Nissan/Datsun 200SX/510/610/710/810/Maxima 1973-1984 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION



All Models, Except 810, 1980-81 200SX/510 and Maxima

When unplugging wires and hoses, mark each hose and its connection with a piece of masking tape, then match code the 2 pieces of tape with the numbers 1, 2, 3, etc. When assembling, simply match up the pieces of tape.

  1. Remove the air cleaner assembly together with all of the attending hoses.
  2.  
  3. Disconnect the throttle linkage and fuel and vacuum lines from the carburetor.
  4.  
  5. The carburetor can be removed from the manifold at this point or can be removed as an assembly with the intake manifold.
  6.  
  7. Loosen the intake manifold attaching nuts, working from the two ends toward the center, and then remove them.
  8.  
  9. Remove the intake manifold from the engine.
  10.  
  11. Using a putty knife or equivalent, clean the gasket mounting surfaces.
  12.  
  13. Install the intake manifold and gasket on the engine. Always use a new gasket. Tighten the mounting bolts from the center working to the end, in two or three stages. Tighten the intake manifold bolts to 14-19 ft. lbs. or the nuts 12-15 ft. lbs.
  14.  
  15. Install throttle linkage, fuel and vacuum lines and the air cleaner assembly.
  16.  
  17. Start engine and check for leaks.
  18.  

810 and Maxima Models


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Fig. Fig. 1 Location of the intake manifold mounting bolts-gasoline powered 810 models



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Fig. Fig. 2 Exploded view of the intake manifold-to-gasket relationship-diesel powered 810 models



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Fig. Fig. 3 To remove the intake manifold, unbolt the upper bolts



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Fig. Fig. 4 Remove the lower attaching bolts to the manifold



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Fig. Fig. 5 Lift the manifold away from the cylinder head



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Fig. Fig. 6 Before re-installation, the gasket surfaces must be scraped clean thoroughly

Certain procedures may apply only to the gasoline engine. Always release the fuel pressure on fuel injected engines before removing any fuel system component.

  1. Disconnect all hoses to the air cleaner and remove the air cleaner.
  2.  
  3. Disconnect all air, water vacuum and fuel hoses to the intake manifold. Remove the cold start valve and fuel pipe as an assembly. Remove the throttle linkage.
  4.  
  5. Remove the B.P.T. valve control tube from the intake manifold. Remove the EGR hoses.
  6.  
  7. Disconnect all electrical wiring to the fuel injection unit. Note the location of the wires and mark them in some manner to facilitate reinstallation.
  8.  
  9. Make sure all wires, hoses, lines, etc. are removed. Unscrew the intake manifold bolts. Keep the bolts in order since they are of two different sizes. Remove the manifold.
  10.  
  11. Install the intake manifold to the engine. Use a new gasket, clean both sealing surfaces, and tighten the bolts in several stages, working from the center outward.
  12.  
  13. Reconnect all electrical wiring to the fuel injection unit.
  14.  
  15. Install the EGR valve hose and B.P.T. valve control.
  16.  
  17. Reconnect the throttle linkage.
  18.  
  19. Install the fuel pipe assembly and the cold start valve.
  20.  
  21. Reconnect all air, water vacuum and fuel hoses to the intake manifold.
  22.  
  23. Install the air cleaner reconnect all hoses to the correct location.
  24.  
  25. Start engine and check for leaks.
  26.  

1980-81 200SX/510 Models


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Fig. Fig. 7 Remove the manifold with injectors, etc. still attached

Always release the fuel pressure on fuel injected engines before removing any fuel system component.

  1. Drain the coolant and disconnect the battery cable.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. On the fuel injected engine, remove the air cleaner hoses. On the carbureted engine, remove the air cleaner.
  2.  
  3. Remove the radiator hoses from the manifold.
  4.  
  5. For the carbureted engine, remove the fuel, air and vacuum hoses from the carburetor. Remove the throttle linkage and remove the carburetor.
  6.  
  7. Remove the throttle cable and disconnect the fuel pipe and the return fuel line on fuel injection engines. Plug the fuel pipe to prevent spilling fuel.
  8.  

When unplugging wires and hoses, mark each hose and its connection with a piece of masking tape, then match code the two pieces of tape with the numbers 1, 2, 3, etc. When assembling, simply match the pieces of tape.

  1. Remove all remaining wires, tubes, the air cleaner bracket (carbureted engines) and the E.G.R. and P.C.V. tubes from the rear of the intake manifold. Remove the air induction pipe from the front of the carbureted engine. Remove the manifold supports on the fuel injected engine.
  2.  
  3. Unbolt and remove the intake manifold. On fuel injected engines, remove the manifold with injectors, E.G.R. valve, fuel tubes, etc., still attached.
  4.  
  5. Clean the gasket mounting surfaces then install the intake manifold on the engine. Always use a new intake manifold gasket.
  6.  
  7. Connect all electrical connections, tubes, the air cleaner bracket (carbureted engines) and the E.G.R. and P.C.V. tubes to the rear of the intake manifold. Install the air induction pipe to the front of the carbureted engine. Install the manifold supports on the fuel injected engine.
  8.  
  9. Install the throttle cable and reconnect the fuel pipe and the return fuel line on fuel injection engines.
  10.  
  11. Install the carburetor and throttle linkage. Reconnect the fuel, air and vacuum hoses to the carburetor on these models.
  12.  
  13. Install the radiator hoses to the intake manifold.
  14.  
  15. On the fuel injected engine, install the air cleaner hoses. On the carbureted engine, install the air cleaner.
  16.  
  17. Refill the coolant level and connect the battery cable. Start the engine and check for leaks.
  18.  

 
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