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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 >> Removal Procedure

Removal 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: View Of Heater Inlet Hose Clamp
    GM1873268Courtesy of GENERAL MOTORS CORP.
  1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) or Cooling System Draining and Filling (Static Fill) .
  2. Remove the charger air outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement .
  3. Remove the air intake pipe. Refer to Air Intake Pipe Replacement .
    4. Fig 2: View Of Engine Wiring Harness Lead, Nut & Cover
    GM1871196Courtesy of GENERAL MOTORS CORP.
  4. Open the intake air heater (IAH) harness lead cover (2).
  5. Remove the engine wiring harness lead nut (1) from the IAH stud.
  6. Remove the engine wiring harness lead (3) from the IAH stud.
    7. Fig 3: View Of Electrical Harness Bolts
    GM1873415Courtesy of GENERAL MOTORS CORP.
  7. Remove the electrical harness bolts (1).
  8. Reposition the harness clip from the intake manifold tube, as needed.
    9. Fig 4: View Of Air Inlet Tube To Intake Manifold Tube Bolt & Nut
    GM1873422Courtesy of GENERAL MOTORS CORP.
  9. Remove the air inlet tube to intake manifold tube bolt and nut.
    10. Fig 5: View Of Air Inlet Tube & Components
    GM1873444Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the intake air heater electrical connector.
  11. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
  12. Remove the engine harness clip from the air inlet tube.
  13. Remove the air inlet tube nuts and bolt.
  14. Remove the air inlet tube.
  15. Reposition the heater inlet hose clamp (1) at the exhaust gas recirculation (EGR) valve cooler.
  16. Remove the heater inlet hose from the EGR valve cooler and reposition out of the way.
    17. Fig 6: View Of EGR Valve Cooler Coolant Hose Clamp & Nut
    GM1873269Courtesy of GENERAL MOTORS CORP.
  17. Remove the EGR valve cooler coolant hose clamp nut (2).
  18. Reposition the EGR valve cooler coolant hose clamp (1).
  19. Remove the EGR valve cooler coolant hose from the EGR valve cooler. Reposition the hose out of the way.
    20. Fig 7: View Of EGR Valve Cooler Bolts & Nuts
    GM1873274Courtesy of GENERAL MOTORS CORP.
  20. Remove the right exhaust pipe to EGR valve cooler nuts (2).
  21. Remove the rear EGR valve cooler bolts (1).
  22. Disconnect the fuel rail pressure sensor connector.
    23. Fig 8: EGR Cooler Heat Shield & Bolts
    GM2488294Courtesy of GENERAL MOTORS CORP.
  23. Remove the outside bolt (2) of the EGR cooler heat shield.
  24. Loosen the inside EGR cooler heat shield bolt (1) and rotate the heat shield counter-clockwise.
    25. Fig 9: View Of EGR Valve Cooler & Bolts
    GM1873275Courtesy of GENERAL MOTORS CORP.
  25. Remove the front EGR valve cooler bolts (1).
    26. Fig 10: Identifying EGR Valve Cooler, Gasket & EGR Temperature Sensors
    GM1998504Courtesy of GENERAL MOTORS CORP.
  26. Remove 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 .
  27. Remove the EGR valve cooler (2) and gasket (1). Discard the gasket.
    28. Fig 11: Identifying Fuel Injection Fuel Feed Manifold Bolt, Fuel Feed Pipe Nut & EGR Brackets
    GM1867255Courtesy of GENERAL MOTORS CORP.
  28. If necessary, perform the following steps in order to remove the EGR brackets:
    1. Remove the fuel injection fuel feed manifold bolt (3).
    2. Remove the fuel feed pipe nut (1) and reposition the clip.
    3. Remove the EGR bracket bolt (2).
    4. Remove the EGR brackets (4).
    29. Fig 12: Identifying EGR Valve & Mounting Bolts
    GM1867258Courtesy of GENERAL MOTORS CORP.
  29. If replacing the EGR valve cooler, perform the following steps:
    1. Reposition the EGR valve cooler hose clamp and remove the hose (4).
    2. Remove the EGR valve bolts (2).
    3. Remove the EGR valve (3).
    4. Remove and discard the EGR valve gaskets (1).
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