GM Service Manual Online
For 1990-2009 cars only

Charge Air Cooling System Draining and Filling Static Fill

Draining Procedure

Special Tools

    • J 26568 Coolant and Battery Tester
    • J 38185 Hose Clamp Pliers

    Object Number: 1606522  Size: SH

    Warning: To avoid being burned, do not remove the charge air coolant cap while the system is hot. The cooling system will release scalding fluid and steam under pressure if charge air coolant cap is removed while the system is still hot.

    Note: Make sure the intercooler system is cool and that the pump is not in the ON position.

  1. Remove the manifold sight shield. Refer to Intake Manifold Sight Shield Replacement.
  2. Remove the charge air coolant cap.
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  4. Place a drain pan under the charge air cooler radiator.

  5. Object Number: 1735637  Size: SH
  6. Remove the drain plug from the charge air cooler radiator.
  7. Drain the charge air cooling system.
  8. Inspect the coolant.
  9. Follow the appropriate procedure based on the condition of the coolant:
  10. • Normal in appearance--Follow the filling procedure.
    • Discolored--Follow the flush procedure. Refer to Flushing.
  11. Install the drain plug to the charge air cooler radiator.
  12. Remove the drain pan from under the charge air coolant radiator.
  13. Lower the vehicle.

Filling Procedure


    Object Number: 1606527  Size: SH

    Caution: The procedure below must be followed. Improper coolant level could result in poor system performance.

    Note: The charge air cooling system is filled through the fitting in the charge air coolant pump outlet hose.

    Be sure the coolant does not make contact with the drive belt or any other surfaces. Coolant contact will cause belt noise and require belt replacement.

  1. Place a moderate amount of absorbent material below the charge air cooler manifold lines (1) to ensure that coolant does not contact the belts or other components.

  2. Object Number: 1735599  Size: SH
  3. Remove the cap on the charge air cooler pump outlet hose.

  4. Object Number: 1735598  Size: SH

    Note: Use a 50/50 mixture of DEX-COOL® antifreeze and clean drinkable water.

    Pour coolant in very small amounts to avoid coolant spillage from the charge air coolant cap port or from the funnel.

  5. Using a small funnel, slowly fill the charge air cooling system through the charge air coolant cap port with a 50/50 coolant mixture until the level is slightly below the charge air coolant cap port. Refer to Approximate Fluid Capacities.

  6. Object Number: 1735599  Size: SH
  7. Install the cap on the charge air cooler pump outlet hose.

  8. Object Number: 1644372  Size: SH
  9. Install a new charge air cooler cooling fill cap O-ring.

  10. Object Number: 1644371  Size: SH
  11. Install a new charge air cooler cooling fill cap.

  12. Object Number: 1644374  Size: SH
  13. Ensure the charge air cooler cooling fill cap is installed in the proper orientation:
  14. • The alignment boss (1) is at the rear of the charge air cooler manifold.
    • The alignment boss (2) is at the front of the charge air cooler cooling filling cap.

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1644370  Size: SH
  15. Install the charge air coolant cap bolts and tighten to 10 N·m (89 lb in).
  16. Note: Do not cycle the charge air cooling system without the charge air cooling cap in place or coolant loss will occur.

  17. Cycle the charge air cooling system ON by using the Tech 2 or by starting the engine for approximately 2 minutes.
  18. Cycle the charge air cooling system OFF.
  19. Remove the charge air coolant cap bolts.
  20. Remove the charge air coolant cap.
  21. Note: It is normal to have a very small pocket of air at the top of the system below the fill cap on a properly filled charge air cooling system.

  22. Ensure that coolant is almost level with the coolant cap fill port (1). Top off with a 50/50 coolant mixture through the charge air coolant cap port if necessary.

  23. Object Number: 1606522  Size: SH
  24. Install the charge air coolant cap.
  25. Install the charge air coolant cap bolts and tighten to 10 N·m (89 lb in).
  26. Repeat steps 10-16 two more times to ensure the system is properly purged of air.
  27. Inspect the concentration of the engine coolant, using the J 26568 .
  28. Inspect the charge air cooling system for leaks.
  29. Install the manifold sight shield. Refer to Intake Manifold Sight Shield Replacement.