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

Removal Procedure

    Object Number: 877275 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Loosen the charged air cooler outlet duct 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.

  3. Remove the charged air cooler outlet duct.

    4. Object Number: 788838 Size: SH
  4. Disconnect the exhaust gas recirculation (EGR) throttle valve solenoid electrical connector.

    5. Object Number: 788849 Size: SH
  5. Disconnect the EGR throttle valve solenoid vacuum lines (1).

    6. Object Number: 788850 Size: SH
  6. Remove the solenoid bolt and solenoid (1).

Installation Procedure

    Object Number: 788850 Size: SH

    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.

  1. Install the solenoid (1) and bolt.

    2. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 788849 Size: SH
  2. Connect the EGR throttle valve vacuum lines (1).

    3. Object Number: 788838 Size: SH
  3. Connect the EGR throttle valve solenoid electrical connector.

    4. Object Number: 877275 Size: SH
  4. Install the charged air cooler outlet duct to the intake.
  5. Align the mark on the duct (2) with the mark on the turbocharger.
  6. Position the clamp (1) as shown for proper clearance.

    7. Tighten
    Tighten the clamp to 6 N·m (53 lb in).

  7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.