Fuel Rail: Service and Repair

Fig. 40 Fuel Injector Rail Assembly:

NOTE: The left and right sections of the fuel rail are connected with a (non-serviceable) flexible connecting hose (Fig. 40). Do not attempt to separate the rail halves at this connecting hose. Due to the design of this connecting hose, it does not require 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.

REMOVAL

WARNING: NATURAL GAS MUST FIRST BE PURGED FROM FUEL SYSTEM BEFORE REMOVAL. REFER TO FUEL SYSTEM PURGING.

1. Remove engine cover. Refer to Engine Cover in the 2000 RAM VAN/WAGON-REAR WHEEL DRIVE.
2. Purge fuel system.
3. Remove air cleaner housing at throttle body.
4. Disconnect fuel injector electrical harness at each injector. Each harness connector is numerically tagged (INJECTOR # 1, INJECTOR # 2, etc.) with its corresponding engine cylinder number.
5. Disconnect electrical connectors at MAP sensor, LAC motor and TPS.
6. Disconnect electrical connectors at fuel pressure sensor, low-pressure fuel solenoid and fuel temperature sensor.

Fig. 41 Fuel Line At Solenoid:

Fig. 42 Copper Washer (Gasket):

7. Disconnect low-pressure fuel line at low-pressure fuel shut-off solenoid (Fig. 41). A copper washer (gasket) is placed between line and solenoid (Fig. 42). Note direction of washer when removing.
8. Remove throttle body assembly. Refer to Throttle Body Removal/installation in the 2000 RAM VAN/ WAGON-REAR WHEEL DRIVE.
9. Remove 3 air conditioning compressor support bracket bolts (Fig. 40).
10. Remove 4 fuel rail-to-intake manifold mounting bracket bolts (Fig. 40).
11. Gently rock and pull the left half of fuel rail until fuel injectors just start to clear intake manifold. Gently rock and pull the right half of fuel rail until fuel injectors just start to clear intake manifold. Repeat this procedure (left/right) until all fuel injectors have cleared intake manifold.
12. Remove fuel rail (with injectors attached) from engine.

Fig. 43 Fuel Injector And Clip Removal/Installation:

13. If fuel injectors are to be removed, remove clip(s) retaining injector(s) to fuel rail (Fig. 43).

INSTALLATION
1. Thoroughly clean each injector before installing new O-rings. Apply a small amount of Parker (TM) O-lube to each fuel injector O-ring and into opening on intake manifold. This will help in fuel rail installation. Do not use a silicone based lubricant on O-rings.

CAUTION: The O-rings used on CNG powered engine are similar in size to O-rings used with gasoline powered engine, but are made of a different material and are also a different color. Do not interchange CNG and gasoline powered O-rings.

2. Position fuel rail/fuel injector assembly to injector openings on intake manifold.
3. Guide each injector into intake manifold openings. Be careful not to tear injector O-rings.
4. Push the right half of fuel rail down until fuel injectors have bottomed on injector shoulder. Push the left half of fuel rail down until fuel injectors have bottomed on injector shoulder.
5. Install fuel rail mounting bolts.
6. Install the A/C support bracket (if equipped).
7. Install a new copper washer (gasket) between fuel line and low-pressure fuel shut-off solenoid (Fig. 42).
8. Connect fuel line to low-pressure fuel shut-off solenoid. Tighten line to 27 Nm (20 ft. lbs.) torque. Check for interference between fuel line and fuel injector connectors for cylinders # 6 and # 8.
9. Install throttle body assembly. Refer to Throttle Body Removal/installation in the 2000 RAM VAN/ WAGON-REAR WHEEL DRIVE.
10. Connect fuel injector electrical harness at each injector.
11. Connect wiring at fuel low-pressure sensor, fuel temperature sensor and low-pressure fuel shutoff solenoid.
12. Connect electrical connectors at MAP sensor, IAC motor and TPS.
13. Check system components for natural gas leaks. Refer to Testing For Gas Leaks.
14. Install air cleaner housing to throttle body.
15. Install engine cover.