Altima 2007-2009

Intake Manifold

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Removal & Installation



2.5L Engine

Specific to:

Nissan Altima 2007-2008

  1. Release the fuel pressure.
  2.  
  3. Drain coolant.
  4.  
  5. Disconnect the Mass Air Flow (MAF) sensor.
  6.  
  7. Remove air cleaner and air duct assembly.
  8.  
  9. Remove windshield wipers and cowl.
  10.  
  11. Disconnect the following components from the intake manifold:

    PCV hose
     
    EVAP hose and EVAP canister purge volume control solenoid
     
    Electric throttle control actuator
     
    Brake booster vacuum hose
     

  12.  
  13. Disconnect the fuel line quick connector on the engine side.
  14.  
  15. Disconnect throttle control actuator coolant hoses.
  16.  
  17. Remove the bolts and nuts and remove the intake manifold assembly. Cover engine openings to avoid entry of foreign materials.
  18.  

To install:

  1. Install a new manifold gasket and fit the manifold into place. Working from the center towards the ends, torque the nuts and bolts to 14 ft. lbs. (20 Nm), then repeat the torque sequence.
  2.  
  3. Reconnect all wiring, hoses and vacuum lines.
  4.  
  5. Refill the cooling system and run the engine to check for leaks.
  6.  
  7. Reinstall the cowl and wiper arms.
  8.  

Specific to:

Nissan Altima 2009-2010


WARNING
To avoid the danger of being scalded, never drain the coolant when the engine is hot.

  1. Release the fuel pressure.
  2.  
  3. Drain coolant when engine is cooled.
  4.  
  5. Disconnect the MAF sensor electrical connector.
  6.  
  7. Remove air cleaner and air duct assembly.
  8.  
  9. Remove cowl top finisher.

    Click image to see an enlarged view

    Fig. Exploded view of intake manifold assembly

  10.  
  11. Disconnect the following components at the intake side:

    PCV hose
     
    EVAP hose and EVAP canister purge volume control solenoid
     
    Electric throttle control actuator
     
    Brake booster vacuum hose
     

  12.  
  13. Disconnect the fuel quick connector on the engine side.
    1. Remove quick connector cap.

      Click image to see an enlarged view

      Fig. Remove quick connector cap

    2.  
    3. With the sleeve side of tool facing quick connector, install tool onto fuel tube.

      Click image to see an enlarged view

      Fig. With the sleeve side of tool facing quick connector, install tool onto fuel tube

    4.  
    5. Insert tool into quick connector until sleeve contacts and goes no further. Hold the tool on that position.
      CAUTION
      Inserting the tool hard will not disconnect quick connector. Hold tool where it contacts and goes no further.

    6.  
    7. Pull the quick connector straight out from the fuel tube.
      CAUTION



      Pull quick connector holding it at the A position, as shown.
       
      Do not pull with lateral force applied. O-ring inside quick connector may be damaged.
       
      Prepare container and cloth beforehand as fuel will leak out.
       
      Avoid fire and sparks.
       
      Be sure to cover openings of disconnected pipes with plug or plastic bag to avoid fuel leakage and entry of foreign materials.
       

    8.  

  14.  
  15. When removing fuel hose quick connector at vehicle piping side, perform as follows.
    1. Remove quick connector cap.
    2.  
    3. Hold the sides of the connector, push in tabs and pull out the tube. (The figure is shown for reference only.)
    4.  
    5. If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling.
      CAUTION



      The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary.
       
      Do not use any tools to remove the quick connector.
       
      Keep the resin tube away from heat. Be especially careful when welding near the tube.
       
      Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube.
       
      Do not bend or twist the tube during installation and removal.
       
      Do not remove the remaining retainer on tube.
       
      When the tube is replaced, also replace the retainer with a new one. Retainer color: Green.
       
      To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.
       

    6.  

  16.  
  17. Disconnect electric throttle control actuator coolant hoses.
  18.  
  19. Loosen bolts diagonally, and remove the electric throttle control actuator.
    CAUTION
    Handle carefully to avoid any damage.

  20.  
  21. Remove the bolts and nuts in the order shown and remove the intake manifold assembly.
    CAUTION
    Cover engine openings to avoid entry of foreign materials.



    Click image to see an enlarged view

    Fig. Remove the bolts and nuts in the order shown

  22.  

To install:

  1. Installation is in the reverse order of removal. Follow the tightening sequences below.
  2.  
  3. Tighten intake manifold bolts and nuts.
    1. Tighten in numerical order as shown.
      CAUTION
      After tightening the five bolts in the order shown, the 1, 6 position designates that the first bolt tightened is to be retightened to specification.



      Click image to see an enlarged view

      Fig. Tighten in numerical order as shown

    2.  

  4.  
  5. Install the Electric Throttle Control Actuator:
    1. Tighten the bolts of electric throttle control actuator equally and diagonally in several steps.
    2.  
    3. After installation perform procedure in "INSPECTION AFTER INSTALLATION".
    4.  

  6.  

Connecting Quick Connector On The Fuel Hose (Engine Side)

Specific to:

Nissan Altima 2009-2010

  1. Make sure no foreign substances are deposited in and around the fuel tube and quick connector, and there is no damage to them.
  2.  
  3. Thinly apply new engine oil around the fuel tube tip end.
  4.  
  5. Align center to insert quick connector straight into fuel tube.
  6.  
  7. Insert fuel tube into quick connector until the top spool on fuel tubes is inserted completely and the second level spool is positioned slightly below the quick connector bottom end.
    CAUTION



    Hold at position A as shown, when inserting the fuel tube into the quick connector.

    Click image to see an enlarged view

    Fig. Hold at position A as shown, when inserting the fuel tube into the quick connector

     
    Carefully align to center to avoid inclined insertion to prevent damage to the O-ring inside the quick connector.
     
    Insert the fuel tube until you hear a -click- sound and actually feel the engagement.
     
    To avoid misidentification of engagement with a similar sound, be sure to perform the next step.
     

  8.  
  9. Before clamping the fuel hose with the hose clamp, pull the quick connector hard by hand, holding at the A position, as shown. Make sure it is completely engaged (connected) so that it does not come off of the fuel tube.
    NOTE
    Recommended pulling force is 11 lbs. (50 N).

  10.  
  11. Install quick connector cap on quick connector joint.

    Click image to see an enlarged view

    Fig. Install quick connector cap on quick connector joint

  12.  
  13. Direct arrow mark on quick connector cap to upper side (fuel hose side).
  14.  
  15. Install fuel hose to hose clamp.
  16.  

Connecting Quick Connector On The Fuel Hose (Vehicle Piping Side)

Specific to:

Nissan Altima 2009-2010

  1. Make sure no foreign substances are deposited in and around the fuel tube and quick connector, and there is no damage to them.
  2.  
  3. Align center to insert quick connector straight into fuel tube.

    Click image to see an enlarged view

    Fig. Align center to insert quick connector straight into fuel tube

    1. Insert fuel tube until a click is heard.
    2.  
    3. Install quick connector cap on quick connector joint. Direct arrow mark on quick connector cap upper side.
    4.  
    5. Install fuel hose to hose clamp.
    6.  

  4.  

Inspection After Installation

Specific to:

Nissan Altima 2009-2010

  1. Make sure there is no fuel leakage at connections as follows:
    1. Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections.
    2.  
    3. Start the engine and rev it up and check for fuel leaks at connections.
    4.  
    5. Perform procedures for -Throttle Valve Closed Position Learning- after finishing repairs.
    6.  
    7. If electric throttle control actuator is replaced, perform procedures for -Idle Air Volume Learning- after finishing repairs.
      WARNING
      Do not touch engine immediately after stopping as engine is extremely hot.


      NOTE
      Use mirrors for checking on connections out of the direct line of sight.

    8.  

  2.  

3.5L Engine

Specific to:

Nissan Altima 2007-2008

  1. Remove the upper intake manifold.
    NOTE
    Cover any engine openings to avoid the entry of any foreign material.



    Remove air cleaner case lid, mass air flow sensor, and air intake tube as one assembly.
     
    Partially drain the coolant.
     
    Disconnect fuel tube quick connector at the fuel rail by pressing in the tabs on the sides and pulling straight out.
     
    Disconnect the power brake booster vacuum hose, the coolant hoses from the electric throttle control actuator, the swirl control vacuum lines, the fuel injectors electrical connectors, and the PCV hose.
     



    Disconnect the electric throttle control actuator electrical connector and coolant hoses.
     
    Remove the wiper blades and cowl.
     
    Remove the upper intake manifold.
     

  2.  

Specific to:

Nissan Altima 2009-2010


WARNING
To avoid the danger of being scalded, never drain the coolant when the engine is hot.

  1. Release the fuel pressure.
  2.  
  3. Disconnect the battery negative terminal.
  4.  
  5. Remove the cowl top.
  6.  
  7. Remove the engine cover.
  8.  
  9. Remove front air duct and air duct hose.
  10.  
  11. If necessary, remove the electric throttle control actuator bolts in the reverse order as shown and remove the electric throttle control actuator and position aside.
    CAUTION
    Handle carefully to avoid any shock to the electric throttle control actuator. Do not disassemble.



    Click image to see an enlarged view

    Fig. Remove the electric throttle control actuator bolts in the reverse order as shown

  12.  
  13. If necessary, remove power valve bolts in the reverse order as shown and remove the power valves.

    Click image to see an enlarged view

    Fig. Remove power valve bolts in the reverse order as shown

  14.  
  15. Disconnect the following:
    CAUTION
    Cover any engine openings to avoid the entry of any foreign material.



    Power brake booster vacuum hose
     
    Fuel injector electrical connectors
     
    PCV hose
     
    Electric throttle control actuator electrical connector
     
    EVAP canister purge hose
     

  16.  
  17. Remove the EVAP canister purge volume solenoid valve bracket bolt. Position the valve aside.
  18.  
  19. Loosen the intake manifold collector bolts in the order as shown, and remove the intake manifold collector and gasket.

    Click image to see an enlarged view

    Fig. Loosen the intake manifold collector bolts in the order as shown

  20.  
  21. If necessary remove the following components:

    VIAS control solenoid valve
     
    EVAP canister purge volume control solenoid valve
     

  22.  
  23. Disconnect fuel tube quick connector at vehicle piping side.
  24.  
  25. To remove the quick connector cap, hold the sides of the connector, push in the tabs and pull out the tube.
    CAUTION


    NOTE
    If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling.



    The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary.
     
    Do not use any tools to remove the quick connector.
     
    Keep the resin tube away from heat. Be especially careful when welding near the tube.
     
    Prevent acid liquids such as battery electrolyte, etc. from getting on the resin tube.
     
    Do not bend or twist the tube during removal or installation.
     
    Do not remove the remaining retainer on the tube
     
    When the tube is replaced, also replace the retainer with a new one.
     
    To keep the connecting portion clean and to avoid damage and foreign materials entering, cover the ends of the fuel tubes with plastic bags or something similar.
     

  26.  
  27. Remove the fuel rail with the fuel injectors attached, from the intake manifold. Remove the fuel injector O-rings and use new O-rings for installation.
  28.  
  29. Loosen the bolts in the order as shown, and remove the intake manifold.

    Click image to see an enlarged view

    Fig. Loosen the bolts in the order as shown

  30.  

To install:

  1. Installation is in the reverse order of removal. Follow the procedure below for specific tightening sequences and procedures.
  2.  
  3. Install intake manifold bolts in two steps in the numerical order as shown.

    Click image to see an enlarged view

    Fig. Install intake manifold bolts in two steps in the numerical order as shown

    1. Step 1: 65 inch lbs. (7 Nm)
    2.  
    3. Step 2: 19 ft. lbs. (25 Nm)
      NOTE
      After installation, it is necessary to re-calibrate the electric throttle control actuator.

    4.  

  4.  
  5. Perform the "Throttle Valve Closed Position Learning" when harness connector of the electric throttle control actuator is disconnected.
  6.  
  7. Perform the "Idle Air Volume Learning" when the electric throttle control actuator is replaced.
  8.  
  9. Install the quick connector as follows:
    1. Make sure no foreign substances are deposited in and around the fuel tube and quick connector and that there is no damage.
    2.  
    3. Align the center to insert the quick connector straight onto the fuel tube.
    4.  
    5. Insert the fuel tube until a click is heard.
    6.  
    7. Install the quick connector cap on the quick connector joint. Align the arrow mark on the quick connector cap to the upper side.
    8.  
    9. Install the fuel hose into the hose clamp.
    10.  

  10.  

Inspection After Installation
  1. Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections.
  2.  
  3. Start the engine and rev it up and check for fuel leaks at connections.
    CAUTION
    Do not touch engine immediately after stopping as engine is extremely hot.


    NOTE
    Use mirrors for checking on connections out of the direct line of sight.

  4.  

 
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