Fuel Delivery: Rail-Fuel: Removal: 5.7L

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. 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.

Fig 1: 5.7L SPARK PLUG CABLE ROUTING

Courtesy of DAIMLERCHRYSLER CORP.

1 - #8 COIL-TO- #5 SPARK PLUG (MARKED 5/8)	7 - CABLE TRAY
2 - #5 COIL-TO- #8 SPARK PLUG (MARKED 5/8)	8 - CLIPS (SPARK PLUG CABLE-TO-TRAY- RETENTION)
3 - #7 COIL-TO- #4 SPARK PLUG (MARKED 4/7)	9 - #2 COIL-TO- #3 SPARK PLUG (MARKED 2/3)
4 - #3 COIL-TO- #2 SPARK PLUG (MARKED 2/3)	10 - #6 COIL-TO- #1 SPARK PLUG (MARKED 1/6)
5 - #1 COIL-TO- #6 SPARK PLUG (MARKED 1/6)	11 - #4 COIL-TO- #7 SPARK PLUG (MARKED 4/7)
6 - CLIPS (TRAY-TO-MANIFOLD RETENTION)

1. Remove fuel tank filler tube cap.
2. Perform Fuel System Pressure Release Procedure.
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 2: 5.7L SPARK PLUG CABLE ROUTING TRAY

   Courtesy of DAIMLERCHRYSLER CORP.
7. Remove spark plug cable tray from engine by releasing 4 retaining clips (2). Remove tray and cables from engine as an assembly.
8. Disconnect electrical connectors at all 8 ignition coils. Refer to IGNITION SYSTEM - SERVICE INFORMATION .
9. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. Refer to STANDARD PROCEDURE - QUICK-CONNECT FITTINGS  .
   Fig 3: REMOVE/INSTALL INJECTOR CONNECTOR

   Courtesy of DAIMLERCHRYSLER CORP.
10. Disconnect electrical connectors at all 8 fuel injectors. Refer to Fig 3 . 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.
11. Disconnect electrical connectors at all throttle body sensors.
    Fig 4: 5.7L FUEL RAIL

    Courtesy of DAIMLERCHRYSLER CORP.
12. Remove four fuel rail mounting bolts (2) and holdown clamps.
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. Repeat this procedure (left/right) until all injectors have cleared machined holes.
14. Remove fuel rail (with injectors attached) from engine.
15. If fuel injectors are to be removed, refer to INJECTOR-FUEL  .