GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2002 🢒 GMC K Sierra - 4WD 🢒 Preface 🢒 Cautions and Notices 🢒 Exhaust Gas Recirculation Valve Replacement

Removal Procedure

    Object Number: 798898 Size: SH
  1. Drain cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  2. Remove air intake duct. Refer to Air Cleaner Outlet Duct Replacement .
  3. Remove the turbocharger boost sensor bracket bolt.
  4. Remove the turbocharger boost sensor with bracket.
  5. Remove the intake heater and gasket.
  6. Remove the upper intake manifold tube nuts and upper tube.

    7. Object Number: 777482 Size: SH
  7. Disconnect exhaust gas recirculation (EGR) valve vacuum hose.

    8. Object Number: 784238 Size: SH
  8. Remove EGR inlet cooling hose (2) from cooling tube (1).

    9. Object Number: 784234 Size: SH
  9. Remove EGR outlet cooling hose (1) from cooling tube (2).

    10. Object Number: 777490 Size: SH
  10. Remove nuts retaining EGR assembly to intake manifold.

    11. Object Number: 784226 Size: SH
  11. Remove nuts retaining EGR assembly to exhaust pipe.
  12. Remove bolts retaining EGR assembly to EGR bracket.
  13. Remove EGR assembly from engine.

    14. Object Number: 784229 Size: SH
  14. Remove bolts (1) Retaining EGR to EGR cooling tube.
  15. Separate EGR from EGR cooling tube.

Installation Procedure

    Object Number: 784229 Size: SH
  1. Install EGR to EGR cooling tube.

    2. 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.

  2. Install bolts (1) to retain EGR to EGR cooling tube.

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


    Object Number: 784226 Size: SH
  3. Install EGR assembly to engine.
  4. Install bolts to retain EGR assembly to EGR bracket.

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

  5. Install nuts to retain EGR assembly to exhaust pipe.

    6. Tighten
    Tighten nuts to 20 N·m (15 lb ft).


    Object Number: 777490 Size: SH
  6. Install nuts to retain EGR assembly to intake manifold.

    7. Tighten
    Tighten nuts to 19 N·m (14 lb ft).


    Object Number: 784234 Size: SH
  7. Install EGR outlet cooling hose (1) to EGR cooling tube (2).

    8. Object Number: 784238 Size: SH
  8. Install EGR inlet cooling hose (2) to EGR cooling tube (1).

    9. Object Number: 777482 Size: SH
  9. Connect EGR vacuum hose to EGR.

    10. Object Number: 798898 Size: SH
  10. Install the upper intake manifold tube and nuts.

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

  11. Install the intake heater and gasket.

    12. Tighten
    Tighten the intake heater to 50 N·m (37 lb ft).

  12. Install the turbocharger boost sensor with bracket.
  13. Install the turbocharger boost sensor bracket bolt.

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

  14. Install air intake duct. Refer to Air Cleaner Outlet Duct Replacement .
  15. Fill cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.