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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 5 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 6.6L (LMM) - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSEXHAUST GAS RECIRCULATION VALVE COOLER REPLACEMENTREMOVAL PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Removal Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Removal Procedure
WARNING: This page is about a different variant/trim than selected.
    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 (LMM) .
  3. Remove the right exhaust pipe. Refer to Exhaust Pipe Replacement - Right Side (6.6L (LMM)) .
  4. Remove the crankcase ventilation hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (LMM) .
  5. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (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. See Special Tools .
    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: EGR Valve Cooler, Gasket And EGR Temperature Sensors
    GM1998504Courtesy of GENERAL MOTORS CORP.
  10. Remove the EGR valve temperature sensors (3). Refer to Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1  and Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2 .
  11. Remove the EGR valve/cooler tube assembly bolts and nut.
  12. Remove the EGR valve/cooler tube assembly (2) and gasket (1) from the engine and place on a clean work surface. Discard the gasket.
    13. Fig 5: Identifying EGR Cooler Tube Bolts
    GM1862364Courtesy of GENERAL MOTORS CORP.
  13. On the bench, remove the EGR valve to EGR cooler tube bolts (2).
  14. Separate the EGR valve (3) from the EGR cooler tube (4).
  15. Remove and discard the intake manifold tube gaskets (1) as required.
  16. Reposition the EGR cooler hose clamp (6) and remove the EGR cooler hose (5) from the EGR cooler.
    17. Fig 6: View Of EGR Cooler Tube Bracket Bolts And Bracket
    GM1862391Courtesy of GENERAL MOTORS CORP.
  17. If required, remove the EGR cooler tube bracket bolts and 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.