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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine Controls - 6.6L - Introduction (2 Of 2)) >> Repair Instructions >> Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  3. Using a pick or a small flat-bladed screw driver, remove and discard the quick connect fitting clip from the charged air cooler outlet duct.
  4. Remove the charged air cooler outlet duct from the intake.
    Fig 1: Removing Charged Air Cooler Outlet Duct
    GM1653035Courtesy of GENERAL MOTORS CORP.
  5. Drain the cooling system. Refer to Draining and Filling Cooling System (w/RPO HP2) or Draining and Filling Cooling System (w/o RPO HP2) .
  6. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Air Cleaner Outlet Duct Replacement .
  7. Remove the electrical harness bolts.
    Fig 2: Removing Electrical Harness Bolts
    GM1602057Courtesy of GENERAL MOTORS CORP.
  8. Remove the engine harness power lead nut (2) from the intake air heater stud.
    Fig 3: Disconnecting Engine Harness Power Lead
    GM1653262Courtesy of GENERAL MOTORS CORP.
  9. Remove the engine harness power lead (1) from the intake air heater stud.
  10. Disconnect the intake air heater (IAH) electrical connector (1).
    Fig 4: Disconnecting IAH And MAP Sensor Electrical Connectors
    GM1602064Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (2).
  12. Remove the engine harness clip from the side of the air inlet tube.
    13. Fig 5: Disconnecting Air Inlet Tube From Intake Manifold Tube
    GM1602059Courtesy of GENERAL MOTORS CORP.
  13. Remove the air inlet tube to intake manifold tube bolt and nut.
    14. Fig 6: Removing Air Inlet Tube
    GM1602060Courtesy of GENERAL MOTORS CORP.
  14. Remove the air inlet tube nuts.
  15. Remove the air inlet tube.
    16. Fig 7: View Of EGR Valve Electrical Connector
    GM1335463Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
  17. Disconnect the EGR cooler tube heater hose.
  18. Remove the EGR coolant pipe bolts.
  19. Remove the EGR coolant pipe.
    Fig 8: View Of Exhaust Gas Recirculation (EGR) Coolant Pipe, Hose & Bolts
    GM1335419Courtesy of GENERAL MOTORS CORP.
  20. Remove the rear EGR cooler tube bolts.
    Fig 9: Removing Rear EGR Cooler Tube Bolts
    GM1335568Courtesy of GENERAL MOTORS CORP.
  21. Remove the EGR cooler tube bolts.
    Fig 10: Removing EGR Mount Bolt
    GM1335571Courtesy of GENERAL MOTORS CORP.
  22. Remove the EGR cooler tube.
    Fig 11: Removing EGR And Cooler
    GM1335573Courtesy of GENERAL MOTORS CORP.
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