How to Replace the Intake Manifold in a Nissan Pathfinderby ContributorUpdated November 07, 2017
How to Replace the Intake Manifold in a Nissan Pathfinder. The Nissan Pathfinder prides itself as a sport utility vehicle on its appeal to "truck people." Produced between 1989 and 1995, the truck was offered with four different engines. The procedure for removing and installing the intake manifold in the Z24i and KA24E is the same and easily undertaken by a do-it-yourself mechanic.
Remove the Intake Manifold
Relieve the pressure in the fuel system and drain the coolant (see Warnings). Disconnect the negative battery cable.
Remove the hoses to the air cleaner. Disconnect the radiator hoses from the manifold, then remove the throttle cable and disconnect the fuel pipe and the return line.
Label all wires, hoses and connections with masking tape. Label the connection with the same number as the hose or wire to be disconnected, then match them later when reconnecting.
Remove the GGR and PCV tube from the back side of the intake manifold. Remove the manifold supports.
Loose the bolts to the manifold and then remove them. Lift the manifold with the injectors from the engine.
Install the Intake Manifold
Clean the gasket mounting surfaces thoroughly using compressed air and solvent. Install a new gasket and then set the manifold in place on the engine.
Tighten the mounting bolts working from the center out in a criss-cross pattern. Use several passes to tighten the bolts to 12 to 15 foot pounds.
Connect all electrical lines and vacuum tubes, including the EGR and PCV tubes to the back side of the manifold. Set the intake manifold supports in place.
Install the throttle cable after reconnecting the fuel pipe and return line. Connect the radiator hoses to the manifold and install the air cleaner hoses.
Refill the cooling system with the proper type and amount of coolant. Connect the negative battery cable.
Start the engine. Examine all the connections for fuel, oil or vacuum leaks.
Use a golf tee to plus the fuel pipe so that fuel does not spill out.
Drain coolant into a container that can be sealed. Reuse the coolant unless it is contaminated or several years old.