GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Cobalt 🢒 Body Repair 🢒 Bumpers and Fascias 🢒 Charge Air Cooler Outlet Pipe Replacement

Removal Procedure

    Object Number: 2002696 Size: SH
  1. Loosen the charge air cooler outlet pipe clamp (1) at the intake manifold (2).
  2. Disconnect the engine wiring harness electrical connector from the intake air pressure and temperature sensor.
  3. Reposition the hose clamp and remove the vacuum hose from the outlet pipe.
  4. Remove the right engine splash shield. Refer to Engine Splash Shield Replacement - Right Side.

    5. Object Number: 2002697 Size: SH
  5. Loosen the charge air cooler outlet pipe clamp (1) at the charge air cooler assembly (2).
  6. Remove the charge air cooler outlet pipe (3).

Installation Procedure

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 2002697 Size: SH
  1. Install the charge air cooler outlet pipe (3) to the charge air cooler assembly (2) and tighten the clamp tp 5 N·m (44 lb in).
  2. Install the right engine splash shield. Refer to Engine Splash Shield Replacement - Right Side.

    3. Object Number: 2002696 Size: SH
  3. Connect the engine wiring harness electrical connector to the intake air pressure and temperature sensor.
  4. Install the vacuum hose and reposition the hose clamp.
  5. Install the charge air cooler outlet pipe to the intake manifold (2) and tighten the charge air cooler outlet pipe clamp (1) to 5 N·m (44 lb in).