SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 380 (ENGINE CONTROLS - 6.6L (LB7) (INTRODUCTION))REPAIR INSTRUCTIONSEXHAUST GAS RECIRCULATION (EGR) VALVE REPLACEMENTREMOVAL PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Removal Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Removal Procedure
WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Drain cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) 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. Fig 1: Turbocharger Boost Sensor & Bracket
    GM798898Courtesy of GENERAL MOTORS CORP.
  5. Remove the intake heater and gasket.
  6. Remove the upper intake manifold tube nuts and upper tube.
  7. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose.
    8. Fig 2: EGR Valve Vacuum Hose
    GM777482Courtesy of GENERAL MOTORS CORP.
  8. Remove EGR inlet cooling hose (2) from cooling tube (1).
    9. Fig 3: Cooling Tube & EGR Inlet Cooling Hose
    GM784238Courtesy of GENERAL MOTORS CORP.
  9. Remove the EGR outlet cooling hose (1) from cooling tube (2).
    10. Fig 4: Cooling Tube & EGR Outlet Cooling Hose
    GM784234Courtesy of GENERAL MOTORS CORP.
  10. Remove the EGR assembly to intake manifold nuts.
    11. Fig 5: EGR Assembly To Intake Manifold Nuts
    GM777490Courtesy of GENERAL MOTORS CORP.
  11. Remove the EGR assembly to exhaust pipe nuts.
  12. Remove the EGR assembly to EGR bracket (2) bolts.
    13. Fig 6: EGR Bracket Bolts & Nuts
    GM784226Courtesy of GENERAL MOTORS CORP.
  13. Remove the EGR assembly from the engine.
  14. Remove the EGR to EGR cooling tube bolts (1).
    15. Fig 7: EGR Cooling Tube Bolts
    GM784229Courtesy of GENERAL MOTORS CORP.
  15. Separate the EGR valve from the EGR cooling tube.
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

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.