### Intake Manifold

#### REMOVAL & INSTALLATION

##### 1982–83 200SX (Z Series Engine)

NOTE: 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. Remove the air cleaner hoses.
3. Remove the radiator hoses from the manifold.
4. 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.

   NOTE: 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.

5. Remove all remaining wires, tubes and the EGR. and PCV lines from the rear of the intake manifold. Remove the manifold supports.
6. Unbolt and remove the intake manifold. Remove the manifold with injectors, EGR. valve, fuel assembly, etc., still attached.

   To install:

7. Clean the gasket mounting surfaces then install the intake manifold on the engine. Always use a new intake manifold gasket. Tighten the intake manifold bolts EVENLY in 23 stages (working from the center to the ends) to specifications.
8. Connect all electrical connections, tubes and the EGR. and PCV lines to the rear of the intake manifold. Install the manifold supports.
9. Install the throttle cable and reconnect the fuel pipe and the return fuel lines.
10. Install the radiator hoses to the intake manifold.
11. Install the air cleaner hoses.
12. Refill the coolant level and connect the battery cable. Start the engine and check for leaks.

##### 1984–88 200SX(CA Series Engine)Stanza (CA20E Engine)

1. Disconnnect the negative battery cable and drain the cooling system.
2. Remove the air cleaner hoses.
3. Remove the radiator hoses from the manifold.
4. Relieve the fuel pressure. Remove the throttle cable and disconnect the fuel pipe and the fuel return line. Plug the fuel pipe to prevent spilling fuel.
5. Remove all remaining wires, tubes and the EGR and PCV tubes from the rear of the intake manifold. Remove the manifold supports.
6. Unbolt and remove the intake manifold. Remove the manifold with the fuel injectors/injection body, EGR valve, fuel pipes and associated running gear still attached.
7. Remove the intake manifold gasket and clean the gasket surfaces.

   To install:

8. Install the intake manifold with a new gasket. Tighten the intake manifold bolts EVENLY in 23 stages (working from the center to the ends) to specifications (14–19 ft. lbs.)
9. Install the intake manifold supports. Connect the fuel pipe, fuel return line and the throttle cable. Reconnect all necessary lines, hoses and or electrical connections.
10. Connect the radiator hoses to the intake manifold. Connect the air cleaner hoses.
11. Fill the cooling system and connect the negative battery cable. Roadtest the vehicle for proper operation.

##### 200SX (VG30E Engine)

Fig. 1: Removing collector — loosen bolts in this order

Fig. 2: Removing intake manifold — loosen bolts in this order

Fig. 3: Installing intake manifold — tighten bolts in this order

Fig. 4: Installing collector to intake manifold — tighten bolts in this order

NOTE: When removing and installing the collector assembly and intake manifold follow the sequence patterns––refer to the illustrations.

1. Relieve the fuel system pressure, disconnect the negative battery cable and drain the cooling system.
2. Disconnect the valve cover-to-throttle chamber hose at the valve cover.
3. Disconnect the heater housing-to-water inlet tube at the water inlet.
4. Remove the bolt holding the water and fuel tubes to the head.
5. Remove the heater housing-to-thermostat housing tube.
6. Remove the intake collector cover and then remove the collector itself.
7. Disconnect the fuel line and remove the intake manifold bolts. Remove the intake manifold assembly, with the fuel tube assembly still attached, from the vehicle.

   To install:

8. Install the intake manifold with a new gasket. Tighten the intake manifold bolts in 23 stages in the proper sequence to specifications.
9. Connect the fuel line.
10. Install the intake manifold collector with a new gasket. Install the collector cover assembly.
11. Connect the heater-to-thermostat housing tube.
12. Attach the water and fuel tubes to the cylinder head with the mounting bolt.
13. Connect the valve cover-to-throttle chamber hose.
14. Fill the cooling system to the proper level and connect the negative battery cable.
15. Road test the vehicle for proper operation. Make all the necessary engine adjustments.

##### 240SX (KA24E and KA24DE Engines) and Stanza (KA24E Engine)

Fig. 5: Intake manifold bolt torque sequence — KA24E engine

Fig. 6: Intake manifold collector bolt torque sequence — KA24E engine

Fig. 7: Intake manifold bolt torque sequence — KA24DE engine

Fig. 8: Intake manifold collector bolt torque sequence — KA24DE engine

1. Relieve the fuel system pressure, disconnect the negative battery cable and drain the cooling system.
2. Remove the air duct between the air flow meter and the throttle body.
3. Disconnect the throttle cable.
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.
7. Disconnect the EGR valve tube from the exhaust manifold.
8. Remove the intake manifold mounting brackets.
9. Unbolt the intake manifold collector/throttle body from the intake manifold or just remove the mounting bolts and separate the intake manifold from the cylinder head with the collector attached.
10. Using a putty knife or equivalent, clean the gasket mounting surfaces. Check the intake manifold for cracks and warpage.

    To install:

11. Install the intake manifold and gasket on the engine. Tighten the mounting bolts 1215 ft. lbs. from the center working to the end, in 23 stages. If the collector was separated from the intake manifold, torque the collector bolts to 1215 ft. lbs. from the center working to the end.
12. Install intake manifold mounting brackets.
13. Connect the EGR valve tube to the exhaust manifold.
14. Install the spark plug wires.
15. Connect the electrical connectors and the vacuum hoses to the throttle body and intake manifold/collector assembly.
16. Connect the fuel line(s) to the fuel injector assembly.
17. Connect the throttle cable.
18. Connect the air duct between the air flow meter and the throttle body.
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.

##### Stanza (CA20 Engine)

1. Remove the air cleaner assembly together with all of the hoses.

   NOTE: 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.

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

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

3. Remove the intake manifold bolts or nuts and the manifold from the engine.

   To install:

4. Using a putty knife or equivalent, clean the gasket mounting surfaces.
5. 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 14–19 ft. lbs. (CA20 engine).
6. Install throttle linkage, fuel and vacuum lines and the air cleaner assembly.
7. Start engine and check for leaks.