GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Chevy C Silverado - 2WD 🢒 Engine 🢒 Engine Controls - 6.6L (LLY) 🢒 Exhaust Gas Recirculation Valve Cooler Replacement

Removal Procedure

    Object Number: 1334381 Size: SH
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  3. Loosen the charged air cooler outlet duct to intake hose clamp.

    4. 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 outlet duct from the intake.
  5. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  6. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Air Cleaner Outlet Duct Replacement .

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

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

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

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

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

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

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

    17. Object Number: 1335573 Size: SH
  17. 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 25 N·m (18 lb ft).


    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. Install the PCV hose/pipe. Refer to Air Cleaner Outlet Duct Replacement .

    13. Object Number: 1334381 Size: SH

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

  13. Install the charged air cooler outlet duct to the intake.
  14. Tighten the charged air cooler outlet duct to intake hose clamp.

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

  15. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
  16. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.