LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1560 (Engine Control System & Fuel System - 6.6L (LMM) - Repair Instructions) >> Repair Instructions >> Exhaust Gas Recirculation Valve Cooler Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2010 GMC Sierra, 2010 GMC Cab & Chassis Sierra, 2010 Chevrolet Silverado, and 2010 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying EGR Valve & Mounting Bolts
    GM1867258Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  1. If the EGR valve cooler was replaced, perform the following steps:
    1. Position the EGR valve (3) to the cooler.
    2. Install the EGR valve bolts (2).

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

    3. Install the EGR valve cooler hose (4) and position the hose clamp.
    4. Install NEW EGR valve gaskets (1).
    2. Fig 2: Identifying Fuel Injection Fuel Feed Manifold Bolt, Fuel Feed Pipe Nut & EGR Brackets
    GM1867255Courtesy of GENERAL MOTORS CORP.
  2. If necessary, perform the following steps in order to install the EGR brackets:
    1. Position the EGR brackets (4).
    2. Install the EGR bracket bolt (2).

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

    3. Position the clip and install the fuel feed pipe nut (1).

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

    4. Install the fuel injection fuel feed manifold bolt (3).

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

    3. Fig 3: Identifying EGR Valve Cooler, Gasket & EGR Temperature Sensors
    GM1998504Courtesy of GENERAL MOTORS CORP.
  3. Install a NEW EGR valve cooler gasket (1) onto the cooler studs, and install the EGR cooler (2) to the engine.
  4. Install the EGR temperature sensors (3). Refer to Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1  or Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2 .
    5. Fig 4: View Of EGR Valve Cooler & Bolts
    GM1873275Courtesy of GENERAL MOTORS CORP.
  5. Install the front EGR valve cooler bolts (1).

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

    6. Fig 5: EGR Cooler Heat Shield & Bolts
    GM2488294Courtesy of GENERAL MOTORS CORP.
  6. Rotate the EGR cooler heat shield clock-wise and align the outside bolt hole.
  7. Tighten the inside EGR cooler heat shield bolt (1) to 25 N.m (18 lb ft).
  8. Connect the electrical connector to the fuel rail pressure sensor and tighten the outside bolt (2) to 25 N.m (18 lb ft).
    9. Fig 6: View Of EGR Valve Cooler Bolts & Nuts
    GM1873274Courtesy of GENERAL MOTORS CORP.
  9. Install the rear EGR valve cooler bolts (1).

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

  10. Install the right exhaust pipe to EGR valve cooler nuts (2).

    Tighten:  Tighten the nuts to 53 N.m (39 lb ft).

    11. Fig 7: View Of EGR Valve Cooler Coolant Hose Clamp & Nut
    GM1873269Courtesy of GENERAL MOTORS CORP.
  11. Position the EGR valve cooler coolant hose, and install the hose to the EGR valve cooler.
  12. Position the EGR valve cooler coolant hose clamp (1).
  13. Install the EGR valve cooler coolant hose clamp nut (2).

    Tighten:  Tighten the nut to 24 N.m (18 lb ft).

    14. Fig 8: View Of Heater Inlet Hose Clamp
    GM1873268Courtesy of GENERAL MOTORS CORP.
  14. Position the heater inlet hose and install the hose to the EGR valve cooler.
  15. Position the heater inlet hose clamp (1) at the EGR valve cooler.
    16. Fig 9: View Of Air Inlet Tube & Components
    GM1873444Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution
  16. Install the air inlet tube and NEW gaskets.
  17. Install the air inlet tube nuts and bolt.

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

  18. Connect the intake air heater electrical connector.
  19. Connect the MAP sensor electrical connector.
  20. Install the engine harness clip to the air inlet tube.
    21. Fig 10: View Of Air Inlet Tube To Intake Manifold Tube Bolt & Nut
    GM1873422Courtesy of GENERAL MOTORS CORP.
  21. Install the air inlet tube to intake manifold tube bolt and nut.

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

    22. Fig 11: View Of Electrical Harness Bolts
    GM1873415Courtesy of GENERAL MOTORS CORP.
  22. Install the electrical harness bolts (1).

    Tighten:  Tighten the bolts to 4 N.m (35 lb in).

    23. Fig 12: View Of Engine Wiring Harness Lead, Nut & Cover
    GM1871196Courtesy of GENERAL MOTORS CORP.
  23. Install the engine wiring harness lead (3) to the IAH stud.
  24. Install the engine wiring harness lead nut (1) to the IAH stud.

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

  25. Close the IAH harness lead cover (2).
  26. Install the air intake pipe. Refer to Air Intake Pipe Replacement .
  27. Install the charger air outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement .
  28. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) or Cooling System Draining and Filling (Static Fill) .
scientia non olet · About LEMON Manuals