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Home >> Chevrolet >> 2009 >> Chevy Express G2500, Van Cargo Extended, 6.6 6 >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System & Fuel System - 6.6L LMM - Introduction >> Repair Instructions >> Exhaust Gas Recirculation Valve Cooler Replacement >> Installation Procedure

Installation Procedure

    Fig 1: View Of EGR Cooler Tube Bracket Bolts And Bracket
    GM1862391Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  1. If required, position the EGR cooler tube bracket to the cylinder head and install the bolts and tighten to 25 N.m (18 lb ft).
    2. Fig 2: Identifying EGR Cooler Tube Bolts
    GM1862364Courtesy of GENERAL MOTORS CORP.
  2. Install the EGR cooler hose (5) onto the EGR cooler tube and position the EGR cooler hose clamp (6).
  3. Install NEW intake manifold tube gaskets (1) as required.
  4. Position the EGR valve (3) to the EGR cooler tube (4).
  5. Install the EGR valve to EGR cooler tube bolts (2) and tighten to 20 N.m (15 lb ft).
    6. Fig 3: EGR Valve Cooler, Gasket And EGR Temperature Sensors
    GM1998504Courtesy of GENERAL MOTORS CORP.
  6. Install a NEW gasket (1) to the EGR valve cooler tube assembly (2)
  7. Install the EGR valve/cooler tube assembly (2) to the engine.
  8. Install the EGR valve/cooler tube assembly bolts and nut. Tighten the bolts to 25 N.m (18 lb ft).
  9. Install the EGR Valve Temperature sensors. Refer to Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1  and Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2 .
    10. Fig 4: Identifying Engine Wiring Harness Electrical Connector
    GM1862361Courtesy of GENERAL MOTORS CORP.
  10. Connect the engine wiring harness electrical connector (1) to the EGR valve.
    11. Fig 5: Identifying EGR Cooler Pipe Clamp
    GM1862359Courtesy of GENERAL MOTORS CORP.
  11. Install the EGR cooler pipe hose to the EGR cooler tube and reposition the EGR cooler pipe clamp (1).
    12. Fig 6: Identifying EGR Cooler Hose Fitting
    GM1862358Courtesy of GENERAL MOTORS CORP.
  12. Connect the EGR cooler hose fitting (2) to the heater inlet pipe.
  13. Install the heater inlet pipe bracket bolt (1) and tighten to 25 N.m (18 lb ft).
  14. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (Vac N Fill) .
  15. Install the crankcase ventilation hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .
  16. Install the right exhaust pipe. Refer to Exhaust Pipe Replacement - Right Side (6.6L (LMM)) .
  17. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement (LMM) .
  18. Install the generator. Refer to Generator Replacement (With LMM) .
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