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Jay
Jay, Chevy Mechanic
Category: Chevy
Satisfied Customers: 596
Experience:  Several yrs experience, GM Trained,
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how do you change egr valve in a 2003 duramax diesels

Resolved Question:

how do you change egr valve in a 2003 duramax diesels
Submitted: 8 years ago.
Category: Chevy
Expert:  Jay replied 8 years ago.
HelloCustomer Here is the info you seek: If you need any more please reply.

Exhaust Gas Recirculation Valve Replacement

Removal Procedure


    Object Number: 798898  Size: SH

  1. Drain cooling system.
  2. Remove air cleaner outlet duct.
  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

  8. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose.

  9. Object Number: 784238  Size: SH

  10. Remove EGR inlet cooling hose (2) from cooling tube (1).

  11. Object Number: 784234  Size: SH

  12. Remove the EGR outlet cooling hose (1) from cooling tube (2).

  13. Object Number: 777490  Size: SH

  14. Remove the EGR assembly to intake manifold nuts.

  15. Object Number: 784226  Size: SH

  16. Remove the EGR assembly to exhaust pipe nuts.
  17. Remove the EGR assembly to EGR bracket (2) bolts.
  18. Remove the EGR assembly from the engine and discard the EGR gasket.

  19. Object Number: 784229  Size: SH

  20. Remove the EGR to EGR cooling tube bolts (1).
  21. 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. 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

  4. Install the EGR assembly to the engine.
  5. Install the EGR assembly to EGR bracket bolts.
  6. Tighten
    Tighten bolts to 20 N·m (15 lb ft).

  7. Install the EGR assembly to exhaust pipe nuts.
  8. Tighten
    Tighten nuts to 20 N·m (15 lb ft).


    Object Number: 777490  Size: SH

  9. Install the EGR assembly to intake manifold nuts.
  10. Tighten
    Tighten nuts to 19 N·m (14 lb ft).


    Object Number: 784234  Size: SH

  11. Install EGR outlet cooling hose (1) to EGR cooling tube (2).

  12. Object Number: 784238  Size: SH

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

  14. Object Number: 777482  Size: SH

  15. Connect the EGR vacuum hose to the EGR valve.

  16. Object Number: 798898  Size: SH

  17. Install the upper intake manifold tube and nuts.
  18. Tighten
    Tighten the nuts to 10 N·m (89 lb in).

  19. Install the intake heater and gasket.
  20. Tighten
    Tighten the heater to 50 N·m (37 lb ft).

  21. Install the turbocharger boost sensor with bracket.
  22. Install the turbocharger boost sensor bracket bolt.
  23. Tighten
    Tighten the bolt to 10 N·m (89 lb in).

  24. Install air cleaner outlet duct.
  25. Fill cooling system.

Air Cleaner Outlet Duct Replacement

Removal Procedure


    Object Number: 813243  Size: SH

  1. Loosen the outlet duct clamp at the upper intake manifold cover.
  2. Remove the upper intake manifold cover from the outlet duct.
  3. Remove the upper intake manifold cover.

  4. Object Number: 813244  Size: SH

  5. Loosen the outlet duct clamps at the turbocharger and the mass air flow/intake air temperature (MAF/IAT) sensor.
  6. Remove the outlet duct from the turbocharger and MAT/IAT sensor.

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