GM Service Manual Online
For 1990-2009 cars only

Tools Required

    • J 25034-C Power Steering Pump Pulley Remover
    • J 25033-C Power Steering Pump Pulley Installer

Removal Procedure


    Object Number: 877275  Size: SH
  1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement .
  2. Loosen the charged air cooler outlet duct to clamp (1).
  3. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

  4. Remove the charged air cooler outer duct.
  5. Remove the fan clutch. Refer to Fan Clutch Replacement .

  6. Object Number: 788902  Size: SH
  7. Remove the vacuum line from the exhaust gas recirculation (EGR) valve vacuum pump.
  8. Remove drive belt. Refer to Drive Belt Replacement .

  9. Object Number: 649303  Size: SH
  10. Remove the EGR vacuum pump pulley using the J 25034-C .

  11. Object Number: 788903  Size: SH
  12. Remove EGR vacuum pump nuts (1).

  13. Object Number: 788904  Size: SH
  14. Remove the EGR vacuum pump.

Installation Procedure


    Object Number: 788904  Size: SH
  1. Install the EGR vacuum pump.
  2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 788903  Size: SH
  3. Install the EGR vacuum pump bolts (1) .
  4. Tighten
    Tighten the bolts to 22 N·m (16 lb ft).


    Object Number: 643361  Size: SH
  5. Install the EGR vacuum pump pulley using the J 25033-C .
  6. Install the drive belt. Refer to Drive Belt Replacement .

  7. Object Number: 788902  Size: SH
  8. Install the vacuum line to the EGR vacuum pump.
  9. Install the fan clutch. Refer to Fan Clutch Replacement .

  10. Object Number: 877275  Size: SH
  11. Install the charged air cooler outer duct to the intake.
  12. Align the mark on the duct (2) with the mark on the turbocharger.
  13. Position the clamp (1) as shown for proper clearance.
  14. Tighten
    Tighten the clamp to 6 N·m (53 lb in).

  15. Install the air cleaner. Refer to Air Cleaner Assembly Replacement .