GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Chevy K Silverado - 4WD 🢒 General Information 🢒 General Information 🢒 Charged Air Cooler Hoses/Pipes Replacement

Removal Procedure

    Object Number: 877275 Size: SH
  1. Remove the left or right wheelhouse inner panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls - 6.6 L.
  3. Loosen the charged air cooler outlet duct to intake hose clamp (1).

    4. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

  4. Remove the charged air cooler outlet duct from the intake.

    5. Object Number: 877289 Size: SH
  5. Working through the right wheelhouse, loosen the charged air cooler outlet duct clamp at the charged air cooler.
  6. Remove the charged air cooler outlet duct.
  7. Disassemble the hose and pipe, if required.

    8. Object Number: 877281 Size: SH
  8. Loosen the charged air cooler inlet duct to turbocharger clamp (1).

    9. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.

  9. Remove the charged air cooler inlet duct from the turbocharger.

    10. Object Number: 877283 Size: SH
  10. Loosen the charged air cooler inlet duct clamp (3) at the charged air cooler.
  11. Remove the charged air cooler inlet duct. The duct can be removed as one piece with the left wheelhouse inner panel removed.
  12. Disassemble the hose and pipe, if required.
  13. Inspect the hoses for cuts or tears.
  14. Inspect the pipes for damage.
  15. Replace the hose or pipe if damage is found.

Installation Procedure

    Object Number: 877283 Size: SH
  1. Install the charged air cooler inlet duct. The duct is marked for correct installation.
  2. Install the clamp (3) on the charged air cooler inlet duct but do not tighten.
  3. Install the charged air cooler inlet duct to the charged air cooler aligning the marks (2) on the hoses.

    4. Object Number: 877281 Size: SH
  4. Remove the tape from the turbocharger openings.
  5. Install the charged air cooler inlet duct to the turbocharger.
  6. Align the mark on the duct (2) with the mark on the turbocharger.

    7. 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.

  7. Position the clamp (1) as shown for proper clearance.

    8. Tighten
    Tighten the clamp to 6 N·m (53 lb in).


    Object Number: 877289 Size: SH
  8. Assemble the hose and pipe, if required.
  9. Install the charged air cooler outlet duct (2).
  10. Working through the right wheelhouse, tighten the charged air cooler outlet duct clamp (1) at the charged air cooler.

    11. Object Number: 877275 Size: SH
  11. Install the charged air cooler outlet duct to the intake.
  12. Align the mark on the duct (3) with the mark on the intake.
  13. Position the clamp (1) as shown for proper clearance.

    14. Tighten
    Tighten the clamp to 6 N·m (53 lb in).

  14. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls - 6.6 L.
  15. Install the left or right wheelhouse inner panel. Refer to Wheelhouse Panel Replacement in Body Front End.