Nissan 240SX/Altima 1993-1998 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7 and 8



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Fig. Fig. 1: Exploded view of the passenger's side outer engine components-240SX



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Fig. Fig. 2: Exploded view of the rear side outer engine components-Altima



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Fig. Fig. 3: View of the intake manifold bolt locations-they are hard to see on an assembled engine



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Fig. Fig. 4: Intake manifold bolt loosening sequence



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Fig. Fig. 5: Intake manifold bolt tightening sequence



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Fig. Fig. 6: Collector bolt tightening sequence



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Fig. Fig. 7: Throttle body tightening sequence



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Fig. Fig. 8: Intake manifold brace locations


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. The fuel system will remain under pressure after the ignition has been turned OFF.

Altima

During the teardown and photo session on the Altima seen in this guide, removing the intake manifold without removing the entire cylinder head is all but impossible. Most of the bolts which attach the intake manifold to the cylinder head are either hidden or cannot be accessed with standard tools. In addition, clearance around the intake manifold is limited.

Conditions on the vehicle you are servicing may be different and only you can decide if the procedure is within the scope of your ability. Take into consideration the time, effort and money you will spend prior to deciding to do the procedure yourself. Some things are best left to the experts. If you do decide to undertake this job, refer to the Cylinder Head removal and installation procedure, later in this section.

240SX
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Remove the air duct between the air flow meter and the throttle body.
  8.  
  9. Disconnect the throttle cable and the cruise control cable, if so equipped.
  10.  
  11. Disconnect the fuel supply and return lines from the fuel injector assembly. Plug the lines to prevent leakage.
  12.  
  13. Label and disconnect all appropriate electrical harnesses.
  14.  
  15. Label and disconnect all appropriate vacuum hoses.
  16.  
  17. Label and disconnect the spark plug wires from the spark plugs.
  18.  
  19. Remove the throttle body assembly from the intake manifold.
  20.  
  21. Disconnect the EGR valve tube from the exhaust manifold.
  22.  
  23. Remove the intake manifold mounting brackets.
  24.  
  25. Remove the intake manifold collector-to-intake manifold bolts/nuts in the reverse order of their tightening sequence.
  26.  
  27. Separate the collector from the intake manifold.
  28.  
  29. Remove the intake manifold-to-cylinder head bolts in the reverse order of their tightening sequence.
  30.  
  31. Remove the intake manifold from the engine.
  32.  

To install:
  1. Clean the gasket mating surfaces thoroughly.
  2.  
  3. Check the gasket mating surfaces for warpage and compare with the values in the applicable Specifications chart (later in this section).
  4.  
  5. Inspect the intake manifold/collector for damage. Repair or replace components as necessary.
  6.  
  7. Using new gaskets, install the intake manifold to the cylinder head and tighten the mounting bolts/nuts in the indicated sequence to 12-14 ft. lbs. (1-3 Nm).
  8.  
  9. Using new gaskets, install the collector to the intake manifold and tighten the mounting bolts/nuts in the illustrated sequence to 12-14 ft. lbs. (1-3 Nm).
  10.  
  11. Install the intake manifold mounting brackets.
  12.  
  13. Connect the EGR valve tube to the exhaust manifold.
  14.  
  15. Using a new gasket, install the throttle body and tighten the mounting bolts in a crisscross pattern to 13-1 ft. lbs. (5-7 Nm). Be sure to tighten the bolts in two progressive steps.
  16.  
  17. Connect the spark plug wires to the spark plugs.
  18.  
  19. Connect all appropriate vacuum hoses.
  20.  
  21. Connect all appropriate electrical harnesses.
  22.  
  23. Connect the fuel supply and return lines to the fuel injector assembly.
  24.  
  25. Connect the throttle cable and the cruise control cable, if so equipped.
  26.  
  27. Install the air duct between the air flow meter and the throttle body.
  28.  
  29. Fill and bleed the cooling system.
  30.  
  31. Connect the negative battery cable.
  32.  

 
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