Ram Truck 1500, 2500 & 3500 (2006-2008)

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



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. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove fuel tank filler tube cap.
  4.  
  5. Properly relieve the fuel system pressure, as outlined in this section.
  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 air resonator mounting bracket at front of throttle body (2 bolts).
  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 necessary vacuum lines at throttle body.
  18.  
  19. 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.
  20.  
  21. Disconnect electrical connectors at all throttle body sensors.
  22.  
  23. 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

  24.  
  25. Remove 4 fuel rail mounting bolts.
  26.  
  27. 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.
  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. 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.  

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. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove fuel tank filler tube cap.
  4.  
  5. Properly relieve the fuel system pressure, as outlined in this section.
  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 air resonator mounting bracket at front of throttle body (2 bolts).
  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 necessary vacuum lines at throttle body.
  18.  
  19. 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.
  20.  
  21. Disconnect electrical connectors at all throttle body sensors.
  22.  
  23. 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 No. 7 (2), injector No. 5 (3), quick connect fitting (4), injector No. 3 (5), fuel rail (6), injector No. 1 (7), connector tube (8), injector No. 2 (9), injector No. 4 (10), injector No. 6 (11), injector No. 8 (12), pressure test port cap (13)-4.7L engine

  24.  
  25. Remove 4 fuel rail mounting bolts.
  26.  
  27. 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.
  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. 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.  

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. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove fuel tank filler tube cap.
  4.  
  5. Properly relieve the fuel system pressure, as outlined in this section.
  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.

    Click image to see an enlarged view

    Fig. View of the No. 8 coil to No. 5 spark plug (1), No. 5 coil to No. 8 spark plug (2), No. 7 coil to No. 4 spark plug (3), No. 3 coil to No. 2 spark plug (4), No. 1 coil to No. 6 spark plug (5), clips (6), cable tray (7), clips (8), No. 2 coil to No. 3 spark plug (9), No. 6 coil to No. 1 spark plug (10), No. 4 coil to No. 7 spark plug (11)-5.7L engine

  14.  
  15. Remove spark plug cable tray from engine by releasing 4 retaining clips. Remove tray and cables from engine as an assembly.
  16.  
  17. Disconnect electrical connectors at all 8 ignition coils. Refer to Ignition Coil Removal/Installation in Engine Electrical.
  18.  
  19. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection.
  20.  
  21. 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.
  22.  
  23. Disconnect electrical connectors at all throttle body sensors.
  24.  
  25. Remove 4 fuel rail mounting bolts (2) and hold-down clamps (3).
  26.  
  27. 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.
  28.  
  29. Repeat this procedure (left/right) until all injectors have cleared machined holes.
  30.  
  31. Remove fuel rail (with injectors attached) from engine.
  32.  
  33. If fuel injectors are to be removed, refer to the Fuel Injector Removal & Installation procedure in this section.
  34.  

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.  

 
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