Upper Intake Manifold Removal

1. Inspect right-hand valve cover for engine code(s). See Figure 1.

^ Install Kit CC for engine codes: TK352AA, TK354BA, TK352AB, TK354BB, HK352AA, HK354AA.

^ Install Kit DD for engine codes: HG352AA, HG354AA.

1. Install memory saver, then disconnect battery negative cable.

2. Drain approximately two (2) quarts of coolant from the cooling system.

3. Disconnect the Intake Air Temperature (IAT) sensor electrical connector, located on the clean air inlet tube.

4. Remove the clean air inlet tube.

5. Remove the throttle linkage cover.

6. Disconnect the throttle linkage from the throttle body.

7. Disconnect Throttle Position (TP) sensor electrical connector, then unclip connector end from throttle cable bracket.

8. Unclip the throttle cable from the coil pack bracket.

9. Unclip the throttle and speed control cables from the intake manifold.

10. Remove the throttle cable bracket retaining bolts/nuts, then position the throttle cable assembly aside.

11. Disconnect the ignition coil pack electrical connectors.

12. Disconnect the radio suppressor electrical connector.

13. Unclip the alternator wiring harness from the coil pack bracket. Position wiring harness aside.

14. Remove the coil pack bracket retaining nuts, then position the coil pack assembly aside. If necessary, tie back the assembly using tie wraps.

15. Disconnect the Idle Air Control (IAC) sensor electrical connector.

16. Remove the transmission dipstick.





17. Disconnect the EGR Vacuum Regulator (EVR) and the DPFE transducer electrical connectors. Refer to Figure 18.

18. Disconnect the EVR and the EGR valve vacuum lines. See Figure 18.

19. Disconnect the fuel pressure regulator vacuum line.

20. Remove the PCV valve from its grommet.

21. Disconnect vacuum tap from the brake booster.

22. Unclip engine main harness from rear of intake manifold. Refer to Figure 18.





23. Disconnect the Vapor Management Valve (VMV) signal and purge line. See Figure 19.

24. Remove and discard closure hose. The hose is located between the oil fill tube and throttle body.

25. Disconnect the EGR tube from the exhaust manifold.

26. Remove intake manifold cover plate.





27. Remove intake manifold retaining bolts. See Figure 20 for proper loosening sequence.

28. Remove intake manifold from engine, and place top side down on workbench. Support manifold as necessary.

29. Remove gasket from lower intake manifold.

30. Cover lower intake manifold with tape to prevent any dirt from entering cylinder ports.