How to Install an EGR Cooler in Duramax

Common to both gasoline and diesel engines, the Chevy Duramax uses a valve to drive the EGR (Exhaust Gas Recirculation) Cooler system. Along with reducing exhaust gas temperatures by up to 800 degrees, the EGR cooler also improves gas mileage and greatly reduces harmful emissions. The valve is the most important component and eventually clogs, needing replacement. To install or replace your EGR Cooler valve, follow these steps.

  • Disconnect the negative terminal of your battery to avoid unwelcome shocks.
  • Find the engine exhaust manifold, which will be on the driver’s side of a Duramax engine.
  • Locate and follow the tubing connected to the manifold to the other end. It’s connected to your EGR system.
  • Disconnect the wiring harness. Press in on the release tab. This will unlock the harness.
  • Loosen and remove the clip on the metal tubing coming from the exhaust manifold.
  • You can then take out the EGR cooler valve after removing the Torx bolts that hold it in place.
  • Place the new EGR valve in exactly the same position as the old one, securing it with the Torx bolts.
  • Re-attach and replace the manifold exhaust tubing. Be sure tighten the clasp.
  • Re-plug in the wiring harness, snapping it in place.
  • You can now reconnect the battery cable.

Be sure to test your installed EGR Cooler valve by starting your engine. Listen for moving air. If you don’t hear any vacuum-like sounds, you installed the new EGR cooler valve properly. Your EGR Cooler system–and your Duramax diesel–should now conserve fuel help save the environment.

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