove air duct at throttle body air box.
  8.  
  9. Remove air box at throttle body.
  10.  
  11. Remove air resonator mounting bracket at front of throttle body (2 bolts).
  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. Push the 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 all throttle body sensors.
  20.  
  21. Remove 6 ignition coils, as outlined in Engine Electrical.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail mounting bolts (1), quick-connect fitting (2), fuel rail (3), injectors (4-9) and connector tube-3.7L engine

  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. If fuel injectors are to be removed, refer to the Fuel Injector Removal & Installation procedure in this section.
  30.  

To install:

  1. If fuel injectors are to be installed, refer to the Fuel Injector Removal & Installation procedure in this section.
  2.  
  3. Clean out fuel injector machined bores in intake manifold.
  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.
  14.  
  15. Install 6 ignition coils.
  16.  
  17. Connect electrical connectors to throttle body.
  18.  
  19. Connect electrical connectors at all fuel injectors. To install connector, push connector onto injector and then push and lock red colored slider. Make sure the connector is locked to the injector by lightly tugging on connector.
  20.  
  21. Connect necessary vacuum lines to throttle body.
  22.  
  23. Install air resonator mounting bracket near front of throttle body (2 bolts).
  24.  
  25. Connect fuel line latch clip and fuel line to fuel rail.
  26.  
  27. Install air box to throttle body.
  28.  
  29. Install air duct to air box.
  30.  
  31. Connect battery cable to battery.
  32.  
  33. Start engine and check for leaks.
  34.  

3.9L, 5.2L, 5.9L Engines

WARNING
The fuel system is under a constant pressure (even with engine turned off). Before servicing fuel rail assembly, fuel system pressure must be released.


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

  1. Disconnect the negative battery cable.
  2.  
  3. Remove air cleaner.
  4.  
  5. Perform fuel pressure release procedure, as outlined in this section.
  6.  
  7. Remove throttle body from intake manifold. Refer to Throttle Body removal in this section.
  8.  
  9. If equipped with A/C, remove the A-shaped A/C compressor-to-intake manifold support bracket (three bolts).
  10.  
  11. Detach the electrical connectors at all fuel injectors, as follows:
    1. Push red colored slider away from injector (1).
    2.  
    3. 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.
    4.  
    5. To detach the connector, push the red colored slider away from injector (1).

      Click image to see an enlarged view

      Fig. While pushing slider, depress tab (2) and remove connector (3) from injector

    6.  

  12.  
  13. For 3.9L engines, disconnect electrical connector at intake manifold air temperature sensor. Do not remove sensor.
  14.  
  15. Disconnect fuel tube (line) at side of fuel rail. Refer to Quick-Connect Fittings for procedures,
  16.  
  17. Remove the remaining fuel rail mounting bolts.
  18.  
  19. Gently rock and pull the left fuel rail until the fuel injectors just start to clear the intake manifold. Gently rock and pull the right fuel rail until the fuel injectors just start to clear the intake manifold. Repeat this procedure (left/right) until all fuel injectors have cleared the intake manifold.
  20.  
  21. Remove fuel rail (with injectors attached) from engine.
  22.  
  23. Remove the clip(s) retaining the injector(s) to fuel rail.
  24.  

To install:

  1. Apply a small amount of 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. Position the fuel rail/fuel injector assembly to the injector openings on the intake manifold.
  6.  
  7. Guide each injector into the intake manifold. Be careful not to tear the injector O-ring.
  8.  
  9. Push the right fuel rail down until fuel injectors have bottomed on injector shoulder. Push the left fuel rail down until fuel injectors have bottomed on injector shoulder.
  10.  
  11. Install fuel rail mounting bolts.
  12.  
  13. Connect electrical connector to intake manifold air temperature sensor.
  14.  
  15. Connect electrical connectors at all fuel injectors, as follows:
    1. Push connector onto injector (1) and then push and lock red colored slider (2).
    2.  
    3. Verify connector is locked to injector by lightly tugging on connector.
    4.  

  16.  
  17. Install the A/C support bracket (if equipped).
  18.  
  19. Install throttle body to intake manifold, as outlined in this section.
  20.  
  21. Install fuel tube (line) at side of fuel rail.
  22.  
  23. Install air cleaner.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Start engine and check for leaks.
  28.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  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.  

  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



Click image to see an enlarged view

Fig. Remove the latch to disconnect the fuel line



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

Fig. Remove the fuel rail retaining bolts



Click image to see an enlarged view

Fig. Unplug the fuel injector connectors



Click image to see an enlarged view

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

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 tubes. Due to design of tubes, it does not use any clamps. Never attempt to install a clamping device of any kind to tubes. When removing fuel rail assembly for any reason, be careful not to bend or kink tubes.

  1. Remove fuel tank filler tube cap.
  2.  
  3. Properly relieve the fuel system pressure, as outlined in this section.
  4.  
  5. Remove negative battery cable at battery.
  6.  
  7. Remove air duct at throttle body air box.
  8.  
  9. Remove air box at throttle body.
  10.  
  11. Remove air resonator mounting bracket at front of throttle body (2 bolts).
  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 from all 8 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 all throttle body sensors.
  20.  
  21. Remove 8 ignition coils, as outlined in Engine Electrical.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail mounting bolts (1), injector #7 (2), injector #5 (3), quick connect fitting (4), injector #3 (5), fuel rail (6), injector #1 (7), connector tube (8), injector #2 (9), injector #4 (10), injector #6 (11), injector #8 (12), pressure test port cap (13)-4.7L engine

  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. If fuel injectors are to be removed, refer to the Fuel Injector Removal & Installation procedure in this section.
  30.  

To install:

  1. If fuel injectors are to be installed, refer to the Fuel Injector Removal & Installation procedure in this section.
  2.  
  3. Clean out fuel injector machined bores in intake manifold.
  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.
  14.  
  15. Install 8 ignition coils.
  16.  
  17. Connect electrical connectors to throttle body.
  18.  
  19. Connect electrical connectors at all fuel injectors. To install connector, push connector onto injector and then push and lock red colored slider. Make sure the connector is locked to the injector by lightly tugging on connector.
  20.  
  21. Connect necessary vacuum lines to throttle body.
  22.  
  23. Install air resonator mounting bracket near front of throttle body (2 bolts).
  24.  
  25. Connect fuel line latch clip and fuel line to fuel rail.
  26.  
  27. Install air box to throttle body.
  28.  
  29. Install air duct to air box.
  30.  
  31. Connect battery cable to battery.
  32.  
  33. Start engine and check for leaks.
  34.  

  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.  

5.7L 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. Remove fuel tank filler tube cap.
  2.  
  3. Properly relieve the fuel system pressure, as outlined in this section.
  4.  
  5. Remove negative battery cable at battery.
  6.  
  7. Remove flex tube (air cleaner housing to engine).
  8.  
  9. Remove air resonator box at throttle body.
  10.  
  11. 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.

    Click image to see an enlarged view

    Fig. View of the #8 coil to #5 spark plug (1), #5 coil to #8 spark plug (2), #7 coil to #4 spark plug (3), #3 coil to #2 spark plug (4), #1 coil to #6 spark plug (5), clips (6), cable tray (7), clips (8), #2 coil to #3 spark plug (9), #6 coil to #1 spark plug (10), #4 coil to #7 spark plug (11)-5.7L engine

  12.  
  13. Remove spark plug cable tray from engine by releasing 4 retaining clips. Remove tray and cables from engine as an assembly.
  14.  
  15. Disconnect electrical connectors at all 8 ignition coils. Refer to Ignition Coil Removal/Installation in Engine Electrical.
  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. 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.
  20.  
  21. Disconnect electrical connectors at all throttle body sensors.
  22.  
  23. Remove 4 fuel rail mounting bolts (2) and hold-down clamps (3).
  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.
  26.  
  27. Repeat this procedure (left/right) until all injectors have cleared machined holes.
  28.  
  29. Remove fuel rail (with injectors attached) from engine.
  30.  
  31. If fuel injectors are to be removed, refer to the Fuel Injector Removal & Installation procedure in this section.
  32.  

To install:

  1. If fuel injectors are to be installed, refer to the Fuel Injector Removal & Installation procedure in this section.
  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.
  12.  
  13. Position spark plug cable tray 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. Install electrical connectors to all 8 ignition coils.
  20.  
  21. Connect electrical connector to throttle body.
  22.  
  23. Attach the electrical connectors at all fuel injectors. To install connector, push connector onto injector and then push and lock red colored slider. Make sure the connector is locked to the injector by lightly tugging on connector.
  24.  
  25. Connect the fuel line latch clip and fuel line to fuel rail.
  26.  
  27. Install air resonator to throttle body (2 bolts).
  28.  
  29. Install flexible air duct to air box.
  30.  
  31. Connect battery cable to battery.
  32.  
  33. Start engine and check for leaks.
  34.  

8.0L Engine

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

  1. Disconnect the negative battery cable.
  2.  
  3. Remove air cleaner housing and tube.
  4.  
  5. Perform fuel pressure release procedure. Refer to Fuel Delivery System section of this group.
  6.  
  7. Disconnect throttle body linkage and remove throttle body from intake manifold. Refer to Throttle Body removal in this group.
  8.  
  9. Remove ignition coil pack and bracket assembly at intake manifold and right engine valve cover (four bolts).
  10.  
  11. Remove upper half of intake manifold. Refer to Engines for procedures.
  12.  
  13. Detach the electrical connectors at all fuel injectors, as follows:
    1. Push red colored slider away from injector (1).
    2.  
    3. 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.
    4.  
    5. To detach the connector, push the red colored slider away from injector (1).

      Click image to see an enlarged view

      Fig. While pushing slider, depress tab (2) and remove connector (3) from injector

    6.  

  14.  
  15. Disconnect fuel line quick-connect fitting at left-rear end of fuel rail. A special 3 / 8 inch fuel line disconnection tool will be necessary.
  16.  
  17. Remove the six fuel rail mounting bolts from the lower half of intake manifold.
  18.  
  19. Gently rock and pull the left fuel rail until the fuel injectors just start to clear the intake manifold.
  20.  
  21. Gently rock and pull the right fuel rail until the fuel injectors just start to clear the intake manifold. Repeat this procedure (left/right) until all fuel injectors have cleared the intake manifold.
  22.  
  23. Remove fuel rail (with injectors attached) from engine.
  24.  
  25. Remove the clip(s) retaining the injector(s) to fuel rail.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail mounting-V-10 engine

  26.  

To install:

  1. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation. Install injector(s) and injector clip(s) to fuel rail.
    NOTE
    The fuel injector electrical connectors on all 10 injectors should be facing to the right (passenger) side of the vehicle.

  2.  
  3. Position the fuel rail/fuel injector assembly to the injector openings on the intake manifold.
  4.  
  5. Guide each injector into the intake manifold. Be careful not to tear the injector O-ring.
  6.  
  7. Push the right fuel rail down until fuel injectors have bottomed on injector shoulder. Push the left fuel rail down until fuel injectors have bottomed on injector shoulder.
  8.  
  9. Install the six fuel rail mounting bolts into the lower half of intake manifold. Tighten bolts to 11 ft. lbs. (15 Nm).
  10.  
  11. Connect electrical connectors at all fuel injectors. To install connector, push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector. The injector wiring harness is numerically tagged.
  12.  
  13. Install upper half of intake manifold.
  14.  
  15. Connect main fuel line at fuel rail.
  16.  
  17. Install ignition coil pack and bracket assembly at intake manifold and right engine valve cover (four bolts).
  18.  
  19. Install throttle body to intake manifold, as outlined in this section.
  20.  
  21. Install throttle body linkage to throttle body.
  22.  
  23. Install air cleaner tube and housing.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Start engine and check for leaks.
  28.  

  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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