AutoZone 1963 Mercury Monterey 6.4L 2BL 8cyl | Repair Guides | Engine Mechanical | Engine Mechanical Components | Intake Manifold | AutoZone.com

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    Nissan Frontier, Xterra 1998-05

    Intake Manifold

    Print

    Removal & Installation



    2.5L Engine


    Click image to see an enlarged view

    Fig. Intake manifold and related components-2.5L engine

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Properly relieve the fuel system pressure.
    4.  
    5. Disconnect the negative battery cable. Drain the cooling system.
    6.  
    7. Remove the air cleaner case, air cleaner and air duct.
    8.  
    9. Disconnect the water hoses from the electric throttle control actuator.
    10.  
    11. Remove the mass air flow sensor from the intake manifold. Remove the quick connector cap and disconnect the quick connector at the engine side.
    12.  
    13. Remove the electric throttle control actuator retaining bolts. Be sure to remove the bolts by reversing the order of the tightening torque sequence.
    14.  
    15. Remove the electric throttle control actuator and gasket.
    16.  
    17. Disconnect the harness, vacuum hoses and PCV hoses from the intake manifold and position them to the side.
    18.  
    19. Remove the intake manifold retaining bolts. Be sure to remove the bolts by reversing the order of the tightening torque sequence.
    20.  
    21. Remove the intake manifold, fuel tube protector and gasket from the engine.
    22.  
    23. As necessary, remove the EVAP canister purge volume solenoid valve and vacuum hose adapter from the intake manifold.
    24.  
    25. Disconnect the sub frame harness from the fuel injectors. Remove the fuel tube and fuel injector assembly from the intake manifold, if required.
    26.  

    To install:

    Click image to see an enlarged view

    Fig. Intake manifold bolt torque sequence-2.5L engine



    Click image to see an enlarged view

    Fig. Electric throttle control actuator bolt torque sequence-2.5L engine

    1. Installation is the reverse of the removal procedure.
    2.  
    3. Be sure to use new gaskets.
    4.  
    5. Be sure to tighten the intake manifold retaining bolts to specification and in the proper sequence.
      NOTE
      Refer to the torque sequence illustration, No.6 means double tightening of bolt No.1. M8xM38mm (1.50 inches) are green in color (No1, No.6). M8xM35mm (1.38 inch) (No.2, No.3). Nut (No.4, No.5).

    6.  
    7. Be sure to tighten the electric throttle control actuator retaining bolts to specification and in the proper sequence.
      NOTE
      See throttle valve closed position learning and idle air volume learning procedures, for relearning information.

    8.  
    9. Be sure to fill the cooling system with the proper grade and type engine coolant.
    10.  
    11. Start the engine and check for leaks.
    12.  

    3.3L Engines
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Relieve the fuel system pressure.
    6.  
    7. Remove or disconnect the following:

      Negative battery cable
       
      Air intake duct
       
      Accelerator cable
       
      Cruise control cable
       
      Idle Air Control (IAC) valve connector
       
      Throttle Position (TP) sensor and switch connectors
       
      Ignition coil and power transistor connectors
       
      Exhaust Gas Recirculation (EGR) Solenoid valve connector
       
      EGR temperature sensor connector
       
      Radiator hoses
       
      Heater hoses
       
      Positive Crankcase Ventilation (PCV) valve and hose
       
      Evaporative Emissions (EVAP) canister vacuum and purge hoses
       
      Brake booster vacuum hose
       
      Fuel pressure regulator vacuum hose
       
      EGR tube
       
      Spark plug wires
       
      Distributor
       
      Left bank injector connectors
       
      Thermal transmitter
       
      Upper intake manifold ground cable (VG33)
       
      Supercharger (VG33ER)
       
      Breather pipe
       
      Upper intake manifold (VG33)
       
      Intake manifold collector (VG33ER)
       
      Fuel lines
       
      Right bank injector connectors
       
      Fuel supply manifold
       
      Engine Coolant Temperature (ECT) sensor connector
       
      Lower intake manifold. Loosen the fasteners in the sequence shown.
       

    8.  


      Click image to see an enlarged view

      Fig. Intake manifold loosening sequence-3.3L engine


    To install:



    Click image to see an enlarged view

    Fig. Intake manifold torque sequence-3.3L engine

    1. Install the lower intake manifold with a new gasket.
    2.  
    3. Tighten the fasteners in sequence as follows:
      1. Step 1: 35 inch lbs. (4 Nm)
      2.  
      3. Step 2: 78 inch lbs. (9 Nm)
      4.  
      5. Step 3: 70-84 inch lbs. (8-10 Nm)
      6.  

    4.  
    5. Install or connect the following:

      ECT sensor connector
       
      Fuel supply manifold
       
      Right bank injector connectors
       
      Fuel lines
       
      Upper intake manifold
       
      Breather pipe
       
      Upper intake manifold ground cable
       
      Thermal transmitter
       
      Left bank injector connectors
       
      Distributor
       
      Spark plug wires
       
      EGR tube
       
      Fuel pressure regulator vacuum hose
       
      Brake booster vacuum hose
       
      EVAP canister vacuum and purge hoses
       
      PCV valve and hose
       
      Heater hoses
       
      Radiator hoses
       
      EGR temperature sensor connector
       
      EGR Solenoid valve connector
       
      Ignition coil and power transistor connectors
       
      TP sensor and switch connectors
       
      IAC valve connector
       
      Cruise control cable
       
      Accelerator cable
       
      Air intake duct
       
      Negative battery cable
       

    6.  
    7. Fill the cooling system.
    8.  
    9. Start the engine and check for leaks.
    10.  

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Relieve the fuel system pressure.
    6.  
    7. Remove or disconnect the following:

      Negative battery cable
       
      Air intake duct
       
      Accelerator cable
       
      Cruise control cable
       
      Idle Air Control (IAC) valve connector
       
      Throttle Position (TP) sensor and switch connectors
       
      Ignition coil and power transistor connectors
       
      Exhaust Gas Recirculation (EGR) Solenoid valve connector
       
      EGR temperature sensor connector
       
      Radiator hoses
       
      Heater hoses
       
      Positive Crankcase Ventilation (PCV) valve and hose
       
      Evaporative Emissions (EVAP) canister vacuum and purge hoses
       
      Brake booster vacuum hose
       
      Fuel pressure regulator vacuum hose
       
      EGR tube
       
      Spark plug wires
       
      Distributor
       
      Left bank injector connectors
       
      Thermal transmitter
       
      Upper intake manifold ground cable
       
      Breather pipe
       
      Upper intake manifold
       
      Fuel lines
       
      Right bank injector connectors
       
      Fuel supply manifold
       
      Engine Coolant Temperature (ECT) sensor connector
       
      Lower intake manifold. Loosen the fasteners in the sequence shown.

      Click image to see an enlarged view

      Fig. Intake manifold loosening sequence-3.3L engine

       

    8.  

    To install:

    Click image to see an enlarged view

    Fig. Intake manifold torque sequence-3.3L engine

    1. Install the lower intake manifold with a new gasket.
    2.  
    3. Tighten the fasteners in sequence as follows:
      1. Step 1: 35 inch lbs. (4 Nm)
      2.  
      3. Step 2: 78 inch lbs. (9 Nm)
      4.  
      5. Step 3: 70-84 inch lbs. (8-10 Nm)
      6.  

    4.  
    5. Install or connect the following:

      ECT sensor connector
       
      Fuel supply manifold
       
      Right bank injector connectors
       
      Fuel lines
       
      Upper intake manifold
       
      Breather pipe
       
      Upper intake manifold ground cable
       
      Thermal transmitter
       
      Left bank injector connectors
       
      Distributor
       
      Spark plug wires
       
      EGR tube
       
      Fuel pressure regulator vacuum hose
       
      Brake booster vacuum hose
       
      EVAP canister vacuum and purge hoses
       
      PCV valve and hose
       
      Heater hoses
       
      Radiator hoses
       
      EGR temperature sensor connector
       
      EGR Solenoid valve connector
       
      Ignition coil and power transistor connectors
       
      TP sensor and switch connectors
       
      IAC valve connector
       
      Cruise control cable
       
      Accelerator cable
       
      Air intake duct
       
      Negative battery cable
       

    6.  
    7. Fill the cooling system.
    8.  
    9. Start the engine and check for leaks.
    10.  

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Relieve the fuel system pressure.
    6.  
    7. Remove or disconnect the following:

      Negative battery cable
       
      Air intake duct
       
      Accelerator cable
       
      Cruise control cable
       
      Idle Air Control (IAC) valve connector
       
      Throttle Position (TP) sensor and switch connectors
       
      Ignition coil and power transistor connectors
       
      Exhaust Gas Recirculation (EGR) Solenoid valve connector
       
      EGR temperature sensor connector
       
      Radiator hoses
       
      Heater hoses
       
      Positive Crankcase Ventilation (PCV) valve and hose
       
      Evaporative Emissions (EVAP) canister vacuum and purge hoses
       
      Brake booster vacuum hose
       
      Fuel pressure regulator vacuum hose
       
      EGR tube
       
      Spark plug wires
       
      Distributor
       
      Left bank injector connectors
       
      Thermal transmitter
       
      Upper intake manifold ground cable (VG33)
       
      Supercharger (VG33ER)
       
      Breather pipe
       
      Upper intake manifold (VG33)
       
      Intake manifold collector (VG33ER)
       
      Fuel lines
       
      Right bank injector connectors
       
      Fuel supply manifold
       
      Engine Coolant Temperature (ECT) sensor connector
       
      Lower intake manifold. Loosen the fasteners in the sequence shown.

      Click image to see an enlarged view

      Fig. Intake manifold loosening sequence-3.3L engine

       

    8.  

    To install:

    Click image to see an enlarged view

    Fig. Intake manifold torque sequence-3.3L engine

    1. Install the lower intake manifold with a new gasket.
    2.  
    3. Tighten the fasteners in sequence as follows:
      1. Step 1: 35 inch lbs. (4 Nm)
      2.  
      3. Step 2: 78 inch lbs. (9 Nm)
      4.  
      5. Step 3: 70-84 inch lbs. (8-10 Nm)
      6.  

    4.  
    5. Install or connect the following:

      ECT sensor connector
       
      Fuel supply manifold
       
      Right bank injector connectors
       
      Fuel lines
       
      Upper intake manifold
       
      Breather pipe
       
      Upper intake manifold ground cable
       
      Thermal transmitter
       
      Left bank injector connectors
       
      Distributor
       
      Spark plug wires
       
      EGR tube
       
      Fuel pressure regulator vacuum hose
       
      Brake booster vacuum hose
       
      EVAP canister vacuum and purge hoses
       
      PCV valve and hose
       
      Heater hoses
       
      Radiator hoses
       
      EGR temperature sensor connector
       
      EGR Solenoid valve connector
       
      Ignition coil and power transistor connectors
       
      TP sensor and switch connectors
       
      IAC valve connector
       
      Cruise control cable
       
      Accelerator cable
       
      Air intake duct
       
      Negative battery cable
       

    6.  
    7. Fill the cooling system.
    8.  
    9. Start the engine and check for leaks.
    10.  

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Relieve the fuel system pressure.
    6.  
    7. Remove or disconnect the following:

      Negative battery cable
       
      Air intake duct
       
      Accelerator cable
       
      Cruise control cable
       
      Idle Air Control (IAC) valve connector
       
      Throttle Position (TP) sensor and switch connectors
       
      Ignition coil and power transistor connectors
       
      Exhaust Gas Recirculation (EGR) Solenoid valve connector
       
      EGR temperature sensor connector
       
      Radiator hoses
       
      Heater hoses
       
      Positive Crankcase Ventilation (PCV) valve and hose
       
      Evaporative Emissions (EVAP) canister vacuum and purge hoses
       
      Brake booster vacuum hose
       
      Fuel pressure regulator vacuum hose
       
      EGR tube
       
      Spark plug wires
       
      Distributor
       
      Left bank injector connectors
       
      Thermal transmitter
       
      Upper intake manifold ground cable
       
      Breather pipe
       
      Upper intake manifold
       
      Fuel lines
       
      Right bank injector connectors
       
      Fuel supply manifold
       
      Engine Coolant Temperature (ECT) sensor connector
       
      Lower intake manifold. Loosen the fasteners in the sequence shown.

      Click image to see an enlarged view

      Fig. Intake manifold loosening sequence-3.3L engine

       

    8.  

    To install:

    Click image to see an enlarged view

    Fig. Intake manifold torque sequence-3.3L engine

    1. Install the lower intake manifold with a new gasket.
    2.  
    3. For 1998-01 engines, tighten the fasteners in sequence as follows:
      1. Step 1: 35 inch lbs. (4 Nm)
      2.  
      3. Step 2: 78 inch lbs. (9 Nm)
      4.  
      5. Step 3: 70-84 inch lbs. (8-10 Nm)
      6.  

    4.  
    5. Install or connect the following:

      ECT sensor connector
       
      Fuel supply manifold
       
      Right bank injector connectors
       
      Fuel lines
       
      Upper intake manifold
       
      Breather pipe
       
      Upper intake manifold ground cable
       
      Thermal transmitter
       
      Left bank injector connectors
       
      Distributor
       
      Spark plug wires
       
      EGR tube
       
      Fuel pressure regulator vacuum hose
       
      Brake booster vacuum hose
       
      EVAP canister vacuum and purge hoses
       
      PCV valve and hose
       
      Heater hoses
       
      Radiator hoses
       
      EGR temperature sensor connector
       
      EGR Solenoid valve connector
       
      Ignition coil and power transistor connectors
       
      TP sensor and switch connectors
       
      IAC valve connector
       
      Cruise control cable
       
      Accelerator cable
       
      Air intake duct
       
      Negative battery cable
       

    6.  
    7. Fill the cooling system.
    8.  
    9. Start the engine and check for leaks.
    10.  

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Relieve the fuel system pressure.
    6.  
    7. Remove or disconnect the following:

      Negative battery cable
       
      Air intake duct
       
      Accelerator cable
       
      Cruise control cable
       
      Idle Air Control (IAC) valve connector
       
      Throttle Position (TP) sensor and switch connectors
       
      Ignition coil and power transistor connectors
       
      Exhaust Gas Recirculation (EGR) Solenoid valve connector
       
      EGR temperature sensor connector
       
      Radiator hoses
       
      Heater hoses
       
      Positive Crankcase Ventilation (PCV) valve and hose
       
      Evaporative Emissions (EVAP) canister vacuum and purge hoses
       
      Brake booster vacuum hose
       
      Fuel pressure regulator vacuum hose
       
      EGR tube
       
      Spark plug wires
       
      Distributor
       
      Left bank injector connectors
       
      Thermal transmitter
       
      Upper intake manifold ground cable (VG33)
       
      Supercharger (VG33ER)
       
      Breather pipe
       
      Upper intake manifold (VG33)
       
      Intake manifold collector (VG33ER)
       
      Fuel lines
       
      Right bank injector connectors
       
      Fuel supply manifold
       
      Engine Coolant Temperature (ECT) sensor connector
       
      Lower intake manifold. Loosen the fasteners in the sequence shown.

      Click image to see an enlarged view

      Fig. Intake manifold bolt loosening sequence-3.3L engine

       

    8.  

    To install:

    Click image to see an enlarged view

    Fig. Intake manifold bolt torque sequence-3.3L engine

    1. Install the lower intake manifold with a new gasket.
    2.  
    3. Tighten the fasteners in sequence as follows:
      1. Step 1: 35 inch lbs. (4 Nm)
      2.  
      3. Step 2: 78 inch lbs. (9 Nm)
      4.  
      5. Step 3: 70-84 inch lbs. (8-10 Nm)
      6.  

    4.  
    5. Install or connect the following:

      ECT sensor connector
       
      Fuel supply manifold
       
      Right bank injector connectors
       
      Fuel lines
       
      Upper intake manifold
       
      Breather pipe
       
      Upper intake manifold ground cable
       
      Thermal transmitter
       
      Left bank injector connectors
       
      Distributor
       
      Spark plug wires
       
      EGR tube
       
      Fuel pressure regulator vacuum hose
       
      Brake booster vacuum hose
       
      EVAP canister vacuum and purge hoses
       
      PCV valve and hose
       
      Heater hoses
       
      Radiator hoses
       
      EGR temperature sensor connector
       
      EGR Solenoid valve connector
       
      Ignition coil and power transistor connectors
       
      TP sensor and switch connectors
       
      IAC valve connector
       
      Cruise control cable
       
      Accelerator cable
       
      Air intake duct
       
      Negative battery cable
       

    6.  
    7. Fill the cooling system.
    8.  
    9. Start the engine and check for leaks.
    10.  

    4.0L Engine


    Click image to see an enlarged view

    Fig. Intake manifold collector and related components-4.0L engine

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Properly relieve the fuel system pressure.
    4.  
    5. Disconnect the negative battery cable. Drain the cooling system.
    6.  
    7. Remove the engine cover. Remove the air cleaner case (upper) with the mass air flow sensor and air duct assembly.
    8.  
    9. Disconnect the water hoses from the electric throttle control actuator. Disconnect the harness connector.
    10.  
    11. Remove the electric throttle control actuator retaining bolts. Be sure to remove the bolts by reversing the order of the tightening torque sequence.
    12.  
    13. Remove the electric throttle control actuator.
    14.  
    15. Remove the brake booster vacuum hose and the PCV hose. Remove the intake manifold collector support.
    16.  
    17. Disconnect the EVAP hoses and harness connector from the EVAP canister purge volume control solenoid valve. Remove the EVAP canister purge volume control solenoid valve.
    18.  
    19. Remove the VIAS control solenoid valve and vacuum tank.
    20.  
    21. Remove the intake manifold collector retaining bolts. Be sure to remove the bolts by reversing the order of the tightening torque sequence.
    22.  
    23. Remove the intake manifold collector from the engine.
    24.  
    25. Remove the fuel tube and fuel injector assembly.
    26.  
    27. Remove the intake manifold retaining bolts. Be sure to remove the bolts by reversing the order of the tightening torque sequence.
    28.  
    29. Remove the intake manifold from the engine.
    30.  

    To install:

    Click image to see an enlarged view

    Fig. Intake manifold bolt torque sequence-4.0L engine

    1. Installation is the reverse of the removal procedure.
    2.  
    3. Be sure to use new gaskets.
    4.  
    5. Be sure to tighten the intake manifold retaining bolts to specification and in the proper sequence in two or more steps.
    6.  
    7. Be sure to tighten the intake manifold collector retaining bolts to specification and in the proper sequence.
    8.  
    9. Be sure to tighten the electric throttle control actuator retaining bolts to specification and in the proper sequence.
      NOTE
      See throttle valve closed position learning and idle air volume learning procedures, for relearning information.



      Click image to see an enlarged view

      Fig. Intake manifold collector bolt torque sequence-4.0L engine



      Click image to see an enlarged view

      Fig. Electric throttle control actuator bolt torque sequence-4.0L engine

    10.  

     
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