Dodge Ram: Fuel Rail and Injector Replacing?

Complete Details for All model Dodge Ram Fuel rail and Fuel injector replacing procedure.

The procedure with all details and diagrams.

Covers all U.S. and Canadian models of the Dodge Ram 1500, 2500, 3500, 2WD & 4WD From year 2001 to 2005.

Fuel Rail (Supply Manifold) & Injectors
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. Remove fuel tank filler tube cap.
2. Properly relieve the fuel system pressure, as outlined in this section.
3. Remove negative battery cable at battery.
4. Remove air duct at throttle body air box.
5. Remove air box at throttle body.
6. Remove air resonator mounting bracket at front of throttle body (2 bolts).
7. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection.
8. Remove necessary vacuum lines at throttle body.
9. 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.
10. Disconnect electrical connectors at all throttle body sensors.
11. Remove 6 ignition coils, as outlined in Engine Electrical. 
    
    
    
    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
    
    
12. Remove 4 fuel rail mounting bolts.
13. 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.
14. Remove fuel rail (with injectors attached) from engine.
15. If fuel injectors are to be removed, refer to the Fuel Injector Removal & Installation procedure in this section.

To install:

1. If fuel injectors are to be installed, refer to the Fuel Injector Removal & Installation procedure in this section.
2. Clean out fuel injector machined bores in intake manifold.
3. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation.
4. Position fuel rail/fuel injector assembly to machined injector openings in cylinder head.
5. Guide each injector into cylinder head. Be careful not to tear injector O-rings.
6. 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.
7. Install 4 fuel rail mounting bolts and tighten.
8. Install 6 ignition coils.
9. Connect electrical connectors to throttle body.
10. 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.
11. Connect necessary vacuum lines to throttle body.
12. Install air resonator mounting bracket near front of throttle body (2 bolts).
13. Connect fuel line latch clip and fuel line to fuel rail.
14. Install air box to throttle body.
15. Install air duct to air box.
16. Connect battery cable to battery.
17. Start engine and check for leaks.

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. Remove air cleaner.
3. Perform fuel pressure release procedure, as outlined in this section.
4. Remove throttle body from intake manifold. Refer to Throttle Body removal in this section.
5. If equipped with A/C, remove the A-shaped A/C compressor-to-intake manifold support bracket (three bolts).
6. Detach the electrical connectors at all fuel injectors, as follows:
   1. Push red colored slider away from injector (1).
   2. 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.
   3. To detach the connector, push the red colored slider away from injector (1). 
      
      
      
      Fig. While pushing slider, depress tab (2) and remove connector (3) from injector
      
      
7. For 3.9L engines, disconnect electrical connector at intake manifold air temperature sensor. Do not remove sensor.
8. Disconnect fuel tube (line) at side of fuel rail. Refer to Quick-Connect Fittings for procedures,
9. Remove the remaining fuel rail mounting bolts.
10. 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.
11. Remove fuel rail (with injectors attached) from engine.
12. Remove the clip(s) retaining the injector(s) to fuel rail.

To install:

1. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation.
2. Install injector(s) and injector clip(s) to fuel rail.
3. Position the fuel rail/fuel injector assembly to the injector openings on the intake manifold.
4. Guide each injector into the intake manifold. Be careful not to tear the injector O-ring.
5. 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.
6. Install fuel rail mounting bolts.
7. Connect electrical connector to intake manifold air temperature sensor.
8. 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. Verify connector is locked to injector by lightly tugging on connector.
9. Install the A/C support bracket (if equipped).
10. Install throttle body to intake manifold, as outlined in this section.
11. Install fuel tube (line) at side of fuel rail.
12. Install air cleaner.
13. Connect the negative battery cable.
14. Start engine and check for leaks.

1. Before servicing the vehicle, refer to the Precautions Section.
2. Relieve fuel system pressure.
3. 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

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. Start the engine and check for leaks.

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. Properly relieve the fuel system pressure, as outlined in this section.
3. Remove negative battery cable at battery.
4. Remove air duct at throttle body air box.
5. Remove air box at throttle body.
6. Remove air resonator mounting bracket at front of throttle body (2 bolts).
7. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection.
8. Remove necessary vacuum lines at throttle body.
9. 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.
10. Disconnect electrical connectors at all throttle body sensors.
11. Remove 8 ignition coils, as outlined in Engine Electrical. 
    
    
    
    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
    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
12. Remove 4 fuel rail mounting bolts.
13. 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.
14. Remove fuel rail (with injectors attached) from engine.
15. If fuel injectors are to be removed, refer to the Fuel Injector Removal & Installation procedure in this section.

To install:

1. If fuel injectors are to be installed, refer to the Fuel Injector Removal & Installation procedure in this section.
2. Clean out fuel injector machined bores in intake manifold.
3. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation.
4. Position fuel rail/fuel injector assembly to machined injector openings in cylinder head.
5. Guide each injector into cylinder head. Be careful not to tear injector O-rings.
6. 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.
7. Install 4 fuel rail mounting bolts and tighten.
8. Install 8 ignition coils.
9. Connect electrical connectors to throttle body.
10. 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.
11. Connect necessary vacuum lines to throttle body.
12. Install air resonator mounting bracket near front of throttle body (2 bolts).
13. Connect fuel line latch clip and fuel line to fuel rail.
14. Install air box to throttle body.
15. Install air duct to air box.
16. Connect battery cable to battery.
17. Start engine and check for leaks.

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. Properly relieve the fuel system pressure, as outlined in this section.
3. Remove negative battery cable at battery.
4. Remove flex tube (air cleaner housing to engine).
5. Remove air resonator box at throttle body.
6. 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. 
   
   
   
   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
   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
7. Remove spark plug cable tray from engine by releasing 4 retaining clips. Remove tray and cables from engine as an assembly.
8. Disconnect electrical connectors at all 8 ignition coils. Refer to Ignition Coil Removal/Installation in Engine Electrical.
9. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection.
10. 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.
11. Disconnect electrical connectors at all throttle body sensors.
12. Remove 4 fuel rail mounting bolts (2) and hold-down clamps (3).
13. 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.
14. Repeat this procedure (left/right) until all injectors have cleared machined holes.
15. Remove fuel rail (with injectors attached) from engine.
16. If fuel injectors are to be removed, refer to the Fuel Injector Removal & Installation procedure in this section.

To install:

1. If fuel injectors are to be installed, refer to the Fuel Injector Removal & Installation procedure in this section.
2. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation.
3. Position fuel rail/fuel injector assembly to machined injector openings in intake manifold.
4. Guide each injector into intake manifold. Be careful not to tear injector O-rings.
5. 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.
6. Install 4 fuel rail hold-down clamps and 4 mounting bolts.
7. Position spark plug cable tray and cable assembly to intake manifold. Snap 4 cable tray retaining clips into intake manifold.
8. Install all cables to spark plugs and ignition coils.
9. Connect electrical connector to throttle body.
10. Install electrical connectors to all 8 ignition coils.
11. Connect electrical connector to throttle body.
12. 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.
13. Connect the fuel line latch clip and fuel line to fuel rail.
14. Install air resonator to throttle body (2 bolts).
15. Install flexible air duct to air box.
16. Connect battery cable to battery.
17. Start engine and check for leaks.

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. Remove air cleaner housing and tube.
3. Perform fuel pressure release procedure. Refer to Fuel Delivery System section of this group.
4. Disconnect throttle body linkage and remove throttle body from intake manifold. Refer to Throttle Body removal in this group.
5. Remove ignition coil pack and bracket assembly at intake manifold and right engine valve cover (four bolts).
6. Remove upper half of intake manifold. Refer to Engines for procedures.
7. Detach the electrical connectors at all fuel injectors, as follows:
   1. Push red colored slider away from injector (1).
   2. 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.
   3. To detach the connector, push the red colored slider away from injector (1). 
      
      
      
      Fig. While pushing slider, depress tab (2) and remove connector (3) from injector
      While pushing slider, depress tab (2) and remove connector (3) from injector
8. 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.
9. Remove the six fuel rail mounting bolts from the lower half of intake manifold.
10. Gently rock and pull the left fuel rail until the fuel injectors just start to clear the intake manifold.
11. 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.
12. Remove fuel rail (with injectors attached) from engine.
13. Remove the clip(s) retaining the injector(s) to fuel rail. 
    
    
    
    Fig. Exploded view of the fuel rail mounting-V-10 engine
    
    

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. Position the fuel rail/fuel injector assembly to the injector openings on the intake manifold.
3. Guide each injector into the intake manifold. Be careful not to tear the injector O-ring.
4. 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.
5. Install the six fuel rail mounting bolts into the lower half of intake manifold. Tighten bolts to 11 ft. lbs. (15 Nm).
6. 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.
7. Install upper half of intake manifold.
8. Connect main fuel line at fuel rail.
9. Install ignition coil pack and bracket assembly at intake manifold and right engine valve cover (four bolts).
10. Install throttle body to intake manifold, as outlined in this section.
11. Install throttle body linkage to throttle body.
12. Install air cleaner tube and housing.
13. Connect the negative battery cable.
14. Start engine and check for leaks.

These details will help.

Thanks.           

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