Xcessive Manufacturing.com

Nissan intake manifold (New Casting)

‘89-’98 240 SX KA24DE U.S.A (DOHC)

Your kit should include:

·         1 Xcessive designed Intake runner

·         1 Xcessive Plenum

·         1 Xcessive thermal intake gasket

·         9 – 8mm x 1.25 x 30 Plated bolts

·         1 – 8mm x 1.25 x 45 Plated bolt

·         1 Stock KA Stainless steel throttle cable bracket (Not included with Q45 unless ordered)

·         2 - 8mm x 1.25 x 50 Plated bolts (Fuel Rail)

·         2 – 38mm Fuel rail Aluminum stand offs

·         4 – 9/16” ID x 3/32 O-rings for stock injectors

·         10 - 6mm Plated flange head plenum bolts

·         2 Vacuum port plugs , 1/8”

·         2 Hose barbs, 1 each 1/8" and 3/8"

·         1 – 3/8” Npt to ¾” Barb

Installation Instructions

1. Be sure the engine has adequately cooled before starting disassembly.
2. Disconnect all factory electrical connections on the stock manifold.
3. Disconnect the fuel lines and remove the fuel rail and injectors. Stock injector O-rings will not be needed.
4. Disconnect the air intake from the throttle body.
5. Remove the stock plenum from the lower runners. This allows easier access to the bolts on the head flange, as well as allowing removal of the lower block brace, which will not be used. There will be coolant and vacuum lines that need to be disconnected to allow removal of the stock intake.
6. It will be necessary to reroute or close off coolant/heater hoses for the installation of this manifold.
7. Remove the old manifold studs from the head and clean the head of all old gasket material.
8. Transfer the two coolant sensors from the old runners to the new set. Install the sensors with a thread sealant such as silicone or RTV.  Install the ¾” hose barb on the bottom of the water neck for the coolant reticulation line.
9. Install the new intake runners and thermal gasket with the new bolts provided. The 5 short bolts are for the top row, the one long bolt goes next to the water outlet port on the bottom, the remaining 4 mid length bolts are for the bottom holes below the ports.
10. Fit the new plenum to locate the vacuum ports required for your installation. This plenum has two ports on top and two ports on the bottom for multiple hookups as needed. The 3/8" barb is for the brake booster the 1/8” barb is for the fuel pressure regulator.
11. Install the plenum with the 10 supplied flange head bolts using a bead of sealant like silicone or RTV.
12. Install the throttle body with a stock gasket or sealant using the two lower bolts first, the two upper bolts will hold the throttle cable bracket.
13. The fuel rail will require the rear mounting tab to have the lower rear corner modified or it will hit the runners and not allow the rail to sit flat. Remove approximately ¼” (6mm) from the corner, a file, grinder or saw will work.
14. Install the 4 new O-rings on the nose of the stock injectors, install the fuel rail with the new aluminum stand off tubes and 8mm bolts using the two lower mounting tabs of the fuel rail, plug in the necessary wiring. The IAC's will not be used and the throttle blade will require adjustment for proper idle.
15. Reconnect the intake piping. Stock intake tubes may require modification or replacement.
16. Be sure to check your hood clearance if using a Q45 throttle body.

Some modifications may be required to install and use this product. This product is for off road use only and not intended for use on emissions controlled vehicles. By purchasing this product you are assuming all liabilities associated with its installation and use