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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 950 (Engine Controls - 6.6L (Lb7) (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.
  1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) in Engine Cooling.
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  3. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement (Federal Emissions) or Intake Manifold Tube Replacement (California Emissions) in Engine Mechanical - 6.6L.
  4. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose.
    5. Fig 1: EGR Valve Vacuum Hose
    GM777482Courtesy of GENERAL MOTORS CORP.
  5. Remove the EGR inlet cooling hose (2) from the cooling tube (1).
    6. Fig 2: Cooling Tube & EGR Inlet Cooling Hose
    GM784238Courtesy of GENERAL MOTORS CORP.
  6. Remove the EGR outlet cooling hose (1) from the cooling tube (2).
    7. Fig 3: Cooling Tube & EGR Outlet Cooling Hose
    GM784234Courtesy of GENERAL MOTORS CORP.
  7. Remove the EGR assembly to intake manifold nuts.
    8. Fig 4: EGR Assembly To Intake Manifold Nuts
    GM777490Courtesy of GENERAL MOTORS CORP.
  8. Remove the EGR assembly to exhaust pipe nuts.
  9. Remove the EGR assembly to EGR bracket bolts (2).
    10. Fig 5: EGR Bracket Bolts & Nuts
    GM784226Courtesy of GENERAL MOTORS CORP.
  10. Remove the EGR assembly.
  11. Remove the EGR assembly to EGR cooling tube bolts (1).
    12. Fig 6: EGR Cooling Tube Bolts
    GM784229Courtesy of GENERAL MOTORS CORP.
  12. Separate the EGR assembly from the EGR cooling tube.
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