Nissan Altima HL32 Hybrid. Manual - part 378

EM-26

< ON-VEHICLE REPAIR >

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INTAKE MANIFOLD

a. Remove quick connector cap.

b. With the sleeve side of Tool facing quick connector, install Tool

onto fuel tube.

c.

Insert Tool into quick connector until sleeve contacts and goes

no further. Hold the Tool on that position.

CAUTION:

Inserting the Tool hard will not disconnect quick connector.

Hold Tool where it contacts and goes no further.

d. Pull the quick connector straight out from the fuel tube.

CAUTION:

• Pull quick connector holding it at the (A) position, as

shown.

• Do not pull with lateral force applied. O-ring inside quick

connector may be damaged.

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

• Avoid fire and sparks.

• Be sure to cover openings of disconnected pipes with plug or plastic bag to avoid fuel leakage

and entry of foreign materials.

8. When removing fuel hose quick connector at vehicle piping side, perform as follows.
a. Remove quick connector cap.
b. 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.

CAUTION:

• The tube can be removed when the tabs are completely

depressed. Do not twist it more than necessary.

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

• Keep the resin tube away from heat. Be especially careful

when welding near the tube.

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

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

• Do not remove the remaining retainer on tube.

• When the tube is replaced, also replace the retainer with a new one.

Retainer color: Green.

• To keep clean the connecting portion and to avoid damage and foreign materials, cover them

completely with plastic bags or something similar.

9. Disconnect electronic throttle control actuator coolant hoses.
10. Loosen bolts diagonally, and remove the electronic throttle control actuator. 

CAUTION:

Handle carefully to avoid any damage.

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INTAKE MANIFOLD

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11. Remove the bolts and nuts in the order shown and remove the

intake manifold assembly, using power tools.

CAUTION:

Cover engine openings to avoid entry of foreign materials.

Inspection After Removal

Surface Distortion

• Using straightedge and feeler gauge, inspect surface distortion of intake manifold collector and intake mani-

fold surface. Refer to 

EM-98, "Standard and Limit"

.

INSTALLATION

Installation is in the reverse order of removal. Follow the tightening sequences below.

Tightening Intake Manifold Bolts and Nuts

• Tighten in numerical order as shown.

CAUTION:

After tightening the five bolts in the order shown, the 1, 6

position designates that the first bolt tightened is to be

retightened to specification.

• Installation of Electronic Throttle Control Actuator:

- Tighten the bolts of electronic throttle control actuator equally and diagonally in several steps.

- After installation perform procedure in "INSPECTION AFTER INSTALLATION".

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. Thinly apply new engine oil around the fuel tube tip end.
3. 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.

CAUTION:

• Hold at position (A) as shown, when inserting the fuel

tube into the quick connector.

• Carefully align to center to avoid inclined insertion to pre-

vent damage to the O-ring inside the quick connector.

• Insert the fuel tube until you hear a “click” sound and

actually feel the engagement.

• To avoid misidentification of engagement with a similar

sound, be sure to perform the next step.

4. 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 50 N (5.1 kg, 11.2 lb).

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INTAKE MANIFOLD

5. Install quick connector cap on quick connector joint.

• Direct arrow mark on quick connector cap to upper side (fuel

hose side).

6. Install fuel hose to hose clamp.

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. 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.

INSPECTION AFTER INSTALLATION

Make sure there is no fuel leakage at connections as follows:
1. Apply fuel pressure to fuel lines using CONSULT III. Then check for fuel leaks at connections. 
2. Start the Hybrid System and rev it up using CONSULT III and check for fuel leaks at connections.

• Perform procedures for “Throttle Valve Closed Position Learning” after finishing repairs. Refer to 

EC-15,

"THROTTLE VALVE CLOSED POSITION LEARNING : Special Repair Requirement"

.

• If electric throttle control actuator is replaced, perform procedures for “Idle Air Volume Learning” after

finishing repairs. Refer to 

EC-16, "IDLE AIR VOLUME LEARNING : Special Repair Requirement"

.

WARNING:

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.

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EXHAUST MANIFOLD AND THREE WAY CATALYST

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EXHAUST MANIFOLD AND THREE WAY CATALYST

Removal and Installation

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REMOVAL

1. Remove the engine undercover using power tools.
2. Disconnect the electrical connector of air fuel ratio (A/F) sensor 1, and unhook the harness from the

bracket and middle clamp on the cover.

3. Remove the air fuel ratio (A/F) sensor 1 using Tools.

CAUTION:

• Be careful not to damage air fuel ratio (A/F) sensor.

• Discard any air fuel ratio (A/F) sensor which has been dropped from a height of more than 0.5 m

(19.7 in) onto a hard surface such as a concrete floor; replace with a new one.

4. Remove the exhaust manifold cover (lower).
5. Remove the exhaust front tube. Refer to 

EX-6, "Removal and Installation"

.

6. Remove the exhaust manifold cover (upper).

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1.

Exhaust manifold cover (upper)

2.

Exhaust manifold stay

3.

Manifold yoke (type B)

4.

Manifold yoke (type A)

5.

Exhaust manifold cover (lower) 

6.

Exhaust manifold and three way catalyst 
assembly

7.

Exhaust manifold gasket

8.

Air fuel ratio (A/F) sensor 1 

A. To cylinder head

Tool numbers

: 

—

 (J-44626)

: KV10117100 (J-36471-A)