EGR System Modifications

Volume 1 Issue 4 - Duramax Issues and Answers

I have just purchased an '05 LLY Crew Dually 4x4 and am learning about overheating issues (Summer Issue – thank you) and other design concerns. The most recent item to come to my attention is the EGR system. It appears that many DMax owners recommend blocking off the EGR, welding some ports, installing a fingerstick(?) to eliminate code generation and rerouting the PCV. All of this appears to eliminate intake contamination. Is this something important to do? If the system is so bad, how did GM let it go? Many have found carbon build up under 20,000 miles.


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Joel Paynton is an award-winning GM technician who specializes in Duramax fuel systems. He also does custom programming for any GM powertrain. Visit him on the web at


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