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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 977 (Engine Controls - 6.6L (LLY) (Introduction)) >> Repair Instructions >> Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement >> Installation Procedure

Installation 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.
    Fig 1: View Of EGR & Cooler
    GM1335573Courtesy of GENERAL MOTORS CORP.
  1. Install the EGR cooler tube.
    2. Fig 2: Locating EGR Cooler Tube Bolts
    GM1335571Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the EGR cooler tube bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    3. Fig 3: Locating Rear EGR Cooler Tube Bolts
    GM1335568Courtesy of GENERAL MOTORS CORP.
  3. Install the rear EGR cooler tube bolts.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

    4. Fig 4: View Of Exhaust Gas Recirculation (EGR) Coolant Pipe, Hose & Bolts
    GM1335419Courtesy of GENERAL MOTORS CORP.
  4. Install the EGR coolant pipe.
  5. Install the EGR coolant pipe bolts.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

  6. Connect the EGR cooler tube heater hose.
    7. Fig 5: View Of EGR Valve Electrical Connector
    GM1335463Courtesy of GENERAL MOTORS CORP.
  7. Connect the EGR valve electrical connector.
    8. Fig 6: View Of Air Inlet Tube
    GM1335564Courtesy of GENERAL MOTORS CORP.
  8. Install the air inlet tube.
  9. Install the air inlet tube nuts.

    Tighten:  Tighten the nuts to 25 N.m (18 lb ft).

    10. Fig 7: View Of Air Inlet Tube To Intake Manifold Tube
    GM1335562Courtesy of GENERAL MOTORS CORP.
  10. Install the air inlet tube to intake manifold tube bolt and nut.

    Tighten:  Tighten the bolt/nut to 10 N.m (89 lb in).

    11. Fig 8: View Of Electrical Harness Tie Strap
    GM1335476Courtesy of GENERAL MOTORS CORP.
  11. If necessary, install a tie strap to the electrical harness.
  12. Install the PCV hose/pipe. Refer to Air Cleaner Outlet Duct Replacement .
    13. Fig 9: View Of Charged Air Cooler Outlet Duct
    GM1334381Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lubricate the end of the duct prior to installation.
  13. Install the charged air cooler outlet duct to the intake.
  14. Tighten the charged air cooler outlet duct to intake hose clamp.

    Tighten:  Tighten the clamp to 6 N.m (53 lb in).

  15. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
  16. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) in Engine Cooling.
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