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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 941 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 6.6L (LMM) - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSEXHAUST GAS RECIRCULATION VALVE REPLACEMENTREMOVAL PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Removal Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Removal Procedure
WARNING: This page is about a different car, the 2007 GMC Savana Special, 2007 GMC Savana Camper Special, 2007 GMC Savana, and 2007 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying EGR Cooler Hose Fitting
    GM1862358Courtesy of GENERAL MOTORS CORP.
  1. Remove the generator. Refer to Generator Replacement (6.6L) .
  2. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement (LLY, LBZ) or Intake Manifold Tube Replacement (LMM) .
  3. Remove the right exhaust pipe. Refer to Exhaust Pipe Replacement - Right Side (6.6L (LBZ/LLY)) or Exhaust Pipe Replacement - Right Side (6.6L (LMM)) .
  4. Remove the crankcase ventilation hose/pipe. Refer to Crankcase Ventilation Hoses/Pipes Replacement (LLY, LBZ) or Crankcase Ventilation Hoses/Pipes Replacement (LMM) .
  5. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) or Draining and Filling Cooling System (Vac N Fill) .
  6. Remove the heater inlet pipe bracket bolt (1).
  7. Using the J 43181  , disconnect the exhaust gas recirculation (EGR) cooler hose fitting (2) from the heater inlet pipe.
    8. Fig 2: Identifying EGR Cooler Pipe Clamp
    GM1862359Courtesy of GENERAL MOTORS CORP.
  8. Reposition the EGR cooler pipe clamp (1) and remove the EGR cooler pipe hose from the EGR cooler tube.
    9. Fig 3: Identifying Engine Wiring Harness Electrical Connector
    GM1862361Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the engine wiring harness electrical connector (1) from the EGR valve.
    10. Fig 4: Identifying EGR Valve/Cooler Tube Assembly Bolts And Nut
    GM1862362Courtesy of GENERAL MOTORS CORP.
  10. Remove the EGR valve/cooler tube assembly bolts and nut.
  11. Remove the EGR valve/cooler tube assembly from the engine and place on a clean work surface.
    12. Fig 5: Identifying EGR Cooler Tube Bolts
    GM1862364Courtesy of GENERAL MOTORS CORP.
  12. On the bench, remove the EGR valve to EGR cooler tube bolts (2).
  13. Separate the EGR valve (3) from the EGR cooler tube (4).
  14. Remove and discard the intake manifold tube gaskets (1) as required.
    15. Fig 6: Identifying EGR Bracket Bolt, Nut, And Egr Bracket
    GM1731887Courtesy of GENERAL MOTORS CORP.
  15. If required, remove the EGR bracket bolt, nut, and EGR bracket.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.