Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Drain cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) in Engine Cooling.
Remove air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
Remove the turbocharger boost sensor bracket bolt.
Remove the turbocharger boost sensor with bracket.

Fig 1: Turbocharger Boost Sensor & Bracket

GM798898

Courtesy of GENERAL MOTORS CORP.

Remove the intake heater and gasket.
Remove the upper intake manifold tube nuts and upper tube.
Disconnect the exhaust gas recirculation (EGR) valve vacuum hose.

Fig 2: EGR Valve Vacuum Hose

GM777482

Courtesy of GENERAL MOTORS CORP.

Remove EGR inlet cooling hose (2) from cooling tube (1).

Fig 3: Cooling Tube & EGR Inlet Cooling Hose

GM784238

Courtesy of GENERAL MOTORS CORP.

Remove the EGR outlet cooling hose (1) from cooling tube (2).

Fig 4: Cooling Tube & EGR Outlet Cooling Hose

GM784234

Courtesy of GENERAL MOTORS CORP.

Remove the EGR assembly to intake manifold nuts.

Fig 5: EGR Assembly To Intake Manifold Nuts

GM777490

Courtesy of GENERAL MOTORS CORP.

Remove the EGR assembly to exhaust pipe nuts.
Remove the EGR assembly to EGR bracket (2) bolts.

Fig 6: EGR Bracket Bolts & Nuts

GM784226

Courtesy of GENERAL MOTORS CORP.

Remove the EGR assembly from the engine.
Remove the EGR to EGR cooling tube bolts (1).

Fig 7: EGR Cooling Tube Bolts

GM784229

Courtesy of GENERAL MOTORS CORP.

Separate the EGR valve from the EGR cooling tube.