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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 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.
  1. Install the EGR valve to the EGR cooling tube.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the EGR to EGR cooling tube bolts (1).

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

    3. Fig 1: EGR Cooling Tube Bolts
    GM784229Courtesy of GENERAL MOTORS CORP.
  3. Install the EGR assembly to the engine.
  4. Install the EGR assembly to EGR bracket bolts.

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

  5. Install the EGR assembly to exhaust pipe nuts.

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

    6. Fig 2: EGR Bracket Bolts & Nuts
    GM784226Courtesy of GENERAL MOTORS CORP.
  6. Install the EGR assembly to intake manifold nuts.

    Tighten:  Tighten nuts to 19 N.m (14 lb ft).

    7. Fig 3: EGR Assembly To Intake Manifold Nuts
    GM777490Courtesy of GENERAL MOTORS CORP.
  7. Install EGR outlet cooling hose (1) to EGR cooling tube (2).
    8. Fig 4: Cooling Tube & EGR Outlet Cooling Hose
    GM784234Courtesy of GENERAL MOTORS CORP.
  8. Install the EGR inlet cooling hose (2) to the EGR cooling tube (1).
    9. Fig 5: Cooling Tube & EGR Inlet Cooling Hose
    GM784238Courtesy of GENERAL MOTORS CORP.
  9. Connect the EGR vacuum hose to the EGR valve.
    10. Fig 6: EGR Valve Vacuum Hose
    GM777482Courtesy of GENERAL MOTORS CORP.
  10. Install the upper intake manifold tube and nuts.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

  11. Install the intake heater and gasket.

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

    12. Fig 7: Turbocharger Boost Sensor & Bracket
    GM798898Courtesy of GENERAL MOTORS CORP.
  12. Install the turbocharger boost sensor with bracket.
  13. Install the turbocharger boost sensor bracket bolt.

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

  14. Install air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  15. Fill 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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