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Dodge Durango
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Fuel System » Fuel delivery system » Removal and installation
Fuel injector rail-4.7L v-8 engine

WARNING: 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 (Fig. 34). 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.

REMOVAL

(1) Remove fuel tank filler tube cap.

(2) Perform Fuel System Pressure Release Procedure.

(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 wiring at rear of generator.

(7) Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. Refer to Quick-Connect Fittings.

(8) Remove vacuum lines at throttle body.

(9) Disconnect electrical connectors at all 8 fuel injectors. To remove connector refer to (Fig. 35). Push red colored slider away from injector (1). 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.

(10) Disconnect electrical connectors at throttle body.

(11) Disconnect electrical connectors at MAP and IAT sensors.

(12) Remove first three ignition coils on each bank (cylinders #1, 3, 5, 2, 4 and 6). Refer to Ignition Coil Removal/Installation.

(13) Remove 4 fuel rail mounting bolts (Fig. 34).

(14) 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.

Fig. 34 Fuel Rail Mounting-4.7L V-8 Engine Fig. 34 Fuel Rail Mounting-4.7L V-8 Engine

1 - MOUNTING BOLTS (4)

2 - INJ.#7

3 - INJ.#5

4 - QUICK-CONNECT FITTING

5 - INJ.#3

6 - FUEL INJECTOR RAIL

7 - INJ.#1

8 - CONNECTOR TUBE

9 - INJ.#2

10 - INJ.#4

11 - INJ.#6

12 - INJ.#8

13 - PRESSURE TEST PORT CAP

Fig. 35 Remove/Install Injector Connector-4.7L V-8 Engine Fig. 35 Remove/Install Injector Connector-4.7L V-8 Engine

(15) Remove fuel rail (with injectors attached) from engine.

(16) If fuel injectors are to be removed, refer to Fuel Injector Removal/Installation.

INSTALLATION

(1) If fuel injectors are to be installed, refer to Fuel Injector Removal/Installation.

(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 cylinder head.

(4) Guide each injector into cylinder head. Be careful not to tear injector o-rings.

(5) 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.

(6) Install 4 fuel rail mounting bolts and tighten to 27 N*m (20 ft. lbs.).

(7) Install ignition coils. Refer to Ignition Coil Removal/Installation.

(8) Connect electrical connectors to throttle body.

(9) Connect electrical connectors to MAP and IAT sensors.

(10) Connect electrical connectors at all fuel injectors.

To install connector, refer to (Fig. 35). 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.

(11) Connect vacuum lines to throttle body.

(12) Connect fuel line latch clip and fuel line to fuel rail. Refer to Quick-Connect Fittings.

(13) Connect wiring to rear of generator.

(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.

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    Dodge Durango Service Manual / Fuel System / Fuel delivery system / Removal and installation / Fuel injector rail-4.7L v-8 engine

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