2002 Ford Econoline 150 Replace Upper Intake Gasket

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The Ford Econoline is a series of full-sized vans that the American automobile manufacturer released for the 1961 model year. This vehicle has been the best-selling van in the United States for over 30 years. Consumers can choose between nine different six- and eight-cylinder engines and two- or four-wheel drive models to suit their needs. Installing a new intake manifold in your 2002 Econoline will prevent coolant leaks and improve performance in your engine, regardless of displacement.

Tools Used[edit]

Tools
Intake manifold and gasket kit
Wrench set
Flat-head screwdriver
Torque wrench
Liquid container
Silicone sealant
Gasket adhesive

Replace Upper Intake Gasket[edit]

Removal

  • Disconnect the negative connection of the engine's battery by unscrewing the bolt that holds this in place. Set the connector out of the way so that it does not touch the battery during removal and installation. Halting the electrical current to the engine will ensure safety.
  • Place a liquid container underneath the radiator. Remove the filler cap of the radiator to allow the coolant to drain more easily. Pull the drain plug, or radiator hose, from its connection in the bottom of the radiator and allow all engine coolant to drain completely. Replace this plug or hose once you are finished.
  • Identify and disconnect all electrical wires and cables that are attached to the carburetor, radiator, ignition coil, and intake manifold. Remove the hoses that connect to the air filter. Remove the air filter housing unit from the engine.
  • Unscrew the bolts that hold the intake manifold to the engine block. Remove the intake manifold and set this part aside for later use.
  • Pry the old intake manifold gasket from the engine block with a flat-head screwdriver. Dispose of this part.
  • Remove coolant buildup and any other excess grime with the plastic scraper. Wipe any remaining debris off the engine with a moist cloth to ensure a tight seal when installing the new parts.

Installation

  • Apply gasket sealant to both sides of the intake manifold gasket for leak prevention. Position the new intake manifold gasket over the cylinder heads, ensuring that the holes of both parts align with each other as much as possible.
  • Place the old intake manifold on top of the manifold gasket, making sure the holes of the manifold align with the cylinder head and gasket. Torque the bolts of the manifold to 10 foot-pounds of pressure, then 15, and finally 25.
  • Install the distributor into position, making sure that it rests in the same position as removed. Tighten the distributor with your hand for best results.
  • Reconnect all vacuum hoses and fittings to the intake manifold. Connect all electrical wiring and cables that were removed for manifold installation. Reconnect the air filter housing unit.
  • Pour the engine coolant back into the radiator. Replace the coolant filler cap when you are finished. Screw the bolt that holds the negative connection to the battery to complete this installation. Start the engine of the Econoline and check for any leaks around the intake manifold.

Tips & Warnings[edit]

  • Wear gloves at all times to minimize injury and maintain a clean workspace.