How to Change the Fuel Injector in a 2000 F-150 4.6L

The fuel injectors on the 2000 Ford F-150 with the 4.6-liter are all connected to a fuel rail that is routed around the intake manifold. To remove any or all of the fuel injectors, it is necessary to relieve the fuel pressure and remove the fuel rail. Special tools required to perform the process include a fuel line quick disconnect tool and a fuel pressure tester.

Instructions

Removal

1

Lift the vehicle hood and support it with the hood prop rod. Allow adequate time for the engine to cool completely before continuing. Disconnect the negative battery cable from the battery with the wrench set.

2

Locate the schrader valve that is located on the passenger side of the engine, just above the valve cover on the fuel line, and remove the plastic cap by turning it counter-clockwise. Attach the fuel pressure tester to the schrader valve. Direct the tester outlet tube into the gas can. Slowly turn the manual valve connected to the pressure tester until the pressure begins to read and fuel is dispensed into the gas can. Allow the fuel to run until there is no longer any pressure or gas coming from the tester outlet line.

3

Turn the coolant pressure cap one quarter turn until the hissing noise is heard. Wait until the hissing noise has dissipated and remove the coolant pressure cap. Place the drain pan under the passenger side of the radiator just below the drain cock. Turn the drain cock counter-clockwise until coolant begins to pour from the radiator drain. Allow about a half gallon of coolant to drain and tighten the drain cock. Place the drained coolant in a safe place.

4

Remove the three bolts securing the power steering reservoir to the engine with the socket and ratchet and carefully place the reservoir to the side out of the way. Do not disconnect the lines.

5

Remove the three bolts securing the plastic cover over the accelerator mechanism on the throttle body with the wrench set and remove the plastic cover. Follow the fuel lines from the fire wall to the fuel pressure regulator on the passenger side of the engine and disconnect the vacuum line from the pressure regulator.

6

Disconnect the fuel lines from the fuel rail with the fuel line quick disconnect kit. Be careful not to break the plastic quick disconnect fittings. Plug the disconnected fuel lines with the 3/8-inch line plugs.

7

Disconnect the electrical wire harness on all eight coil packs by squeezing on the tab and pulling the plastic connector housing out of the plug on each of the coil packs.

8

Disconnect the electrical wiring harness from all eight fuel injectors by squeezing on the tabs and pulling the plastic connector housing out of the fuel injector plug.

9

Find the brake booster bracket and tube that is located directly behind the original mounting point of the power steering reservoir. Remove the nut securing the brake booster bracket and tube to the engine with the socket and ratchet. Relieve the pressure clamps at each end of the brake booster tube with the pliers and remove the brake booster tube and bracket from the engine.

10

Remove the vacuum tube for the positive crankcase ventilation valve that runs from the intake manifold to the PCV valve on the driver side of the engine on the valve cover. There are no clamps and the hose will simply pull off of the nipple on the intake manifold and PCV valve.

11

Disconnect the exhaust-to-exhaust gas recirculation valve metal pipe with the combination wrench set. The pipe runs from the passenger side exhaust manifold up to the EGR valve. Disconnect the two remaining EGR transducer tubes with the wrench set and set them all aside. Disconnect the EGR valve vacuum line and set it aside.

12

Remove the hose that connects to the vapor management valve on the intake manifold just above the fuel rail by removing the clamp with a screwdriver and pulling it straight off of the valve assembly.

13

Remove the four bolts that secure the fuel injection rail to the intake manifold with the socket and ratchet. Lift up evenly all the way around the fuel rail and carefully remove it and the injectors from the engine. Remove the fuel injector to be replaced by pulling it straight down from the fuel rail. Inspect the o-ring gaskets on each injector to be returned to the engine for cracks or tears and replace as necessary.

Installation

14

Install the upper and lower o-ring gasket to the new injector to be replaced as well as any lower o-ring gaskets that need to be replaced on injectors that were not replaced. Ensure there are no twists in the o-ring gaskets. Apply a thin coat of new engine oil to the o-rings before installation.

15

Set the fuel rail into place and apply downward pressure on the fuel rail over each injector to seat them into place.

16

Install the four bolts that secure the fuel rail to the intake manifold and tighten them to 7 foot-pounds of torque with the torque wrench.

17

Connect the vapor management hose to the vapor management valve just above the fuel rail by sliding it over the nipple. Connect the EGR vacuum line to the vacuum nipple on top of the EGR valve.

18

Place the EGR pipe onto the EGR valve and exhaust manifold on the passenger side of the engine. Tighten the EGR valve pipe nut fittings at the EGR valve and the exhaust manifold to between 26 and 33 foot-pounds of torque, using a torque wrench with a crow's foot attachment.

19

Connect all the EGR valve hoses to the EGR valve and secure them with the pressure clamps. Install the rubber vacuum hose onto the intake manifold and the PCV valve by sliding the hose over each nipple.

20

Install the brake boost bracket and tube to the engine. Tighten the bracket mounting nut to between 7 and 9 foot-pounds of torque with the torque wrench. Tighten the clamps for the brake booster hoses with the screwdriver.

21

Plug the electrical wiring harness into each fuel injector by pushing the plastic connectors into the plug on each fuel injector; when installed properly the plastic tab will click.

22

Plug the electrical wiring harness into the plug on each coil pack. Press the harness pigtail into the plug on each coil until a click is heard.

23

Remove the caps from both fuel lines that plug into the fuel rail. Push the fuel line quick disconnect ends into the fuel rail until they both click. Connect the vacuum hose to the fuel pressure regulator.

24

Place the plastic cover over the throttle control on the throttle body and tighten the bolts to between 4 and 6 foot-pounds with the torque wrench.

25

Pull the power steering reservoir into place and line up the holes on the reservoir bracket to the holes on the bracket mounting surface. Install the mounting bolts and tighten to between 49 and 67 foot-pounds with the torque wrench and socket.

26

Connect the negative battery cable and tighten the terminal with a wrench. Place the previously drained coolant into the coolant system through the coolant pressure cap opening.

27

Turn the ignition key to on and wait 15 seconds, then turn it back off. Complete the on-off cycle three to five times to pressurize the fuel system. Start the engine and allow it to reach operating temperature with the coolant pressure cap removed. Shut the engine off and replace the coolant pressure cap; tighten it hand tight. Shut the vehicle hood. Pour the gasoline dispensed into the gas can through the schrader valve into the gas tank.