GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2005 🢒 TopKick C-Series (Crew) C4/C5 🢒 Engine 🢒 Engine Cooling 🢒 Charge Air Cooler Replacement

Removal Procedure
  1. If equipped, remove the following:
    2. • Fixed grill
    • The A/C condenser
    • The auxiliary oil cooler
    • The auxiliary transmission cooler

    Object Number: 799719 Size: SH
  2. Remove the clamps from the charge air intake hose.
  3. Remove the hose from the intake manifold inlet pipe and the charge air cooler.
  4. Remove the clamps from the air inlet hose.

    5. Object Number: 799718 Size: SH
  5. Remove the hose from the charge air cooler and the turbocharger inlet.

    6. Object Number: 803034 Size: SH
  6. Remove the mounting bolts from the charger air cooler to the radiator.
  7. Remove the charger air cooler from the radiator.

Installation Procedure

    Object Number: 803034 Size: SH
  1. Install the charge air cooler to the radiator.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the mounting bolts to the radiator.

    3. Tighten
    Tighten the bolts to 45 N·m (33 lb ft).


    Object Number: 799718 Size: SH
  3. Install the hose assembly to the charger air cooler and the turbocharger inlet.

    4. Object Number: 799719 Size: SH
  4. Install the hose assembly to the charge air cooler and the intake manifold inlet pipe.
  5. Tighten the hose clamps.

    6. Tighten
    Tighten the hose clamps to 6 N·m (53 lb in).