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Ford 4.0L (OHV) Upper Intake Manifold Assembly Removal & Installation Removal 1. Disconnect the battery ground cable. 2. I highly recommend taking the hood off. Mark where the bolts connect on the hood to ensure proper alignment upon re-installation. My trick was to use “white-out” to do this, comes with a nice little brush. 3. Remove the air cleaner outlet tube by loosening the clamp next to the MAF and the clamp next to the Throttle Body. 4. Disconnect the accelerator cable from the throttle body arm, and then unclip the accelerator cable from the speed control actuator cable. Move them out of the way. 5. Disconnect the vacuum hoses from the brake vacuum booster, EGR valve and crankcase ventilation hose.
6. Disconnect the wiring harness connectors from the EGR valve, the DPFE sensor, and the idle air control (IAC) valve. 7. Disconnect the DPFE sensor hoses. 8. Disconnect the throttle position sensor (TPS) harness connector. 9. Disconnect the throttle body vapor management hose. This is the small coolant hose that runs directly to a port on the bottom of the TB. 10. Disconnect the spark plug wires from the ignition coil. 11. Disconnect the harness connector from the ignition coil and the radio ignition interference capacitor. 12. Slide the engine sensor control connector off the bracket. This is the large black connector that is located up near the firewall on the driver’s side of the engine bay. 13. Remove all 6 nuts (13mm) holding down the upper intake manifold, and the small attached bracket. 14. Remove the upper intake manifold assembly by pulling straight up. 15. Remove the upper intake manifold gaskets from the upper intake.
Installation 1. Installation of the Upper Intake Manifold Assembly is the reverse of removal. Tighten the nuts in the sequence shown: Ford 4.0L (OHV) Valve Covers & Gaskets – Removal & Installation Removal 1. Remove the upper intake manifold as described above. 2. Disconnect the vacuum line that goes into the top of the EGR valve. 3. Remove the bolts (10 mm) securing the EGR valve to the Tube that goes into the upper intake. 4. Remove the oil level indicator tube. 5. Remove the EGR Tube and the bracket (Be careful not to let the metal gasket fall and get lost). 6. Remove the valve cover bolts (10 mm). 7. Remove the valve covers (requires some lifting and twisting) and the valve cover gaskets. Installation 1. Clean and inspect the gasket sealing surfaces.
Download : 1998 FORD Ranger 4.0L OHV UPPER ENGINE GASKETS REPLACING INSTRUCTIONS
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