How to Replace an EGR Valve on a Duramax

by Bryan Clark

Duramax diesel engines are installed on many of General Motors light and medium capacity pickup trucks. The engines are all equipped with an EGR valve system, which operates by recycling a portion of the exhaust through the engine. This increases fuel economy by ensuring that all of the diesel fuel has been consumed. It also reduces emissions because it prevents the fuel from being released into the atmosphere. Over time, the EGR valve will clog and will need to be replaced.

Step 1

Disconnect the cable on the negative terminal of the battery.

Step 2

Locate the exhaust manifold on the engine. The manifold will be on the right side, or driver's side, of the engine, but its location will vary slightly depending on the particular Duramax model.

Step 3

Locate the metal tubing that is connected to the exhaust manifold. Follow the tubing to its other end, which will be connected to the EGR system.

Step 4

Unplug the wiring harness that is connected to the EGR system by first pressing in on the release tab to unlock it.

Step 5

Unplug the metal exhaust tubing by loosening the clasp that holds it into place. Remove the EGR valve from the engine by removing the Torx bolts that secure it.

Step 6

Place the new EGR valve into the same position as the old one and secure it with bolts.

Step 7

Reattach the exhaust tubing and secure it by tightening the clasp, and reattach the wiring harness by snapping it into place. Reconnect the cable to the negative terminal of the battery.

Step 8

Start the engine, and make sure the EGR valve is functioning properly. If you don't hear moving air or a vacuum sound coming from it, the EGR valve is on correctly.

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