Altima 2007-2009

Exhaust Manifold

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Removal & Installation



2.5L Engine

Specific to:

Nissan Altima 2007-2008

  1. Remove the engine undercover.
  2.  
  3. Disconnect the air fuel ratio (A/F) sensor, unhook the harness from the bracket and remove the sensor.
  4.  
  5. Remove the lower exhaust manifold covers.
  6.  
  7. Remove the front exhaust pipe.
  8.  
  9. Remove the upper exhaust manifold cover.
  10.  
  11. Loosen the manifold nuts and remove the exhaust manifold and three way catalyst. Discard the gasket.
  12.  

To install:

  1. Install a new gasket and fit the manifold/catalyst into place.
  2.  
  3. Install the nuts and torque in sequence to 11 ft. lbs. (15 Nm).

    Click image to see an enlarged view

    Fig. Exhaust manifold bolt torque sequence-2.5L engine

  4.  
  5. Install the exhaust pipe and torque the bolts to 11 ft. lbs. (15 Nm).
  6.  
  7. Install the A/F sensor and reconnect the wiring.
  8.  

Specific to:

Nissan Altima 2009-2010

  1. Remove the engine undercover.
  2.  
  3. Disconnect the electrical connector of Air Fuel Ratio (A/F) sensor 1, and unhook the harness from the bracket and middle clamp on the cover.
  4.  
  5. Remove the Air Fuel Ratio (A/F) sensor 1 using Tool J-44626.
    CAUTION
    Be careful not to damage Air Fuel Ratio (A/F) sensor. Discard any Air Fuel Ratio (A/F) sensor which has been dropped from a height of more than 20 inches (0.5 m) onto a hard surface such as a concrete floor; replace with a new one.

  6.  
  7. Remove the exhaust manifold cover (lower).
  8.  
  9. Remove the exhaust front tube.
  10.  
  11. Remove the exhaust manifold cover (upper).
  12.  
  13. Loosen the nuts in the reverse order as shown, on the exhaust manifold and three way catalyst assembly.

    Click image to see an enlarged view

    Fig. Loosen the nuts in the reverse order as shown

  14.  
  15. Remove the exhaust manifold and three way catalyst assembly and gasket. Discard the gasket.

    Click image to see an enlarged view

    Fig. Exploded view of exhaust manifold and three way catalyst

  16.  

To install:

  1. Installation is in the reverse order of removal.
  2.  
  3. Tighten the nuts in two steps to 31 ft. lbs. (42 Nm) in the numerical order shown, on the exhaust manifold and three way catalyst assembly.

    Click image to see an enlarged view

    Fig. Tighten the nuts to specification in the numerical order shown

  4.  
  5. Clean the Air Fuel Ratio (A/F) sensor 1 threads with the Tool, then apply the anti-seize lubricant to the threads before installing the Air Fuel Ratio (A/F) sensor 1.
    CAUTION
    Do not over-tighten the Air Fuel Ratio (A/F) sensor 1. Doing so may cause damage to the Air Fuel Ratio (A/ F) sensor 1, resulting in a malfunction and the MIL coming on.

  6.  

3.5L Engine

Specific to:

Nissan Altima 2007-2008


NOTE
This procedure requires removing the front subframe. When removing the front and rear engine mount bolts and nuts, lift the engine up slightly for safety.

  1. Raise and safely support the vehicle and remove the front wheel.
  2.  
  3. Remove the engine undercover.
  4.  
  5. Remove the inner wheel well splash shields.
  6.  
  7. Remove the radiator and cooling fan assembly.
  8.  
  9. Remove the front exhaust pipe.
  10.  
  11. Remove the front suspension subframe.

    Remove nut on lower portion of stabilizer bar connecting rod from lower suspension arm.
     
    Remove suspension arm from subframe and swing it outward.
     
    Remove front exhaust pipe.
     
    Support engine or transmission with a jack.
     
    Remove steering gear bolts. Remove steering gear and power steering tube bracket from suspension member. Hang steering gear.
     
    Set a jack under subframe and remove the nuts.
     
    Slowly lower jack to remove subframe from vehicle.
     

  12.  
  13. Remove the left and right catalyst supports.
  14.  
  15. Disconnect and remove the oxygen sensors and air ratio (A/F) sensors.
  16.  
  17. Remove exhaust manifold and three way catalyst heat shields.
  18.  
  19. Remove the catalysts by loosening the bolts first and then removing the nuts and through bolts.
  20.  
  21. To remove the exhaust manifolds, loosen the nuts in reverse of the installation order.

    Click image to see an enlarged view

    Fig. Exhaust manifold bolt torque sequence-3.5L engine

  22.  

To install:

  1. Install a new manifold gasket and fit the manifold into place.
  2.  
  3. Torque the nuts in order to 23 ft. lbs. (31 Nm).
  4.  
  5. If removed, install the catalysts using new gaskets and torque the bolts to 52 ft. lbs. (70 Nm).
  6.  
  7. Install the sensors and heat shields.
  8.  
  9. Raise the subframe into place and start all fasteners:

    Torque the large subframe bolts to 107 ft. lbs. (145 Nm).
     
    Torque the suspension arm bolts to 114 ft. lbs. (155 Nm).
     

  10.  
  11. Reconnect steering gear and stabilizer bar.
  12.  
  13. Install remaining components and run the engine to check for leaks.
  14.  

CVT Models

Specific to:

Nissan Altima 2009-2010


WARNING



Perform the work when the exhaust and cooling system have completely cooled down.
 
When removing the front and rear engine mounting through bolts and nuts, lift the engine up slightly for safety.
 

  1. Remove the engine and transaxle assembly.
  2.  
  3. Remove the RH and LH three way catalyst support brackets.
  4.  
  5. Remove heated oxygen sensor 2 (bank 1), heated oxygen sensor 2 (bank 2), Air Fuel Ratio (A/F) sensor 1 (bank 1) and Air Fuel Ratio (A/F) sensor 1 (bank 2).
    1. Remove harness connector of each sensor, and disconnect the harness from the bracket and middle clamp.
    2.  
    3. Remove both heated oxygen sensors and air fuel ratio (A/F) sensors using Tool.
      CAUTION
      Be careful not to damage heated oxygen sensors or Air Fuel Ratio (A/F) sensors. Discard any heated oxygen sensor which has been dropped from a height of more than 20 inches (0.5 m) onto a hard surface such as a concrete floor; replace with a new sensor.

    4.  

  6.  
  7. Remove exhaust manifold and three way catalyst heat shields.
  8.  
  9. Remove the three way catalyst (manifold) (bank 1) and three way catalyst (manifold) (bank 2) by loosening the bolts first and then removing the nuts and through bolts.
  10.  
  11. Remove the exhaust manifolds RH and LH. Loosen the exhaust manifold nuts in the order as shown.

    Click image to see an enlarged view

    Fig. Remove the exhaust manifolds RH (A) and LH (B); loosen the exhaust manifold nuts in the order as shown

  12.  

To install:

  1. Installation is in the reverse order of removal.
  2.  
  3. Install the exhaust manifold nuts in the order as shown RH and LH.

    Click image to see an enlarged view

    Fig. Install the exhaust manifold nuts in the order as shown RH (A)



    Click image to see an enlarged view

    Fig. Install the exhaust manifold nuts in the order as shown LH (B)

  4.  
  5. Install RH (A) and LH (B) three way catalyst support brackets.
  6.  
  7. Hand tighten the three way catalyst support bracket bolts to seat the support brackets.
  8.  
  9. Tighten the bolts to 16 ft. lbs. (22 Nm) in the numerical order as shown.
    CAUTION
    Do not tighten if support brackets do not fit tightly against oil pan and three way catalysts.


    CAUTION
    Before installing a heated oxygen sensor or Air Fuel Ratio (A/F) sensor, clean the exhaust manifold threads using the oxygen sensor thread cleaner tool, and apply anti-seize lubricant. Do not over-tighten the Air Fuel Ratio (A/F) sensor or heated oxygen sensors. Doing so may cause damage.

  10.  

Left Side

Specific to:

Nissan Altima 2009-2010


WARNING
Perform the work when the exhaust and cooling system have completely cooled down.

  1. Remove the front air duct and air cleaner assembly.
  2.  
  3. Remove the cooling fan assembly.
  4.  
  5. Disconnect the heater hoses.
  6.  
  7. Remove the front suspension member.
  8.  
  9. Remove the front engine mounting bracket.
  10.  
  11. Remove the LH three way catalyst support bracket.
  12.  
  13. Remove heated oxygen sensor 2 (bank 2) and Air Fuel Ratio (A/F) sensor 1 (bank 2).
    1. Remove harness connector of each sensor, and disconnect the harness from the bracket and middle clamp.
    2.  
    3. Remove both heated oxygen sensor and Air Fuel Ratio (A/F) sensor using Tool.
      CAUTION
      Be careful not to damage heated oxygen sensor or Air Fuel Ratio (A/F) sensor. Discard any heated oxygen sensor which has been dropped from a height of more than 20 inches (0.5 m) onto a hard surface such as a concrete floor; replace with a new sensor.

    4.  

  14.  
  15. Remove exhaust manifold and three way catalyst heat shields.
  16.  
  17. Remove the three way catalyst (manifold) (bank 2) by loosening the bolts first and then removing the nuts and through bolts.
  18.  
  19. Remove the exhaust manifold LH (B). Loosen the exhaust manifold nuts in the order as shown.

    Click image to see an enlarged view

    Fig. Loosen the exhaust manifold nuts in the order as shown

  20.  

To install:

  1. Installation is in the reverse order of removal.
  2.  
  3. Install the exhaust manifold nuts in the order as shown RH (A) and LH (B).

    Click image to see an enlarged view

    Fig. Install the exhaust manifold nuts in the order as shown RH



    Click image to see an enlarged view

    Fig. Install the exhaust manifold nuts in the order as shown LH

  4.  
  5. Install RH and LH three way catalyst support brackets.

    Click image to see an enlarged view

    Fig. Install RH (A) and LH (B) three way catalyst support brackets

  6.  
  7. Hand tighten the three way catalyst support bracket bolts to seat the support brackets.
  8.  
  9. Tighten the bolts to 16 ft. lbs. (22 Nm) in the numerical order as shown.
    CAUTION
    Do not tighten if support brackets do not fit tightly against oil pan and three way catalysts.


    CAUTION
    Before installing a heated oxygen sensor or Air Fuel Ratio (A/F) sensor, clean the exhaust manifold threads using the oxygen sensor thread cleaner tool, and apply anti-seize lubricant. Do not over-tighten the Air Fuel Ratio (A/F) sensor or heated oxygen sensors. Doing so may cause damage.

  10.  

Right Side

Specific to:

Nissan Altima 2009-2010


WARNING
Perform the work when the exhaust and cooling system have completely cooled down.



Click image to see an enlarged view

Fig. Exploded view of exhaust manifold and three way catalyst

  1. Remove the front air duct and air cleaner assembly.
  2.  
  3. Disconnect the EVAP vacuum hose and brake booster vacuum hose.
  4.  
  5. Remove cowl top.
  6.  
  7. Remove the front suspension member.
  8.  
  9. Remove the rear engine mounting bracket.
  10.  
  11. Remove the RH three way catalyst support bracket.
  12.  
  13. Remove heated oxygen sensor 2 (bank 1) and Air Fuel Ratio (A/F) sensor 1 (bank 1).
    1. Remove harness connector of each sensor, and disconnect the harness from the bracket and middle clamp.
    2.  
    3. Remove both heated oxygen sensor and Air Fuel Ratio (A/F) sensor using Tool.
      CAUTION
      Be careful not to damage heated oxygen sensor or Air Fuel Ratio (A/F) sensor. Discard any heated oxygen sensor which has been dropped from a height of more than 20 inches (0.5 m) onto a hard surface such as a concrete floor; replace with a new sensor.

    4.  

  14.  
  15. Remove exhaust manifold and three way catalyst heat shields.
  16.  
  17. Remove the three way catalyst (manifold) (bank 1) by loosening the bolts first and then removing the nuts and through bolts.
  18.  
  19. Remove the exhaust manifold RH (A). Loosen the exhaust manifold nuts in the order as shown.

    Click image to see an enlarged view

    Fig. Loosen the exhaust manifold nuts in the order as shown

  20.  

 
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