GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2009 🢒 Sierra Denali 🢒 Engine 🢒 Engine Controls and Fuel - 6.6L 🢒 Charge Air Cooler Inlet Pipe Replacement

Removal Procedure

    Object Number: 1873387 Size: SH
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement.
  2. Loosen the charge air cooler inlet pipe connector clamp (1) at the turbocharger.

    3. Note: Do not use a screwdriver or other tool to pry the connector loose. The connector can be torn or damaged. Loosen the connector by twisting.

  3. Remove the charge air cooler inlet pipe connector (2) from the turbocharger.
  4. Cover the turbocharger opening with tape in order to prevent possible entry of foreign objects.
  5. Remove the wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Left Side.

    6. Object Number: 1873388 Size: SH
  6. Working through the wheelhouse, loosen the charge air cooler inlet pipe connector clamp (1) at the charge air cooler.

    7. Note: Do not use a screwdriver or other tool to pry the connector loose. The connector can be torn or damaged. Loosen the connector by twisting.

  7. Remove the charge air cooler inlet pipe connector (2) from the charge air cooler.
  8. Lower the vehicle.
  9. Remove the charge air cooler inlet pipe from the vehicle.

Installation Procedure

    Object Number: 1873387 Size: SH
  1. Install the charge air cooler inlet pipe to the vehicle.
  2. Remove the turbocharger opening cover.

    3. Note: Do not over tighten the charge air cooler connector clamp. If the clamp is overtightened, the connector may become distorted allowing separation of the connector from the pipe. Make sure the charge air cooler pipe is properly orientated.

  3. Install the charge air cooler inlet pipe connector (2) onto the turbocharger.

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

  4. Tighten the charge air cooler inlet pipe to turbocharger connector clamp (1).

    5. Tighten
    Tighten the clamp to 8 N·m (70 lb in).


    Object Number: 1873388 Size: SH
  5. Raise and support the vehicle half way. Refer to Lifting and Jacking the Vehicle.

    6. Important: Do not over tighten the charged air cooler pipe connector clamp. If the clamp is overtightened, the connector may become distorted allowing separation of the connector from the pipe. Make sure the charge air cooler pipe is properly orientated.

  6. Working through the wheelhouse, install the charge air cooler inlet pipe connector onto the charge air cooler.
  7. Tighten the charge air cooler inlet pipe to charge air cooler connector clamp (1).

    8. Tighten
    Tighten the clamp to 8 N·m (70 lb in).

  8. Install the wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Left Side.
  9. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement.