Nissan Sentra/Pulsar/NX 1982-1996 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION




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.

Carbureted E-Series Engines
  1. Remove the air cleaner assembly together with all of the hoses.
  2.  

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. Disconnect and label the throttle linkage, the fuel and the vacuum lines from the carburetor and the intake manifold components.
  2.  

The carburetor can be removed from the manifold at this point or can be removed as an assembly with the intake manifold.

  1. Remove the intake manifold bolts or nuts and the manifold from the engine.
  2.  
  3. Using a putty knife, clean the gasket mounting surfaces.
  4.  

To install:
  1. 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. Torque the intake manifold bolts to 12-15 ft. lbs. (15-18 Nm).
  2.  
  3. Install throttle linkage, fuel and vacuum lines and the air cleaner assembly.
  4.  
  5. Start engine and check for leaks.
  6.  

1983-87 1.7L Diesel Engine

See Figure 1



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Fig. Fig. 1: Intake manifold gasket positioning-1.7L diesel engine

  1. Disconnect the negative (-) battery cable and drain the engine coolant.
  2.  
  3. Remove the air intake hose.
  4.  
  5. Disconnect the EGR tube, PCV assembly and solenoid valve. Place hoses out of the way.
  6.  
  7. Remove the manifold retaining bolts and remove the manifold.
  8.  

To install:
  1. Clean the gasket mating surfaces.
  2.  
  3. Install a new gasket with the end tab facing the No. 1 cylinder.
  4.  
  5. Install the manifold and torque the bolts to 13-16 ft. lbs. (18-22 Nm).
  6.  
  7. Install the remaining components. Apply anti-seize compound to the EGR tube and torque to 35 ft. lbs. (48 Nm).
  8.  
  9. Connect the negative (-) battery cable and check operation.
  10.  

1984 E15ET Turbocharged Engine

Refer to the Fuel Release Procedure in Fuel System and release the fuel pressure.

  1. Disconnect the air intake duct between the air filter and the air pipe, then the air intake duct between the air pipe and the turbocharger. Remove the air inlet duct between the turbocharger and the throttle body. Remove the air pipe.
  2.  
  3. Disconnect and label all of the electrical connectors and the vacuum hoses to the throttle, the intake manifold assembly and the related components. Remove the high tension wires from the spark plugs.
  4.  
  5. Disconnect the EGR valve tube from the exhaust manifold and the fuel line(s) from the fuel injector assembly.
  6.  

For clearance purposes, it may be necessary to remove the throttle body and the collector chamber from the intake manifold; if the fuel injector assembly is in the way, remove it.

  1. Remove the intake manifold mounting nuts and the intake manifold.
  2.  

To install:
  1. Using a putty knife, clean the gasket mounting surfaces.
  2.  
  3. 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. Torque the intake manifold-to-cylinder head nuts to 12-15 ft. lbs. (16-20 Nm), the intake manifold-to-collector chamber bolts to 35-52 inch lbs. (16-20 Nm) and the air pipe bolt(s) to 78-121 inch lbs. (9-14 Nm).
  4.  
  5. Install the throttle body and the collector chamber on the intake manifold if it was removed.
  6.  
  7. Connect the EGR valve tube to the exhaust manifold and the fuel line(s) to the fuel injector assembly.
  8.  
  9. Install the spark plug wires, electrical connectors and the vacuum hoses to the throttle, the intake manifold assembly and the related components.
  10.  
  11. Connect the air intake duct between the air filter and the air pipe, then connect the air intake duct between the air pipe and the turbocharger. Install the air inlet duct between the turbocharger and the throttle body. Connect the air pipe.
  12.  
  13. Start engine and check for leaks.
  14.  

1987-90 CA16DE, CA18DE, E16i and GA16i Engines

See Figures 2, 3 and 4



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Fig. Fig. 2: Intake manifold loosening sequence-start at the outer corners and crisscross to the center



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Fig. Fig. 3: Intake manifold tightening sequence-start at the center and crisscross to the outer corners



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Fig. Fig. 4: Do not loosen this power valve adjusting screw on the CA16DE or CA18DE engine. This screw is adjusted on the production line at the factory

Refer to the Fuel Release Procedure in Fuel System and release the fuel pressure in the system.

  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 throttle body on the engines).
  4.  
  5. The throttle body can be removed from the manifold at this point or can be removed as an assembly with the intake manifold.
  6.  
  7. Remove the manifold support stay on the CA16DE and CA18DE.
  8.  
  9. Remove the EGR valve assembly, air regulator and F.I.C.D valve from the manifold on the CA16DE and CA18DE.
  10.  
  11. Loosen the intake manifold attaching nuts, working from the two ends toward the center, and then remove them.
  12.  

NEVER tighten or loosen the power valve adjusting screw on the CA16DE or CA18DE engines.

  1. Remove the intake manifold from the engine.
  2.  
  3. Install the intake manifold and gasket on the engine. Always use a new gasket. Tighten the intake manifold attaching nuts, working from the center toward the ends, in two or three stages. Torque the intake manifold to 12-15 ft. lbs. (15-18 Nm) on the E16i and GA16i engines and 27-35 ft. lbs. (34-48 Nm) on the CA16DE and CA18DE engines.
  4.  
  5. Install the EGR valve assembly, air regulator and F.I.C.D valve on the manifold on the CA16DE and CA18DE engine, if equipped.
  6.  
  7. Connect the manifold support stay on the CA16DE and CA18DE engines.
  8.  
  9. Install the throttle body if it was removed, then reconnect all fuel and vacuum lines and any related components.
  10.  
  11. Reconnect the throttle linkage and air cleaner assembly and all hoses.
  12.  

Don't forget to install the support stay on the CA16DE and CA18DE engines.

  1. Start engine and check for leaks.
  2.  

GA16DE Engine

See Figures 5, 6, 7 and 8



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Fig. Fig. 5: Intake manifold collector bolts tightening sequence-GA16DE engine



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Fig. Fig. 6: Intake manifold nuts and bolts tightening sequence-GA16DE engine



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Fig. Fig. 7: Throttle body tightening sequence-GA16DE engine



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Fig. Fig. 8: Throttle body gasket positioning-GA16DE engine


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury. Refer to Fuel System for fuel pressure relieving procedures.

  1. Relieve the fuel system pressure, disconnect the negative (-) battery cable, and drain the cooling system.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Disconnect and tag the throttle linkage, electrical connections and vacuum lines from the throttle body.
  6.  
  7. Remove the intake manifold collector support brackets.
  8.  
  9. The throttle body can be removed from the manifold at this point or can be removed as an assembly with the intake manifold.
  10.  
  11. Remove the bolts holding the upper portion of the intake to the lower portion. Remove the bolts in reverse order of the tightening sequence.
  12.  
  13. Remove the upper portion of the intake.
  14.  
  15. Disconnect the fuel injector wiring harness connectors and the vacuum line from the fuel pressure regulator.
  16.  
  17. Disconnect the fuel hoses from the fuel rail assembly.
  18.  
  19. Remove the bolts that secure the fuel rail to the intake.
  20.  
  21. Remove the injectors with the fuel rail assembly.
  22.  
  23. Loosen the intake manifold retaining bolts in the proper sequence and separate the manifold from the cylinder head. Remove the bolts in reverse order of the tightening sequence
  24.  
  25. Remove the intake manifold gasket and clean all the gasket contact surfaces thoroughly with a gasket scraper and suitable solvent. All traces of old gasket material must be removed to ensure proper sealing. Inspect the intake manifold for cracks. Using a metal straightedge, check the surface of the intake manifold for warpage.
  26.  

To install:
  1. Lay the new intake manifold gasket onto the cylinder head and position the lower intake manifold over the mounting studs and onto the gasket. Install the mounting nuts and bolts; torque them to 13-15 ft. lbs. (18-21 Nm) in sequence.
  2.  
  3. Install the injectors with the fuel rail assembly. Be sure to install the fuel rail insulators.
  4.  
  5. Install the bolts that secure the fuel rail to the intake. Torque the bolts in two steps to 13-15 ft. lbs. (18-21 Nm).
  6.  
  7. Connect the fuel injector wiring harness connectors and the vacuum line from the fuel pressure regulator.
  8.  
  9. Using new hose clamps, connect the fuel hoses from the fuel rail assembly.
  10.  
  11. Using a new gasket, install the upper portion of the intake manifold and torque the bolts to 13-15 ft. lbs. (18-21 Nm) in sequence.
  12.  
  13. If removed, install the throttle body or throttle chamber and tighten the mounting bolts in a crisscross pattern. Torque the bolts in two progressive steps to 13-16 ft. lbs. (18-22 Nm).
  14.  

Be sure to properly position the throttle body gasket with the cutout facing down.

  1. Install the intake manifold collector support brackets.
  2.  
  3. Connect the throttle linkage, electrical connections and vacuum lines.
  4.  
  5. Install the air cleaner.
  6.  
  7. Fill the cooling system to the proper level and connect the negative (-) battery cable.
  8.  
  9. Start the engine, bleed the cooling system, and check for leaks.
  10.  
  11. Road test the vehicle for proper operation.
  12.  

2.0L (SR20DE) Engine

See Figures 9, 10, 11, 12, 13, 14 and 15



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Fig. Fig. 9: Removing the intake manifold



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Fig. Fig. 10: Intake manifold assembly-SR20DE engine



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Fig. Fig. 11: Intake manifold supports-SR20DE engine



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Fig. Fig. 12: Intake manifold loosening sequences-SR20DE engine



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Fig. Fig. 13: Intake collector loosening sequences-SR20DE engine



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Fig. Fig. 14: Intake manifold tightening sequences-SR20DE engine



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Fig. Fig. 15: Intake collector tightening sequences-SR20DE engine

  1. Relieve the fuel system pressure, disconnect the negative (-) battery cable. Refer to Fuel System for procedure to relieve fuel pressure.
  2.  
  3. Drain the cooling system.
  4.  


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

  1. Remove the air cleaner assembly.
  2.  
  3. Disconnect the throttle linkage, electrical connections, fuel and vacuum lines from the throttle body.
  4.  
  5. Remove the EGR tube from the manifold.
  6.  
  7. Remove the drive belts and water pump pulley.
  8.  
  9. Remove the alternator and power steering pump.
  10.  
  11. Remove the intake manifold supports, oil filter bracket and power steering bracket.
  12.  
  13. Loosen the intake manifold retaining bolts in the proper sequence and separate the manifold from the cylinder head.
  14.  
  15. If necessary, remove the fuel rail and separate the intake collector assembly from the intake manifold.
  16.  
  17. Remove the intake manifold gasket and clean all the gasket contact surfaces thoroughly with a gasket scraper and suitable solvent. All traces of old gasket material must be removed to ensure proper sealing. Inspect the intake manifold for cracks. Using a metal straightedge, check the surface of the intake manifold for warpage.
  18.  

To install:
  1. Assemble the collector assembly to the manifold. Torque nuts and bolts in sequence to 13-15 ft. lbs. (18-21 Nm).
  2.  
  3. Lay the new intake manifold gasket onto the cylinder head and position the intake manifold over the mounting studs and onto the gasket. Install the mounting nuts and torque them to 13-15 ft. lbs. (18-21 Nm), in the proper sequence.
  4.  
  5. Connect EGR tube to the manifold.
  6.  
  7. Connect the oil filter and power steering pump brackets.
  8.  
  9. Install the intake manifold supports.
  10.  
  11. Install the power steering pump and alternator.
  12.  
  13. Install the water pump pulley.
  14.  
  15. Install and adjust the drive belts.
  16.  
  17. If removed, install the throttle body assembly.
  18.  
  19. Connect the throttle linkage, electrical connections, fuel and vacuum lines.
  20.  
  21. Install the air cleaner and connect the intake air hose.
  22.  
  23. Fill the cooling system to the proper level and connect the negative (-) battery cable.
  24.  
  25. Road test the vehicle for proper operation.
  26.  

 
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