Fuel Rail - Removal

5.7L

WARNING: The fuel system is under constant pressure even with engine off. Before servicing the fuel rail, fuel system pressure must be released.

1. Perform the fuel system pressure release procedure Service and Repair
2. Remove the negative battery cable.




3. Disconnect the IAT sensor electrical connector (3).
4. Remove the clean air tube (2) from the air cleaner housing (4) and the throttle body.






NOTE: The front grommets (1, 3) are a ball stud type mount and the rear grommets (2) are a sliding peg design.






5. Lift up the front of the engine cover (1) and separate the engine cover front grommets (2) from the ball studs on the intake manifold.





6. Slightly raise the front of the engine cover and slide forward to remove the rear engine cover pegs (2) from the grommets (1) located on the rear of the intake manifold and remove the engine cover.






CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate the fuel rail halves at the connector tube. Due to the design of the connector tube, it does not use any clamps. Never attempt to install a clamping device of any kind to the connector tube. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connector tube.

NOTE: The factory fuel injection electrical harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If the electrical harness is not tagged, note the injector position before electrical harness removal.

7. Disconnect the electrical connectors at all eight fuel injectors. Push the red colored slider away from the injector (1) while pushing slider, depress tab (2) and remove the electrical connector (3) from the injector.





8. Disconnect the PCV hose (1) and position aside to gain access to the fuel rail.
9. Disconnect the fuel line quick connect fitting (2) at the fuel rail Service and Repair
10. Disconnect the make up air hose (3) and position aside to gain access to the fuel rail.
11. Remove the four fuel rail mounting bolts (4) from both the left and right fuel rails.
12. Using a side to side motion, gently rock the left fuel rail while pulling up until all four left side fuel injectors just start to clear the machined holes in the intake manifold.
13. Using a side to side motion, gently rock the right fuel rail while pulling up until all four right side fuel injectors just start to clear the machined holes in the intake manifold.

NOTE: Make sure the O-rings are still attached to the fuel injectors during removal.

14. Remove the left and right fuel rails (with injectors attached) as an assembly from the engine.

NOTE: If the same fuel injectors are to be reinstalled, install new O-rings.

15. If the fuel injectors are to be removed from the fuel rail Fuel Injector - Removal