GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2003 🢒 GMC K Sierra - 4WD 🢒 Engine 🢒 Engine Controls - 6.6L 🢒 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 cleaner outlet 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 the 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 the EGR outlet cooling hose (1) from cooling tube (2).

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

    11. Object Number: 784226 Size: SH
  11. Remove the EGR assembly to exhaust pipe nuts.
  12. Remove the EGR assembly to EGR bracket (2) bolts.
  13. Remove the EGR assembly from the engine and discard the EGR gasket.

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

Installation Procedure

    Object Number: 784229 Size: SH

    Important: Use a NEW EGR valve gasket when installing the EGR valve.

  1. Install the EGR valve to the EGR cooling tube.

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

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

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


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

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

  5. Install the EGR assembly to exhaust pipe nuts.

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


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

    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 the EGR inlet cooling hose (2) to the EGR cooling tube (1).

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

    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 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 cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  15. Fill cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.