How To Install F150 Lightning & Bronco Fuel Injectors

There can be many reasons you want to replace your F-150, Lightning, or Bronco injectors. For the most part, fuel injectors last a very long time, but they can become internally stuck or clogged, causing hesitations, misfires, or causing your truck not to start. Another reason you might look to replace your injectors is to provide additional fuel after modifications like heads, cams, supercharger pulley replacement, upgraded supercharger, etc. Whatever your reason, below is information on how to remove your fuel injectors on your F-150 Lightning and Bronco! 

1999-2004 F-150 Lightning

1. To create more room to work, remove the intake tube and air cleaner assembly by removing the worm gear clamp from the throttle body and disengaging the filter housing clamps. Disconnect the mass air sensor wiring and PCV hose to remove the intake tube assembly fully. 
2. Release the fuel pressure from the fuel system. 
3. Disconnect the (8) fuel injector clips by squeezing on the retaining clips simultaneously and pulling away from the injector. 
   
4. Remove the (4) fuel rail retaining bolts from the lower manifold. (photo shown with supercharger removed but is not required)
   
5. Lift on the fuel rail to give yourself enough room to remove the injectors. At the rear, the clearance will be tight around the intercooler and heater core hoses. Use caution to not damage or stretch any of the wiring or hoses. When in doubt, remove or disconnect any tight items to prevent damage.  

Torque Specs:

• Fuel Rail Bolts - 89 lb-in

1993-1995 F-150 Lightning

1. Remove the rubber intake tube from the throttle body and air intake box.
2. Release the fuel pressure from the fuel system. 
3. Remove the (4) "LIGHTNING" upper intake manifold plaque bolts from the intake manifold.
4. Disconnect the idle air control motor connection at the rear of the throttle body. 
   
5. Disconnect the throttle position sensor (TPS) connection
6. Disconnect the crankcase ventilation tube from the throttle body and oil fill tube nipple.
   
7. Remove the rear PCV by pulling up. It will disengage it from the lower manifold. You can leave the PCV hose connected to the upper manifold if you would like. 
   
8. Disconnect the EGR position sensor plug and vacuum hose connected to the sensor. 
   
9. Label and remove the vacuum hoses from the vacuum tree at the rear of the upper intake manifold.
    
10. Disconnect the vacuum hoses and electrical connection from the thermactor air diverter (TAD) and thermactor air bypass (TAB) control solenoids at the rear of the driver-side intake manifold. 
    
11. Remove the throttle cable splash shield by removing the (2) nuts labeled (A) on the image below from the shield. Remove and set aside the splash shield. Remove the (2) throttle cable bracket bolts labeled (B) in the image below. Disconnect the throttle linkages from the throttle body. 
    
12. Remove the (6) upper intake manifold to lower intake manifold bolts. Check for any remaining hoses or connections still attached to the intake manifold. Carefully remove the upper intake manifold from the engine. 
13. Disconnect the fuel injector clips from the fuel injector. 
14. Remove the (4) fuel rail retaining bolts from the lower intake manifold. 
    
15. Lift up on the fuel rail to disengage the fuel injectors from the intake manifold. Remove the injectors and replace them with new injectors. 
16. Installation is the reverse of the removal. Please note that you will want to replace your upper to lower intake manifold gasket. 

Torque Specs:

• Fuel rail to intake manifold intake bolts - 71-105 lb-in
• Upper intake manifold to lower intake manifold bolts - 12-18 ft-lb
• Throttle cable splash shield nuts - 24-33 lb-in
• Throttle cable bracket bolts - 14-19 ft-lb

1992-1996 Bronco

1. Remove the two intake tubes from the throttle body and air intake box.
2. Release the fuel pressure from the fuel system. 
3. Disconnect the idle air control motor connection at the rear of the throttle body.
   
4. Disconnect the throttle position sensor (TPS) connection and (2) canister purge ports (if equipped)
   
5. Remove the rear PCV hose by removing the hose from the nipple on the back of the intake manifold. 
   
6. Remove the EGR tube from the EGR valve and the (2) intake manifold support nuts. Remove the intake manifold support brace. 
   
7.  Label and remove the vacuum hoses from the vacuum tree at the rear of the upper intake manifold.
   
8. Remove the two nuts retaining the differential pressure feedback (DPFE) EGR sensor. This is located on the front of the intake manifold on the passenger side. 
   
9. Remove the throttle splash shield bolts (A) to remove the throttle cable shield (C). Remove the throttle cable from the throttle body, then remove the throttle cable bolts (B) from the throttle cable bracket. 
   
10. Remove the (6) upper intake manifold to lower intake manifold bolts. Check for any remaining hoses or connections still attached to the intake manifold. Carefully remove the upper intake manifold from the engine. 
11. Remove the (4) fuel rail retaining bolts from the lower intake manifold. 
    
12. Lift up on the fuel rail to disengage the fuel injectors from the intake manifold. Remove the injectors and replace them with new injectors. 
13. Installation is the reverse of the removal. Please note that you will want to replace your upper to lower intake manifold gasket. 

Torque Specs: 

• EGR to Intake Manifold - 13-19 ft-lbs
• Throttle cable splash shield bolts - 45-79 in-lb
• Accelerator cable bracket - 16-19 ft-lb
• Upper intake manifold to lower intake manifold bolts - 12-18 ft-lb

Photos supplied by Alldata.com