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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 >> Removal Procedure

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.
    Fig 1: View Of Charged Air Cooler Outlet Duct
    GM1334381Courtesy of GENERAL MOTORS CORP.
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  3. Loosen the charged air cooler outlet duct to intake hose clamp.
    IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  4. Remove the charged air cooler outlet duct from the intake.
  5. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) in Engine Cooling.
  6. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Air Cleaner Outlet Duct Replacement .
    7. Fig 2: View Of Electrical Harness Tie Strap
    GM1335476Courtesy of GENERAL MOTORS CORP.
  7. If necessary, remove the tie strap from the electrical harness.
    8. Fig 3: View Of Air Inlet Tube To Intake Manifold Tube
    GM1335562Courtesy of GENERAL MOTORS CORP.
  8. Remove the air inlet tube to intake manifold tube bolt and nut.
    9. Fig 4: View Of Air Inlet Tube
    GM1335564Courtesy of GENERAL MOTORS CORP.
  9. Remove the air inlet tube nuts.
  10. Remove the air inlet tube.
    11. Fig 5: View Of EGR Valve Electrical Connector
    GM1335463Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
    12. Fig 6: View Of Exhaust Gas Recirculation (EGR) Coolant Pipe, Hose & Bolts
    GM1335419Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the EGR cooler tube heater hose.
  13. Remove the EGR coolant pipe bolts.
  14. Remove the EGR coolant pipe.
    15. Fig 7: Locating Rear EGR Cooler Tube Bolts
    GM1335568Courtesy of GENERAL MOTORS CORP.
  15. Remove the rear EGR cooler tube bolts.
    16. Fig 8: Locating EGR Cooler Tube Bolts
    GM1335571Courtesy of GENERAL MOTORS CORP.
  16. Remove the EGR cooler tube bolts.
    17. Fig 9: View Of EGR & Cooler
    GM1335573Courtesy of GENERAL MOTORS CORP.
  17. Remove the EGR cooler tube.
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