Sentra 2008

Intake Manifold

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Removal & Installation



2.0L Engine

Specific to:

Nissan Sentra 2007-2012


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

  1. Remove engine room cover.

    Click image to see an enlarged view

    Fig. Remove engine room cover (1).

  2.  
  3. Remove the air duct (inlet) and air ducts. Refer to Air Intake System in the Engine Mechanical Section.
  4.  
  5. Disconnect the EVAP canister purge volume control solenoid valve.
  6.  
  7. Partially drain engine coolant from the radiator. Refer to Radiator in the Engine Cooling Section.
    CAUTION
    Perform this step when engine is cold.


    NOTE
    This step is unnecessary when putting plugs to water hoses (to electric throttle control actuator)

    1. Disconnect water hoses from electric throttle control actuator.
    2.  
    3. Remove electric throttle control actuator.
      CAUTION
      Handle carefully to avoid any shock to electric throttle control actuator.


      NOTE
      Never disassemble.

    4.  

  8.  
  9. Remove the PCV hose and the vacuum hose.
  10.  
  11. Remove oil level gauge.
    NOTE
    Cover the oil level gauge guide openings to avoid entry of foreign materials.

  12.  
  13. Loosen and remove intake manifold bolts.

    Click image to see an enlarged view

    Fig. Loosen and remove intake manifold (1) bolts (A) (B). (Arrow: Engine front)

  14.  
  15. Loosen bolts in reverse order.
    NOTE
    Cover engine openings to avoid entry of foreign materials.



    Click image to see an enlarged view

    Fig. Loosen bolts in reverse order as shown (Arrow: Engine front)

  16.  
  17. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary.
    WARNING
    Handle it carefully and avoid impacts.

  18.  
  19. Remove intake manifold.
  20.  
  21. Remove intake manifold adapter (for California).
  22.  

To install:

  1. Install intake manifold adapter (for California).
    NOTE
    Be sure the intake manifold adapter gasket is seated correctly in groove of intake manifold adapter (for California).

  2.  
  3. Install intake manifold.
    NOTE
    Be sure the intake manifold gasket is seated correctly in groove of intake manifold (except for California).

  4.  
  5. Tighten bolts in numerical order.

    Click image to see an enlarged view

    Fig. Tighten bolts in numerical order as shown (Arrow: Engine front)

  6.  
  7. Tighten intake manifold bolt. Then tighten intake manifold bolt.

    Click image to see an enlarged view

    Fig. Tighten intake manifold bolt (A). Then tighten intake manifold bolt (B).

  8.  
  9. Install electric throttle control actuator.
  10.  
  11. Install water hoses, to electric throttle control actuator (M/T models).
    NOTE
    The clamp shall not interfere with the bulged section.



    Click image to see an enlarged view

    Fig. Install water hoses (3), (5) to electric throttle control actuator as shown (M/T models). The clamp (2) shall not interfere with the bulged section (B).

  12.  
  13. Install water hoses, to electric throttle control actuator (CVT models).
    NOTE
    The clamp shall not interfere with the bulged section.



    Click image to see an enlarged view

    Fig. Install water hoses (3), (5) to electric throttle control actuator as shown (CVT models). The clamp (2) shall not interfere with the bulged section (B).

  14.  
  15. Installation of the remaining components is in the reverse order of removal.
  16.  

Inspection After Installation

  1. Check for engine coolant leaks. Refer to Engine Coolant in the Engine Cooling Section.
  2.  
  3. Start and warm up the engine. Visually check for engine coolant leaks.
  4.  

2.5L Engine

Specific to:

Nissan Sentra 2007-2012


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

  1. Remove the engine room cover.
  2.  
  3. Release the fuel pressure. Refer to Gasoline Fuel Injection System in the Fuel Systems Section
  4.  
  5. Drain engine coolant from the radiator. Refer to Radiator in the Engine Cooling Section
    CAUTION
    Perform this step when engine is cold.


    NOTE
    This step necessary only when removing electric throttle control actuator from the vehicle.

  6.  
  7. Remove the battery tray. Refer to Battery System in the Engine Electrical Section.
  8.  
  9. Disconnect the MAF sensor electrical connector.
  10.  
  11. Remove air cleaner case and air duct assembly. Refer to Air Intake System in the Engine Mechanical Section.
  12.  
  13. Remove cowl top. Refer to Fenders & Body Panels in the Body Section
  14.  
  15. Disconnect the following components at the intake side:

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

  16.  
  17. Disconnect the fuel quick connector on the engine side.

    Using Tool perform the following steps to disconnect the quick connector.

    Click image to see an enlarged view

    Fig. Disconnect the fuel quick connector on the engine side. Using Tool (16441 6N210 [J-45488]) perform the following steps to disconnect the quick connector

     

    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.
    4.  
    5. Insert Tool into quick connector until sleeve contacts and goes no further. Hold the Tool on that position.
      NOTE
      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.
      NOTE
      Pull quick connector holding it at the "A" position, as shown.


      WARNING
      Do not pull with lateral force applied. O-ring inside quick connector may be damaged.


      NOTE
      Do not reuse O-ring.


      NOTE
      Prepare container and cloth beforehand as fuel will leak out.


      WARNING
      Avoid fire and sparks.


      NOTE
      Be sure to cover openings of disconnected pipes with plug or plastic bag to avoid fuel leakage and entry of foreign materials.



      Click image to see an enlarged view

      Fig. With the sleeve side of Tool facing quick connector, install Tool onto fuel tube. Insert Tool into quick connector until sleeve contacts and goes no further. Hold the Tool on that position. Pull the quick connector straight out from the fuel tube.

    8.  

  18.  
  19. 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.)
      NOTE
      The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary.


      NOTE
      Do not use any tools to remove the quick connector.


      NOTE
      Keep the resin tube away from heat. Be especially careful when welding near the tube.


      NOTE
      Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube.


      NOTE
      Do not bend or twist the tube during installation and removal.


      NOTE
      Do not remove the remaining retainer on tube.


      NOTE
      When the tube is replaced, also replace the retainer with a new one. Retainer color: Green.


      WARNING
      To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.



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

      Click image to see an enlarged view

      Fig. Remove quick connector cap. Hold the sides of the connector, push in tabs and pull out the tube. (The figure is shown for reference only.) If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling.

       

    4.  

  20.  
  21. Remove EVAP canister purge volume control solenoid valve.
  22.  
  23. Loosen mounting bolts diagonally, reposition the electric throttle control actuator and position aside without disconnecting the coolant hoses.
    CAUTION
    Handle carefully to avoid any shock to electric throttle control actuator.


    NOTE
    Never disassemble.

  24.  
  25. Disconnect intake manifold collector harness, and vacuum hose.
    NOTE
    Cover engine openings to avoid entry of foreign materials.

  26.  
  27. Loosen the bolts in the order shown to remove the intake manifold assembly, using power tools.

    Click image to see an enlarged view

    Fig. Loosen the bolts in the order shown to remove the intake manifold assembly, using power tools

  28.  

Inspection After Removal

  1. Surface Distortion

    Using straightedge and feeler gauge, inspect surface distortion of intake manifold adapter and intake manifold surface.
     

  2.  

To install:

  1. Tighten the intake manifold bolts and nuts.
    NOTE
    After tightening No.5, retighten the No.1 bolt to specification.



    Click image to see an enlarged view

    Fig. Tighten the intake manifold bolts and nuts in the numerical order as shown

  2.  
  3. Tighten the intake manifold support bolts following the tightening sequence below:

    Temporarily tighten the intake manifold support (rear) bolts.
     
    Tighten the electric throttle control actuator bolts.
     
    Tighten the intake manifold support (rear) bolts.
     
    Temporarily tighten the intake manifold support (front) bolts (intake manifold side).
     
    Tighten the intake manifold support (front) bolts (engine side).
     
    Tighten the intake manifold support (front) bolts (intake manifold side).
     

  4.  
  5. Installation of Electric Throttle Control Actuator:

    Tighten the mounting bolts of electric throttle control actuator equally and diagonally in several steps.
     
    After installation perform procedure in "INSPECTION AFTER INSTALLATION".
     

  6.  

Connecting Quick Connector On The Fuel Hose (Engine Side)

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


    WARNING
    Carefully align to center to avoid inclined insertion to prevent damage to the O-ring inside the quick connector.


    NOTE
    Do not reuse O-ring.


    NOTE
    Insert the fuel tube until you hear a -click- sound and actually feel the engagement.


    NOTE
    To avoid misidentification of engagement with a similar sound, be sure to perform the next step.



    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.

    Click image to see an enlarged view

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

     

  6.  
  7. 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 134.4 inch lbs. (50 N).

  8.  
  9. Install quick connector cap on quick connector joint.

    Direct arrow mark on quick connector cap to upper side (fuel hose side).

    Click image to see an enlarged view

    Fig. Install quick connector cap on quick connector joint. Direct arrow mark on quick connector cap to upper side (fuel hose side).

     

  10.  
  11. Install fuel hose to hose clamp.
  12.  

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

  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.

    Insert fuel tube until a click is heard.
     
    Install quick connector cap on quick connector joint. Direct arrow mark on quick connector cap upper side.
     
    Install fuel hose to hose clamp.

    Click image to see an enlarged view

    Fig. Align center to insert quick connector straight into fuel tube. Insert fuel tube until a click is heard. Install quick connector cap on quick connector joint. Direct arrow mark on quick connector cap upper side.

     

  4.  

Inspection After Installation

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.
    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.



    Perform procedures for -Throttle Valve Closed Position Learning- after finishing repairs. Refer to Diagnostics Section.
     
    If electric throttle control actuator is replaced, perform procedures for -Idle Air Volume Learning- after finishing repairs. Refer to Diagnostics Section.
     

  4.  

 
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