Fuel Rail Swap (5.7 to 6.1)

[T-Rex R/T]

I decided to swap out my 5.7 fuel rail to a 6.1 fuel rail primarily for two reasons: I like the chrome over the "whatever color" the 5.7 rail is and I like the fuel connector line behind the intake instead of over the top of the intake.
After reading a few threads, I figured it would be fairly easy to do with one major thing to be aware of and that was the clearance of the fuel line at the back, driver side of the manifold.

Well, in reality, there are a few more things to contend with...

1). The MAP sensor wire on the back of the manifold is attached just prior to the connector and the wire harness is in the way - (the connection at the back of the manifold has to be removed and where the wire harness is attached has to be removed).
2). The brake vacuum hose connects to the lower back middle of the manifold and is almost impossible to remove. (I pulled the manifold off after about an hour of wrestling with it - I think it's glued on!!)
3). Removing the intake manifold means messing with the EGR tube. I pulled the intake manifold with the tube still connected to the EGR Valve. The tube extends into the manifold about 2-3 inches. In hindsight, I should've disconnected the EGR tube at the EGR valve.
4). The clearances for the fuel rail connector line are VERY CLOSE on the driver side. Using a tube bender to bend the rail is difficult because your bending in the opposite direction tube benders are designed to work and there is a metal support welded on the tube.

Here's a few pics (I should've taken a few more but I was focused on getting everything back together and forgot about the camera)

See the brake vacuum hose back there - it's a PITA!!! Also, note the water hoses and EGR Tube:



Passenger side clears without much problem (note the flat metal support welded on the inside of the tube):



Drivers side is way tighter between the water hose and the manifold (I placed the grey line protector from the 5.7 rail on the 6.1 to prevent potential fuel leak from hoses rubbing):



At the end of the day, it looks good, and was worth it.



One other note, the injectors are easy to remove from the 5.7 rail and install on the 6.1 rail. When removing the 5.7 fuel rail the injectors will stay attached to the rail via a clip, make sure to recover any injector o-rings that stay in the manifold. I had about half of the o-rings stay attached to the injectors and half stayed in the manifold. You can grab them (gently) with a set of needle nose pliers. they are easily reinstalled on the injectors.

[Junior]

Nice Job Buddy! Thanks for taking the time to do the write-up.

[1FST4DR]

Nice write up,Started working on your bracket today.. WOOT!!!

[T-Rex R/T]

Nice write up,Started working on your bracket today.. WOOT!!!

Awesome, I'm looking forward to getting the nitrous wired and plumbed. Thanks for making the bracket for me, it's gonna bring everything together perfect!!

[feros]

very nice write up! thanks