Nissan Pick-ups and Pathfinder 1989-1995

Intake Manifold

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REMOVAL & INSTALLATION



Z24i and KA24E Engines

See Figures 1 and 2

Always relieve the fuel pressure before removing any fuel system component.

  1. Relieve the fuel system pressure, as described in Fuel System .
  2.  
  3. Drain the coolant and disconnect the negative battery cable.
  4.  


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. Remove the air cleaner hoses.
  2.  
  3. Disconnect the radiator hoses from the intake manifold.
  4.  
  5. Remove the throttle cable, then disconnect the fuel pipe and the return fuel line. Plug the fuel pipe to prevent fuel spillage.
  6.  



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Fig. Fig. 1: Intake manifold-Z24i engine



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Fig. Fig. 2: Intake manifold-KA24E engine

Before unplugging wires and hoses, mark each wire or hose and its connection with a piece of masking tape, then mark 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 and tubes, including the EGR and PCV tubes, from the rear of the intake manifold. Remove the manifold supports.
  2.  
  3. Unbolt the intake manifold. Remove the manifold with injectors.
  4.  

To install:
  1. Clean the gasket mounting surfaces, then install the intake manifold on the engine. Always use a new intake manifold gasket. Tighten the mounting bolts outward from the center (using multiple passes) to 12-15 ft. lbs. (16-21 Nm).
  2.  
  3. Fasten all electrical connections and tubes, including the EGR and PCV tubes, to the rear of the intake manifold. Install the manifold supports.
  4.  
  5. Reconnect the fuel pipe and the return fuel line, then install the throttle cable.
  6.  
  7. Connect the radiator hoses to the intake manifold.
  8.  
  9. Install the air cleaner hoses.
  10.  
  11. Refill the coolant level and connect the battery cable. Start the engine and check for leaks.
  12.  

VG30i Engine

See Figures 3, 4 and 5

  1. Relieve the fuel system pressure (refer to Fuel System ), then disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  


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.

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Fig. Fig. 3: Intake manifold assembly bolt loosening sequence-VG30i engine



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Fig. Fig. 4: Intake manifold assembly bolt torque sequence-VG30i engine



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Fig. Fig. 5: Intake manifold assembly-VG30i engine


  1. Disconnect all valves, lines, hoses, cables and or brackets to gain access to the intake manifold assembly retaining bolts.
  2.  
  3. Remove the intake manifold and injection unit assembly. Loosen the intake manifold bolts (in steps) in the sequence shown.
  4.  

To install:
  1. Install the intake manifold and injection unit assembly with a new gasket to the engine. Tighten the manifold bolts and nuts in two or three stages, to 12-14 ft. lbs. (16-20 Nm) in the order shown.
  2.  
  3. Connect all valves, lines, hoses, cables and or brackets to the intake manifold assembly.
  4.  
  5. Refill the cooling system. Reconnect the battery cables.
  6.  
  7. Check fluid levels, then start the engine and check for leaks.
  8.  

VG30E Engine

See Figures 6, 7, 8 and 9

  1. Relieve the fuel system pressure (refer to Fuel System ), then disconnect the negative battery cable.
  2.  
  3. Drain the coolant by removing drain plugs from both sides of the cylinder block.
  4.  


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. Disconnect all valves, lines, hoses, cables and or brackets to gain access to the collector assembly retaining bolts.
  2.  



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Fig. Fig. 6: Intake manifold bolt loosening sequence-VG30E engine



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Fig. Fig. 7: Intake manifold bolt torque sequence-VG30E engine



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Fig. Fig. 8: Removing the intake manifold assembly-read the entire service procedure before beginning this repair



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Fig. Fig. 9: ALWAYS replace the intake manifold gasket upon installation

  1. Remove the collector-to-intake manifold bolts (working from the end bolts to the center bolts).
  2.  
  3. Disconnect the fuel feed and return lines from the injector fuel tube assembly.
  4.  
  5. Detach all fuel injector harness connectors.
  6.  
  7. Remove the injector fuel tube assembly.
  8.  
  9. Tag and separate the engine temperature switch harness connector as well as the thermal transmitter harness connector. Disconnect the coolant line at the thermostat housing.
  10.  
  11. Loosen the intake manifold bolts using multiple passes of the sequence shown, then remove the manifold from the engine.
  12.  

To install:
  1. Install the intake manifold and a new gasket to the engine. Tighten the manifold bolts and nuts (in two or three stages) to 2.2-3.6 ft. lbs. (3-5 Nm), then tighten all bolts to 12-14 ft. lbs. (16-20 Nm) and all nuts to 17-20 ft. lbs. (24-27 Nm), in the order shown.
  2.  
  3. Fasten the engine temperature switch harness connector and the thermal transmitter harness connector. Install the coolant line at the thermostat housing.
  4.  
  5. Install the injector fuel tube assembly.
  6.  
  7. Secure all fuel injector harness connectors.
  8.  
  9. Connect the fuel feed and fuel return lines to the injector fuel tube assembly.
  10.  
  11. Install the collector assembly with a new gasket. Tighten the collector-to-intake manifold bolts in two or three stages (working from the center bolts outward) to 13-16 ft. lbs. (18-22 Nm).
  12.  
  13. Connect all valves, lines, hoses, cables and or brackets to the collector assembly.
  14.  
  15. Refill the cooling system. Reconnect the battery cable.
  16.  
  17. Check all fluid levels and add, as necessary, then start the engine and check for leaks.
  18.  

 
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