### Intake Manifold

#### REMOVAL AND INSTALLATION

##### 1.6L (GA16DE) Engine

###### 1993–95 Models

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.

1. Relieve the fuel system pressure, disconnect the negative battery cable, and drain the cooling system.
2. Remove the air cleaner assembly.
3. Disconnect and tag the throttle linkage, electrical connections, fuel and vacuum lines from the throttle body or throttle chamber.
4. The throttle body/throttle chamber can be removed from the manifold at this point or can be removed as an assembly with the intake manifold.
5. Remove the bolts holding the upper portion of the intake to the lower portion. Remove the bolts in reverse order of the tightening sequence.
6. Remove the upper portion of the intake.
7. 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
8. 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.

   To install:

9. 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 torque them to 12–15 ft. lbs. (16–21 Nm) in sequence.
10. Using a new gasket, install the upper portion of the intake manifold and torque the bolts to 12–15 ft. lbs. (16–21 Nm) in sequence.
11. 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 15 ft. lbs. (21 Nm).

    NOTE: Be sure the gasket for the throttle body is positioned properly.

12. Install the remaining components in the opposite order from which they were removed.
13. Fill the cooling system to the proper level and connect the negative battery cable.
14. Start the engine, bleed the cooling system, and check for leaks.
15. Road test the vehicle for proper operation.

###### 1996–97 Vehicles

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.

1. Relieve the fuel system pressure, disconnect the negative battery cable, and drain the cooling system.
2. Remove the air cleaner assembly.
3. Disconnect and tag the throttle linkage, electrical connections and vacuum lines from the throttle body.
4. Remove the intake manifold collector support brackets.
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. Remove the bolts holding the upper portion of the intake to the lower portion. Remove the bolts in reverse order of the tightening sequence.
7. Remove the upper portion of the intake.
8. Disconnect the fuel injector wiring harness connectors and the vacuum line from the fuel pressure regulator.
9. Disconnect the fuel hoses from the fuel rail assembly.
10. Remove the bolts that secure the fuel rail to the intake.
11. Remove the injectors with the fuel rail assembly.
12. 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
13. 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.

    To install:

14. 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.

    Fig. 1: Lower intake manifold tightening sequence — 1.6L (GA16DE) engines

15. Install the injectors with the fuel rail assembly. Be sure to install the fuel rail insulators.
16. 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).
17. Connect the fuel injector wiring harness connectors and the vacuum line from the fuel pressure regulator.
18. Using new hose clamps, connect the fuel hoses from the fuel rail assembly.
19. 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.

    Fig. 2: Upper intake manifold tightening sequence — 1.6L (GA16DE) engines

20. 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).

    NOTE: Be sure to properly position the throttle body gasket with the cut out facing down.

21. Install the intake manifold collector support brackets.
22. Connect the throttle linkage, electrical connections and vacuum lines.
23. Install the air cleaner.
24. Fill the cooling system to the proper level and connect the negative battery cable.
25. Start the engine, bleed the cooling system, and check for leaks.
26. Road test the vehicle for proper operation.

##### 2.0L (SR20DE) Engine

###### 1993–94 Sentra

Fig. 3: Intake manifold assembly bolt torque sequence — 1993–95 Sentra models with 2.0L (SR20DE) engines

1. Relieve the fuel system pressure, disconnect the negative battery cable and drain the cooling system.
2. Remove the air cleaner assembly.
3. Disconnect the throttle linkage, electrical connections, fuel and vacuum lines from the throttle body.
4. Remove the EGR tube from the manifold.
5. Remove the drive belts and water pump pulley.
6. Remove the alternator and power steering pump.
7. Remove the intake manifold supports, oil filter bracket and power steering bracket.
8. Loosen the intake manifold retaining bolts in the proper sequence and separate the manifold from the cylinder head.
9. If necessary, remove the fuel rail and separate the intake collector assembly from the intake manifold.
10. 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.

    To install:

11. Assemble the collector assembly to the manifold. Torque nuts and bolts in sequence to 13–15 ft. lbs. (18–21 Nm).
12. 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.
13. The balance of installation is the reverse of the removal procedure.
14. Fill the cooling system to the proper level and connect the negative battery cable.
15. Road test the vehicle for proper operation.

###### 1995–97 200SX

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.

1. Relieve the fuel system pressure, disconnect the negative battery cable, and drain the cooling system.
2. Remove the air cleaner assembly.
3. Disconnect the manifold support brackets.
4. Disconnect the throttle linkage, electrical connections, and vacuum lines from the throttle body. Be sure to note the locations of all connections.
5. Remove the EGR tube from the manifold.
6. Unbolt and remove the fuel rail assembly.
7. Remove the drive belts and water pump pulley.
8. Remove the alternator and power steering pump.
9. Remove the oil filter bracket and power steering bracket.
10. Loosen the intake manifold collector retaining bolts in the reverse of installation sequence and separate the collector from the manifold.
11. Loosen the intake manifold assembly retaining bolts in the reverse order of the tightening sequence and separate the manifold from the cylinder head.
12. Remove all gasket material and clean all the gasket contact surfaces thoroughly with a gasket scraper and a 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.

    To install:

13. Using new gaskets, install the intake manifold assembly to the cylinder head and torque the mounting bolts in sequence to 13–15 ft. lbs. (18–21 Nm).

    Fig. 4: Lower intake manifold assembly torque sequence — 1995–97 200SX with 2.0L (SR20DE) engines

14. Using new gaskets, install the intake manifold collector to the intake manifold assembly torque the mounting bolts and nuts in sequence to 13–15 ft. lbs. (18–21 Nm).

    Fig. 5: Upper intake manifold collector torque sequence — 1995–97 200SX with 2.0L (SR20DE) engines

15. Install the remaining components in the reverse order of removal.
16. Fill the cooling system to the proper level and connect the negative battery cable.
17. Bleed the cooling system and road test the vehicle for proper operation.

##### 2.4L (KA24DE) Engine

1. Relieve the fuel system pressure, disconnect the negative battery cable and drain the cooling system.

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

2. Remove the air duct between the air flow meter and the throttle body.
3. Disconnect the throttle cable and the cruise control cable, if equipped.
4. Disconnect the fuel supply and return lines from the fuel injector assembly. Plug the lines to prevent leakage.
5. Disconnect and tag the electrical connectors and the vacuum hoses to the throttle body and intake manifold/collector assembly.
6. Remove the spark plug wires from the spark plugs.
7. Remove the throttle body assembly from the intake manifold.
8. Disconnect the EGR valve tube from the exhaust manifold.
9. Remove the intake manifold mounting brackets.
10. Remove the intake manifold collector to the intake manifold bolts/nuts in the reverse sequence of the tightening procedure and separate the intake manifold from the intake manifold collector.
11. Remove the bolts that secure the intake manifold to the cylinder head and remove the manifold. Be sure to loosen the bolts in the reverse sequence of the tightening procedure.
12. Using a putty knife or equivalent, clean the gasket mounting surfaces. Check the intake manifold/collector for cracks and warpage.

    To install:

13. Using new gaskets, install the intake manifold to the cylinder head and tighten the mounting bolts in sequence to 12–14 ft. lbs. (16–19 Nm).

    Fig. 6: Intake manifold torque sequence — 2.4L (KA24DE) engines

14. Using new gaskets, install the intake manifold collector to the intake manifold and tighten the mounting bolts/nuts in sequence to 12–14 ft. lbs. (16–19 Nm).

    Fig. 7: Intake manifold collector torque sequence — 2.4L (KA24DE) engines

15. Install intake manifold mounting brackets.
16. Connect the EGR valve tube to the exhaust manifold.
17. Using a new gasket, install the throttle body and tighten the mounting bolts in a crisscross pattern to 13–16 ft. lbs. (18–22 Nm). Be sure to tighten the bolts in two progressive steps.
18. The balance of installation is the reverse of the removal procedure.
19. Fill the cooling system to the proper level and connect the negative battery cable.
20. Make all the necessary engine adjustments. Road test the vehicle for proper operation.

##### 3.0L (VE30DE) Engine

1. Disconnect the negative battery cable, drain the cooling system, and release the fuel system pressure.
2. Disconnect the electrical connectors from the throttle position sensor, exhaust gas temperature sensor, coolant temperature sensor, etc.
3. Label and disconnect the hoses from the throttle body, the EGR valve, the EGR control solenoid valve, the intake manifold collector, the power control solenoid valve and the power valve actuator (if equipped with a manual transaxle).
4. Disconnect the accelerator cable from the throttle body.
5. Remove the intake manifold collector support-to-intake manifold collector and the intake manifold collector support-to-cylinder head bolts and remove the support.
6. Remove the intake manifold collector-to-intake manifold bolts and remove the intake manifold collector.

   Fig. 8: Intake manifold torque sequence — 3.0L (VE30DE) engine

   Fig. 9: Intake collector torque sequence — 3.0L (VE30DE) engine

7. Disconnect the electrical connectors from the ignition coils.
8. Disconnect the electrical connector from the crank angle sensor and the power transistor.
9. Disconnect the electrical connectors from the fuel injectors.

   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.

10. Disconnect the fuel injector assembly from the fuel lines.
11. Remove the fuel rail-to-cylinder head bolts.
12. Remove the fuel rail assembly from the engine.
13. Remove the intake manifold-to-engine bolts, in sequence, by reversing the tightening sequence.
14. Lift the intake manifold from the engine and discard the gasket.

    To install:

15. Clean the gasket mounting surfaces.
16. Install the intake manifold and torque the intake manifold-to-engine bolts and nuts in sequence.
17. Torque the intake manifold bolts and nuts in 2 steps as follows:
    1. Torque all bolts and nuts to 26–43 inch lbs. (3–5 Nm).
    2. Torque all bolts 12–14 ft. lbs. (16–20 Nm).
    3. Torque all nuts to 17–20 ft. lbs. (24–27 Nm).
18. Install the fuel rail assembly to the engine.
19. Install and tighten the fuel rail-to-cylinder head bolts.
20. Connect the fuel lines to the fuel injector rail assembly.
21. Connect the electrical connectors to the fuel injectors.
22. Connect the electrical connectors to the ignition coils.
23. Using a new gasket, install the intake manifold collector and torque the intake manifold collector-to-intake manifold bolts, in sequence, to 13–16 ft. lbs. (18–22 Nm).
24. Install the intake manifold collector support and torque the bolts to 12–15 ft. lbs. (16–21 Nm).
25. The remaining components are installed in the reverse order from which they were removed.
26. Connect the negative battery cable.
27. Refill the cooling system.
28. Start the engine and check for leaks.

##### 3.0L (VG30E) Engine

Fig. 10: Intake manifold bolt tightening sequence — 3.0L (VG30E) engine

Fig. 11: Lower intake collector torque sequence — 3.0L (VG30E) engine

Fig. 12: Upper intake collector torque sequence — 3.0L (VG30E) engine

1. Disconnect the negative battery cable and relieve the fuel pressure.
2. Disconnect the air intake duct from the dual duct housing.
3. Disconnect the electrical connectors from the throttle body, the step motor AAC valve and the exhaust gas temperature sensor.
4. Disconnect and label the hoses from the rocker arm cover, the throttle body, the step motor AAC valve, the EGR control valve and the air cut valve.
5. If the spark plug wires are in the way, disconnect them and move them aside. Disconnect the accelerator cable from the throttle body.
6. Remove the upper intake manifold collector-to-intake manifold bolts, in sequence, and lift the assembly from the intake manifold. Discard the gasket.
7. Remove the lower intake manifold collector-to-intake manifold bolts, in sequence, and lift the assembly from the intake manifold. Discard the gasket.
8. If the fuel injector assembly is in the way, perform the following procedures:
   1. Disconnect the electrical connectors from the fuel injectors.
   2. Disconnect the fuel injector assembly from the fuel lines.
   3. Remove the fuel rail-to-cylinder head bolts.
   4. Remove the fuel rail assembly from the engine.
9. Remove the intake manifold-to-engine bolts, in sequence, lift the intake manifold from the engine and discard the gasket.

   To install:

10. Clean the gasket mounting surfaces.
11. Use a new gasket and install the intake manifold by performing the following procedures:
    1. Torque the intake manifold-to-engine nuts/bolts, in sequence, to 2.2–3.6 ft. lbs. (3–5 Nm).
    2. Retighten the intake manifold-to-engine nuts/bolts, in sequence, to 12–14 ft. lbs. (16–20 Nm).
    3. Finally, torque the intake manifold-to-engine nuts/bolts, in sequence, to 17–20 ft. lbs. (24–27 Nm).
12. If the fuel injector assembly was removed, perform the following procedures:
    1. Install the fuel rail assembly to the engine.
    2. Install the fuel rail-to-cylinder head bolts and torque the bolts to 1.8–2.4 ft. lbs. (2.5–3.2 Nm).
    3. Connect the fuel injector assembly to the fuel lines.
    4. Connect the electrical connectors to the fuel injectors.
13. Install the remaining components in the opposite order from which they were removed.
14. Connect the negative battery cable.
15. Start the engine and check for oil leaks.

##### 3.0L (VQ30DE) Engine

1. Disconnect the negative battery cable and drain the cooling system.
2. Release the fuel system pressure.

   CAUTION
   The fuel injection system remains under pressure after the engine has been turned OFF. Properly relieve the fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

3. Remove the throttle body coolant hoses.

   Fig. 13: Intake manifold tightening sequence - 3.0L (VQ30DE) engine

4. Label and disconnect the electrical connectors from the throttle position sensor.
5. Label and disconnect the hoses from the throttle body, the EGR valve, intake manifold collector, IAC valve, and the fuel pressure regulator.
6. Disconnect the canister purge hose and blow-by hose.
7. Disconnect the EGR guide tube.
8. Disconnect the accelerator cable from the throttle body.
9. Remove the intake manifold collector support brackets.
10. Disconnect the right side electrical connectors from the ignition coils.
11. If necessary, disconnect the electrical connector from the crank angle sensor and the power transistor.
12. Remove the intake manifold collector-to-intake manifold bolts/nuts and remove the intake manifold collector.
13. Remove the fuel injector assembly by performing the following procedures:
    1. Disconnect the electrical connectors from the fuel injectors.
    2. Disconnect the fuel lines from the fuel injector assembly.
    3. Remove the fuel rail-to-cylinder head bolts.
    4. Remove the fuel rail assembly from the engine.
14. Remove the intake manifold bolts/nuts in the reverse sequence of the torque procedure.
15. Remove the intake manifold from the engine and discard the gaskets.
16. Clean all gasket mounting surfaces.

    To install:

17. Using new gaskets, install the intake manifold to the engine.
18. Tighten the bolts/nuts in sequence as follows:
    1. Tighten nuts and bolts to 44–86 inch lbs. (5–10 Nm).
    2. Tighten nuts and bolts to 20–23 ft. lbs. (26–31 Nm).
19. Install the fuel injector assembly by performing the following procedures:
    1. Install the fuel rail assembly to the engine.
    2. Install the fuel rail-to-cylinder head bolts and torque the bolts to 15–20 ft. lbs. (21–26 Nm) in two progressive steps.
    3. Connect the fuel lines to the fuel injector assembly.
    4. Connect the electrical connectors to the fuel injectors.
20. Install the remaining components in the reverse order of removal.
21. Refill the cooling system and connect the negative battery cable.
22. Start the engine, bleed cooling system, and check for leaks.

##### 3.0L (VG30DE and VG30DETT) Engines

Fig. 14: Intake manifold tightening sequence — 3.0L (VG30DE and VG30DETT) engines

1. Disconnect the negative battery cable, drain the cooling system, and release the fuel system pressure.
2. Disconnect the electrical connectors from the throttle position sensor, exhaust gas temperature sensor, coolant temperature sensor, etc.
3. Label and disconnect the hoses from the throttle body, the EGR valve, the EGR control solenoid valve, the intake manifold collector, the power control solenoid valve and the power valve actuator (if equipped with a manual transaxle).
4. Disconnect the accelerator cable from the throttle body.
5. Remove the intake manifold collector-to-intake manifold bolts and remove the intake manifold collector.
6. Disconnect the electrical connectors from the ignition coils.
7. Disconnect the electrical connector from the crank angle sensor and the power transistor.
8. Disconnect the electrical connectors from the fuel injectors.
9. Disconnect the fuel injector assembly from the fuel lines.
10. Remove the fuel rail-to-cylinder head bolts.
11. Remove the fuel rail assembly from the engine.
12. Remove the intake manifold-to-engine bolts, in sequence, by reversing the tightening sequence.
13. Lift the intake manifold from the engine and discard the gasket.

    To install:

14. Clean the gasket mounting surfaces.
15. Install the intake manifold and torque the intake manifold-to-engine bolts and nuts in sequence.
16. Torque the intake manifold bolts and nuts in two steps as follows:
    1. Torque all bolt-and-nut combinations to 26–43 inch lbs. (3–5 Nm).
    2. Torque all bolts 12–14 ft. lbs. (16–20 Nm).
    3. Torque all nuts to 17–20 ft. lbs. (24–27 Nm).
17. The balance of installation is the reverse of the removal procedure.
18. Using a new gasket, install the intake manifold collector and torque the intake manifold collector-to-intake manifold bolts to 12–15 ft. lbs. (16–21 Nm).
19. Reconnect the negative battery cable.
20. Refill the cooling system.
21. Start the engine and check for leaks.