Disassembly - Front

1. Remove the BCDD hose and evaporator vacuum hose (if equipped).

2. Loosen the water hose clamp underneath the throttle valve.

3. Make sure the accelerator and ASCD cables are tight in the bracket then remove the bracket with the cables from the manifold.

4. Disconnect the accelerator cable and the ASCD cable from the throttle valve and position them out of the way. Be careful not to kink or pull on the cables.

5. Disconnect the electrical connectors from the throttle sensor and throttle sensor switch.

6. Loosen the clamp for the air duct and remove the air duct from the throttle chamber.

7. Remove the plenum ornament cover. Use an impact driver so you won't damage the screw heads.

8. Using a breaker bar, remove the five plenum bolts. Tap the edge of the plenum with a plastic mallet to free it from the intake manifold and lift the plenum from the intake manifold.

Since the wiring harness is out of the way, you will not need to disconnect any injectors until the plenum has been removed.

NOTE:
Be sure not to damage the air duct and wiring harness as you remove the plenum.

9. Set the plenum aside and immediately cover the intake manifold and plenum holes with the 12 hole plugs, J42056, that were provided as part of this campaign.

10. Once the plenum has been removed and both the plenum and intake manifold have been plugged, disconnect the fuel injector connectors. Do not remove the fuel rails at this time.

11. Remove and retain the fuel inlet hose between the fuel filter and fuel rail.

12. Disconnect and retain the fuel filter inlet hose. This is the pre-formed hose between the fuel filter and the vehicle frame.

13. Install the new pre-formed fuel inlet hose between the filter and the vehicle frame.

*14. Using a sharp gasket scraper, CAREFULLY remove the intake manifold gasket from the intake manifold/plenum surfaces.

NOTE:
Some intake manifold gaskets may contain asbestos. use proper eye and respiratory protection when removing the gasket.

15. A. Carefully cut both hoses from the fuel pressure regulator. Out the hoses in the middle to avoid damaging the regulator tube surface. Do not cut the hoses near the fuel regulator outlets. Scratches or scoring of the fuel tubes can cause fuel leaks.

B. Cut the inlet tube sub-hose and the crossover hose in the middle.

Before removing the injector rails remove the sub-tube.

(There are two bolts holding the tube in place).

16. Remove the fuel rail bracket bolts (if equipped) and then the injector holder bolts.

17. Lift the fuel rail assembly from the engine. Be careful not to drop the injector spacers. Drain any residual fuel from the rails into a suitable container. Tag and retain the parts per Nissan's warranty policy and procedures.

*18. If the fuel pressure regulator failed the pressure test in step 3D (Service Procedure), or if the fuel temperature sensor connector is broken off, replace the fuel pressure regulator at this time.

*NOTE:
Prior to replacing the fuel pressure regulator, use air pressure to make sure the fuel return line is not restricted.

* If you are not replacing the fuel pressure regulator, remove the hose remnants from the regulator using Mac HFL 4790 hose pliers or other suitable hose removal pliers. Be careful no to scratch, gouge, or damage the fuel tube inlet surfaces or fuel temperature sensor in any way.

19. Remove the lower injector insulators from the intake manifold. Also check to ensure that no injector spacers were left behind when you removed the fuel rail.

NOTE:
On top feed models, the injector spacers will be reused.