How-To: Replace Upper Intake Gaskets 4.0 OHV Engine - Ranger-Forums - The Ultimate Ford Ranger Resource

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Old 08-19-2006
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How-To: Replace Upper Intake Gaskets 4.0 OHV Engine

Hi, A while back i changed my upper intake gaskets and thought i'd do a write up. This is my first how to and is in it's rough draft stage right now. I hope this helps out somebody. At very least we will get some good pics out of this. well, here goes..........

How to change upper intake gaskets on a 97 ranger 4.0 OHV engine

This how to is not necessarily the best and not necessarily the only way go about this repair. But it worked for me. TRY THIS AT YOUR OWN RISK. That being said, lets have at it!!!

1. Disconnect the negative battery terminal.

- Be sure the engine is cool enough to work on. Don't forget your safety glasses.

2. Disconnect the the MAF and ATI electrical connectors. Disconnect the PCV hose from the air intake tube.

- Pull out on the PCV hose and work it around and it'll come out.

3. Disconnect the accellerator splash shield and disconnect the accellerator and cruise controll cables.

- The splash shield comes off with 2 bolts.
- You will need to pry the cable assemblly off of the ball stud on the throttle body.
- Pry the plastic ends of the cables apart to seperate them. Be carefull not to break them!!
-When they are seperated, Push in on the plastic retainer that secures the accellerator cable and remove the cable from the bracket.
-Press in with a screw driver on the hole below the cruise controll cable to undo clip and remove the cable. The cable will lift off the bracket.

4. Disconnect all electrical connectors and vacum lines from the intake. It is a good idea to lable and make note of components as you disconncet them. Also make note of how spark plug wires and vac lines are routed.

Coil pack
- Disconnect the wiring harness and spark plug wires. Undo the 4 bolts that hold on the coil pack. Remove the coil pack.

- Disconnect the electrical connector. You can remove the IAC valve if desired.

-Undo the connector.

- Disconnect the electrical connector. I chose to undo the bolts and let the sensor dangle by the hoses.

EGR transduser
-Undo the electrical connector. Undo the bolts. I did not disconnect the vac lines.

Brake booster hose
-Squeeze the clamp to loosen it. Pull the hose off.

PCV valve
- Same as above. You do not need to remove the valve. just disconnect the hose from the intake.

- pull off the vacum line connector from the intake.

Engine wiring harness connector
- Don't need to disconnect it. Just remove it from the mounting bracket. push in on the tab on top to release it.

- There is also a bundle of wires that is held in place by a push connector on the back of the intake.

- you only may need to disconnect the vac line on top. Just pull it off.

5. Remove the throttle body.
-Undo the 4 bolts that hold it on to the intake. There will be an Evaporative Emissions hose underneath the throttle body. disconnect it. Don't mess around with anything els on the throttle body, you could mess up the position of the throttle plate stop screw.

6. Remove the upper intake
- Undo the 6 nuts that hold the upper intake on. Some may be covered by a cap.

- Be sure that everything is disconnected from the intake.

- Pull up on the intake and lift it off of the studs. After it clears the studs turn it left and pull up. The end of the EGR tube curves inside of the intake. Set the intake aside when you have it off.

7. Remove the fuel line nuts.
-Undo the fuel line nut(s). Gas may squirt out.

- (97 and before) Undo the 2 bolts that hold the fuel pressure regulator on the fuel manifold.

8. Undo the studs that hold the fuel manifold on. And remove the fuel manifold.

- When the studs are removed, grab the fuel manifold , pull up and rock it back and fourth till it comes off. some of the fuel injectors may stay on the fuel manifold. If so, remove them and set them back in the engine. Replace the injector o rings if needed.

9. clean off the old gasket.
- Laquer thinner or acetone will help. Just work with it for a while.

10. New gasket and put back on the fuel manifold.
- put a little bit of motor oil on the injector o-rings to help lubericate them.

-lay the new gasket on the lower manifold. Be sure the injectors are in the holes in the engine and fuel manifold. Push the fuel manifold down to set the injectors in place.

11. Install the studs and tighten them 84-120 in/lbs (says haynes)

12. Replace the gaskets on the under side of the upper intake. you may need something sharp to pry them out.

13. Install the intake, fuel lines, throttle body, everything you disconnected and the intake tube.

14. Take a moment to check and be sure that every thing is connected propperly. Also check for any tools you may have left in the engine bay.

15. Start it up. repair complete!!


1. The end of the EGR tube curves inside the intake toward the tb. This makes it kinda of hard to get the intake off.

2. I bought all my gaskets at my local ford dealership. they totalled about $20. The guy at the parts counter gave me an exploded view of my intake for free.

3. When i started my engine afterward my idle speed was at about 2000rpm. "Well, Sh*t !!!!! something's wrong " was my first thought. I started to check for vacum leaks and found none. Then i noticed my idle speed was down to 1500rpm. Every time you disconnect your battery the computer forgets its strategy,but 2000rpm seemed kinda high. I went for a drive and it seemed to be fine. When i got back my idle speed was normal. I was worried i did something but it was just the computer relearning.

4. The reason i replaced my gaskets is because my engine gets a lean condition whenever it gets cold outside. I'll have to wait a while for winter to see if i have done any good.

5. On 1997 4.0 engines(like mine) ford decided used a paper gasket without any rubber. These paper gaskets have been known to cause leaks. Since then ford has changed it to a new gasket with rubber.

well, there it is hope you enjoyed it!! Like i said before this is my first how to and i am open to suggestions. Please let me know if i left out or did anything wrong.

Last edited by CAW; 08-20-2006 at 10:18 AM.
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