GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2006 🢒 GMC Sierra Denali 🢒 Vehicle Control Systems 🢒 Vehicle DTC Information 🢒 Exhaust Gas Recirculation Valve Cooler Replacement

Removal Procedure

    Object Number: 1653035 Size: SH
  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.
  5. Drain the cooling system. Refer to Cooling System Draining and Filling .
  6. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .
  7. Remove the generator. Refer to Generator Replacement .

    8. Object Number: 1602057 Size: SH
  8. Remove the electrical harness bolts.

    9. Object Number: 1653262 Size: SH
  9. Remove the engine harness power lead nut (2) from the intake air heater stud.
  10. Remove the engine harness power lead (1) from the intake air heater stud.

    11. Object Number: 1602064 Size: SH
  11. Disconnect the intake air heater (IAH) electrical connector (1).
  12. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (2).
  13. Remove the engine harness clip from the side of the air inlet tube.

    14. Object Number: 1602059 Size: SH
  14. Remove the air inlet tube to intake manifold tube bolt and nut.

    15. Object Number: 1602060 Size: SH
  15. Remove the air inlet tube nuts.
  16. Remove the air inlet tube.

    17. Object Number: 1335463 Size: SH
  17. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.

    18. Object Number: 1335419 Size: SH
  18. Disconnect the EGR cooler tube heater hose.
  19. Remove the EGR coolant pipe bolts.
  20. Remove the EGR coolant pipe.

    21. Object Number: 1650663 Size: SH
  21. Remove the rear EGR cooler tube bolts.

    22. Object Number: 1335571 Size: SH
  22. Remove the EGR cooler tube bolts.

    23. Object Number: 1335573 Size: SH
  23. Remove the EGR cooler tube.

Installation Procedure

    Object Number: 1335573 Size: SH
  1. Install the EGR cooler tube.

    2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1335571 Size: SH
  2. Install the EGR cooler tube bolts.

    3. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).


    Object Number: 1650663 Size: SH
  3. Install the rear EGR cooler tube bolts.

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


    Object Number: 1335419 Size: SH
  4. Install the EGR coolant pipe.
  5. Install the EGR coolant pipe bolts.

    6. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  6. Connect the EGR cooler tube heater hose.

    7. Object Number: 1335463 Size: SH
  7. Connect the EGR valve electrical connector.

    8. Object Number: 1602060 Size: SH
  8. Install the air inlet tube.
  9. Install the air inlet tube nuts.

    10. Tighten
    Tighten the nuts to 25 N·m (18 lb ft).


    Object Number: 1602059 Size: SH
  10. Install the air inlet tube to intake manifold tube bolt and nut.

    11. Tighten
    Tighten the bolt/nut to 10 N·m (89 lb in).


    Object Number: 1602064 Size: SH
  11. Install the engine harness clip to the side of the air inlet tube.
  12. Connect the MAP sensor electrical connector (2).
  13. Connect the IAH electrical connector (1).

    14. Object Number: 1653262 Size: SH
  14. Install the engine harness power lead (1) to the intake air heater stud.
  15. Install the engine harness power lead nut (2) to the intake air heater stud.

    16. Tighten
    Tighten the nut to 10 N·m (89 lb in).


    Object Number: 1602057 Size: SH
  16. Install a electrical harness bolts.

    17. Tighten
    Tighten the bolts to 4 N·m (35 lb in).

  17. Install the PCV hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .
  18. Install the generator. Refer to Generator Replacement .

    19. Object Number: 1653035 Size: SH
  19. Install a NEW quick connect fitting clip to the charged air cooler duct.
  20. Install the charged air cooler outlet duct to the intake.
  21. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  22. Fill the cooling system. Refer to Cooling System Draining and Filling .