GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2004 🢒 TopKick C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Electrical 🢒 Exhaust Gas Recirculation Valve Cooler Replacement

Removal Procedure
  1. Remove the air cleaner. Refer to Air Cleaner Replacement .
  2. Remove the charged air cooler pipe from the outlet. Refer to Charged Air Cooler Hoses/Pipes Replacement for the 6.6L (LLY) engine.
  3. Drain the cooling system. Refer to Cooling System Draining and Filling .

    4. Object Number: 1335454 Size: SH
  4. Reposition the positive crankcase ventilation (PCV) hose clamp at the resonator tee.
  5. Remove the PCV hose from the tee.

    6. Object Number: 1335456 Size: SH
  6. Remove the PCV hose/pipe bolt.

    7. Object Number: 1335462 Size: SH
  7. Remove the PCV hose/pipe.

    8. Object Number: 1335476 Size: SH
  8. If necessary, remove the tie strap from the electrical harness.

    9. Object Number: 1335562 Size: SH
  9. Remove the air inlet tube to intake manifold tube bolt and nut.

    10. Object Number: 1335564 Size: SH
  10. Remove the air inlet tube nuts.
  11. Remove the air inlet tube.

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

    13. Object Number: 1335419 Size: SH
  13. Disconnect the EGR cooler tube heater hose.
  14. Remove the EGR coolant pipe bolts.
  15. Remove the EGR coolant pipe.

    16. Object Number: 1335568 Size: SH
  16. Remove the rear EGR cooler tube bolts.

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

    18. Object Number: 1335573 Size: SH
  18. 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: 1335568 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: 1335564 Size: SH
  8. Install the air inlet tube.
  9. Install the air inlet tube nuts.

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


    Object Number: 1335562 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: 1335476 Size: SH
  11. If necessary, install a tie strap to the electrical harness.

    12. Object Number: 1335462 Size: SH
  12. Install the PCV hose/pipe.

    13. Object Number: 1335456 Size: SH
  13. Install the PCV hose/pipe bolt.

    14. Tighten
    Tighten the bolt to 18 N·m (13 lb ft).


    Object Number: 1335454 Size: SH
  14. Install the PCV hose to the tee.
  15. Position the PCV hose clamp at the resonator tee.

    16. Important: Lubricate the end of the duct prior to installation.

  16. Install the charged air cooler pipe to the outlet. Refer to Charged Air Cooler Hoses/Pipes Replacement for the 6.6L (LLY) engine.
  17. Install the air cleaner. Refer to Air Cleaner Replacement .
  18. Fill the cooling system. Refer to Cooling System Draining and Filling .