OEM Dodge Sprinter 2500 Fuel Rail

Dodge Sprinter 2500 Fuel Rail Parts and Q&A

• Fuel Rail
  68032065AA
  Q: How to remove the fuel rail from an engine on Dodge Sprinter 2500?

  A:

  Safety requires you to first release the pressure from the fuel system because the rail is under constant pressure even after the engine is off. Remove the Fuel Tank Filler Tube Cap and follow the ordering to release fuel system pressure. First, take out the Air Duct and air box from the Throttle Body and next disconnect the negative Battery Cable. After that, separate the fuel line from the fuel rail and remove any essential vacuum lines attached to the throttle body. Separate the harness from all six Fuel Injectors and from the throttle body and set the engine harness to the side. Take out the four mounting bolts from the fuel rail and softly rock and remove the left side of the fuel rail until the fuel injectors begin to leave the holes in the cylinder head; do the same with the right side of the fuel rail. Remove the fuel rail as soon as you remove the fuel injectors. Depending on the needs, remove the fuel injectors by following the manual's instructions.
• Fuel Rail
  68011691AA
  Q: How to install a Fuel Rail on Dodge Sprinter 2500?

  A:

  If you already removed the Fuel Injectors, start by installing them. Clean the inside of the Fuel Injector Bores in the Intake Manifold and add a bit of engine oil to every fuel injector O-ring before installation. While aligning the fuel rail/fuel injector, guide each injector so it settles inside the cylinder head machined holes and do not pull the injector assembly so roughly that you tear the O-rings. With the right side placed against the key, press the rail towards the back until the Fuel Injectors are flush along the Cylinder Head Shoulder and repeat on the left side. Place the 4 Fuel Rail Mounting Bolts on their points and tighten each one to 14 Nm (10 ft. lbs.). Then, fit in the Engine Harness and connect the Harness Connectors from the tops of the Throttle Body and all 6 fuel injectors. Make certain the Vacuum Lines are fitted to the Throttle Body, link the Fuel Line to complete the connection and secure the Fuel Line with 24 Nm (18 ft. lbs.) torque. After that, install the Air Box and Air Duct to the Throttle Body. Attach the Negative Battery Cable on the last step and then put the Engine Cover into place.