How to Replace a Fuel Injector in a Ford F-Series

Determine which fuel injector your Ford F-Series will need. This depends not only on the make and model, but also the engine size. Each generation of the Ford F-Series trucks features a range of engine sizes. Those made before 1966 generally have six-cylinder engines in the 200 to 300 cubic inch (ci) range.

Look at the development of the V8 engine in F-Series trucks. A 352ci V8 engine was introduced in 1966 and V8 engines quickly increased in size, reaching their peak in the 460ci engine introduced in 1973 that was available until 1979.

Examine the effect of the fuel crisis on the engine size in F-Series trucks. Engines from 1980 on were much smaller but gradually increased in power. The latest generation debuted in 2004 and is available in 4.2L, 4.6L and 5.4L sizes.

Relieve the fuel system pressure and disconnect the negative battery cable with a socket wrench. Remove the air cleaner outlet pipe and disconnect the upper fitting of the exhaust gas recirculation (EGR) system module tube upper fitting with a socket wrench. Loosen the lower fitting of the EGR system module so you can move it aside.

Disconnect the brake booster vacuum hose, electrical connector for the throttle position sensor and the upper vapor tube with a socket wrench. This will allow you to disconnect the EGR system module vacuum hose and electrical connector.

Unplug the electrical connectors for the injection pressure sensor and fuel injectors. Disconnect the injection pressure sensor vacuum hose and the coupling for the fuel tube spring lock. Remove the four fuel rail bolts with a socket wrench and take out the fuel injectors. Remove and discard all the O-ring seals.

Install the new fuel injector by reversing the removal procedure. Lubricate the new O-rings with clean engine oil before you install them. Use a torque wrench to tighten the fuel rail bolts to 89 inch pounds and the EGR system module tube fittings to 30 foot pounds.