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Fuel Delivery - Except Diesel: Rail-Fuel: Removal: 6.1L

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: THE FUEL SYSTEM IS UNDER CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL, FUEL SYSTEM PRESSURE MUST BE RELEASED.
Fig 1: FUEL RAIL - 6.1L
GC0039497Courtesy of DAIMLERCHRYSLER CORP.
CAUTION: The left (3) and right (1) fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tube (2). 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. Perform STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
  3. Remove negative battery cable at battery.
  4. Remove flex tube (air cleaner housing to engine).
    Fig 2: MAP SENSOR LOCATION - 6.1L
    GC0039501Courtesy of DAIMLERCHRYSLER CORP.
  5. Remove electrical connector from MAP sensor (2) at rear of intake manifold (1).
  6. Disconnect vacuum hose from fitting (3) at rear of intake manifold (1).
    Fig 3: FUEL LINE AT FUEL RAIL - 6.1L
    GC0039498Courtesy of DAIMLERCHRYSLER CORP.
  7. Disconnect fuel line (1) at fuel rail fitting. Refer to QUICK CONNECT FITTING  for procedures.
    Fig 4: Disconnecting Electrical Connectors
    GC0039499Courtesy of DAIMLERCHRYSLER CORP.
  8. Disconnect electrical connectors at all 8 fuel injectors. First, pry up on red colored tab (2).
    Fig 5: Removing Connector From Fuel Injector
    GC0039500Courtesy of DAIMLERCHRYSLER CORP.
  9. Press on black colored tab (1) while removing connector (2) from fuel injector (3).
    Fig 6: Locating Fuel Rail Mounting Bolts
    GC0038702Courtesy of DAIMLERCHRYSLER CORP.
  10. Remove four fuel rail mounting bolts (1).
  11. 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.
  12. Remove fuel rail (with injectors attached) from engine.
  13. If fuel injectors are to be removed, refer to INJECTOR-FUEL .
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