GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2009 🢒 TopKick C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Cooling 🢒 Exhaust Gas Recirculation Valve Cooler Replacement

Removal Procedure

    Object Number: 1986968 Size: MH
  1. Drain the coolant. Refer to Cooling System Draining and Filling.
  2. Remove the exhaust heat sensor (29) from the EGR cooler (17).
  3. Remove the heat protector (19) from the EGR cooler (17).
  4. Remove the water hose (21) between the front and rear portions of the EGR cooler (17, 2).
  5. Disconnect the water hose (25) between the EGR cooler (17) and pipe (27).
  6. Disconnect the water hose (23) from the rear EGR cooler (2).
  7. Remove the EGR cooler bolts (1, 9), nut (5) and stud.
  8. Remove the rear EGR cooler (2) and gaskets (3, 18). Discard the gaskets.
  9. Remove the front EGR cooler to bracket bolt (12).
  10. Remove the front EGR cooler bolts (16).
  11. Remove the front EGR cooler (17) and gasket (15). Discard the gasket and bolts.
  12. Remove the lower EGR Cooler bolts (7).
  13. Remove the lower EGR Cooler pipe (6) and Gasket (8). Discard the gasket.

Installation Procedure

    Object Number: 1986968 Size: MH
  1. Install the lower EGR cooler pipe (6), using a NEW gasket (8). Hand tighten the bolts (1).
  2. Install the front EGR cooler (17) to the exhaust manifold, using a NEW gasket (15) and NEW bolts (16). Hand tighten the bolts.
  3. Install the rear EGR cooler (2) to the front and lower EGR cooler (6, 17), using NEW gaskets. Hand tighten the bolts (1, 9) and stud and nut (5).

    4. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1986970 Size: SH
  4. Complete the EGR cooler installation by tightening the following in sequence:

    5. Tighten

    1. Hand tighten the cooler bracket to rear bracket bolt (1).
    2. Hand tighten the EGR cooler to exhaust manifold bolts (2).
    3. Hand tighten the bracket to front cooler bolt (3).
    4. Tighten the front EGR cooler to manifold bolts (4) to 40 N·m (30 lb ft).
    5. Tighten the bracket to front cooler bolt (5) to 25 N·m (18 lb ft).
    6. Hand tighten the front EGR cooler to rear EGR cooler bolts (6).
    7. Hand tighten the rear EGR cooler to bracket bolt (7).
    8. Hand tighten the lower EGR cooler to rear EGR cooler bolts (8).
    9. Hand tighten the lower EGR cooler to intake engine bolts (9).
    10. Tighten the lower EGR cooler bolts (10) to 25 N·m (18 lb ft).
    11. Tighten the lower EGR cooler to rear EGR cooler bolts to (10) to 25 N·m (18 lb ft).
    12. Tighten the front EGR cooler to rear EGR cooler bolts (12) to 46 N·m (34 lb ft).
    13. Tighten the lower EGR cooler to rear EGR cooler bolts (13) to 46 N·m (34 lb ft).
    14. Tighten the cooler bracket to rear bracket bolt (14) to 25 N·m (18 lb ft).

    Object Number: 1986968 Size: MH
  5. Connect the water hose (23) to the rear EGR cooler (2).
  6. Connect the water hose (25) between the EGR cooler (17) and pipe (27).
  7. Install the water hose (21) between the front and rear portions of the EGR cooler (17, 2).
  8. Install the heat protector (19) to the EGR cooler (17).

    9. Tighten
    Tighten the bolt to 19 N·m (14 lb ft).

  9. Install the exhaust heat sensor (29) to the EGR cooler (17).

    10. Tighten
    Tighten the bolt to 44 N·m (32 lb ft).

  10. Fill the coolant system. Refer to Cooling System Draining and Filling.
  11. Verify no leaks from the EGR cooler system.