GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Chevy K Silverado - 4WD 🢒 Engine 🢒 Engine Controls - 6.6L 🢒 Exhaust Gas Recirculation Valve Cooler Replacement

Removal Procedure

    Object Number: 777482 Size: SH
  1. Drain the cooling system. Refer to Cooling System Draining and Filling 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 in Engine Mechanical - 6.6L.
  4. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose.

    5. Object Number: 784238 Size: SH
  5. Remove the EGR inlet cooling hose (2) from the cooling tube (1).

    6. Object Number: 784234 Size: SH
  6. Remove the EGR outlet cooling hose (1) from the cooling tube (2).

    7. Object Number: 777490 Size: SH
  7. Remove the EGR assembly to intake manifold nuts.

    8. Object Number: 784226 Size: SH
  8. Remove the EGR assembly to exhaust pipe nuts.
  9. Remove the EGR assembly to EGR bracket bolts (2).
  10. Remove the EGR assembly.

    11. Object Number: 784229 Size: SH
  11. Remove the EGR assembly to EGR cooling tube bolts (1).
  12. Separate the EGR assembly from the EGR cooling tube.

Installation Procedure

    Object Number: 784229 Size: SH
  1. Install the EGR assembly to the EGR cooling tube.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the EGR assembly to EGR cooling tube bolts (1).

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


    Object Number: 784226 Size: SH
  3. Install the EGR assembly.
  4. Install the EGR assembly to the EGR bracket bolts.

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

  5. Install the EGR assembly to exhaust pipe nuts.

    6. Tighten
    Tighten the nuts to 20 N·m (15 lb ft.)


    Object Number: 777490 Size: SH
  6. Install the EGR assembly to intake manifold nuts.

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


    Object Number: 784234 Size: SH
  7. Install the EGR outlet cooling hose (1) to the EGR cooling tube (2).

    8. Object Number: 784238 Size: SH
  8. Install the EGR inlet cooling hose (2) to the EGR cooling tube (1).

    9. Object Number: 777482 Size: SH
  9. Connect the EGR vacuum hose.
  10. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement in Engine Mechanical - 6.6L.
  11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  12. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.