GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2009 🢒 Sierra - 4WD 🢒 Engine 🢒 Engine Controls and Fuel - 6.6L 🢒 Exhaust Gas Recirculation Valve Cooler Replacement

Removal Procedure

    Object Number: 1873268 Size: SH
  1. Drain the cooling system. Refer to Cooling System Draining and Filling.
  2. Remove the charger air outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement.
  3. Remove the air intake pipe. Refer to Air Intake Pipe Replacement.
  4. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement.
  5. Reposition the heater inlet hose clamp (1) at the exhaust gas recirculation (EGR) valve cooler.
  6. Remove the heater inlet hose from the EGR valve cooler and reposition out of the way.

    7. Object Number: 1873269 Size: SH
  7. Remove the EGR valve cooler coolant hose clamp nut (2).
  8. Reposition the EGR valve cooler coolant hose clamp (1).
  9. Remove the EGR valve cooler coolant hose from the EGR valve cooler. Reposition the hose out of the way.

    10. Object Number: 1873274 Size: SH
  10. Remove the right exhaust pipe to EGR valve cooler nuts (2).
  11. Remove the rear EGR valve cooler bolts (1).

    12. Object Number: 1873275 Size: SH
  12. Remove the front EGR valve cooler bolts (1).

    13. Object Number: 1998504 Size: SH
  13. Remove the EGR temperature sensors (3). Refer to Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 or Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2.
  14. Remove the EGR valve cooler (2) and gasket (1). Discard the gasket.

    15. Object Number: 1867255 Size: SH
  15. If necessary, perform the following steps in order to remove the EGR brackets:
    16. 15.1. Remove the fuel injection fuel feed manifold bolt (3).
    15.2. Remove the fuel feed pipe nut (1) and reposition the clip.
    15.3. Remove the EGR bracket bolt (2).
    15.4. Remove the EGR brackets (4).

    Object Number: 1867258 Size: SH
  16. If replacing the EGR valve cooler, perform the following steps:
    17. 16.1. Reposition the EGR valve cooler hose clamp and remove the hose (4).
    16.2. Remove the EGR valve bolts (2).
    16.3. Remove the EGR valve (3).
    16.4. Remove and discard the EGR valve gaskets (1).

Installation Procedure

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1867258 Size: SH
  1. If the EGR valve cooler was replaced, perform the following steps:
    2. 1.1. Position the EGR valve (3) to the cooler.
    1.2. Install the EGR valve bolts (2).

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

    1.3. Install the EGR valve cooler hose (4) and position the hose clamp.
    1.4. Install NEW EGR valve gaskets (1).

    Object Number: 1867255 Size: SH
  2. If necessary, perform the following steps in order to install the EGR brackets:
    3. 2.1. Position the EGR brackets (4).
    2.2. Install the EGR bracket bolt (2).

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

    2.3.  Position the clip and install the fuel feed pipe nut (1).

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

    2.4. Install the fuel injection fuel feed manifold bolt (3).

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


    Object Number: 1998504 Size: SH
  3. Install a NEW EGR valve cooler gasket (1) onto the cooler studs, and install the EGR cooler (2) to the engine.
  4. Install the EGR temperature sensors (3). Refer to Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 or Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2.

    5. Object Number: 1873275 Size: SH
  5. Install the front EGR valve cooler bolts (1).

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


    Object Number: 1873274 Size: SH
  6. Install the rear EGR valve cooler bolts (1).

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

  7. Install the right exhaust pipe to EGR valve cooler nuts (2).

    8. Tighten
    Tighten the nuts to 53 N·m (39 lb ft).


    Object Number: 1873269 Size: SH
  8. Position the EGR valve cooler coolant hose, and install the hose to the EGR valve cooler.
  9. Position the EGR valve cooler coolant hose clamp (1).
  10. Install the EGR valve cooler coolant hose clamp nut (2).

    11. Tighten
    Tighten the nut to 24 N·m (18 lb ft).


    Object Number: 1873268 Size: SH
  11. Position the heater inlet hose and install the hose to the EGR valve cooler.
  12. Position the heater inlet hose clamp (1) at the EGR valve cooler.
  13. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement.
  14. Install the air intake pipe. Refer to Air Intake Pipe Replacement.
  15. Install the charger air outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement.
  16. Fill the cooling system. Refer to Cooling System Draining and Filling.