GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Kodiak C-Series Motorhome (Cutaway) C4/C5 🢒 Engine 🢒 Engine Controls - 6.6L (LLY) 🢒 Charge Air Cooler Replacement

Removal Procedure
  1. If equipped, remove the following:
    2. • Fixed grill, refer to Grille Replacement .
    • A/C condenser, refer to Condenser Replacement .
    • Auxiliary transmission cooler, refer to Transmission Fluid Auxiliary Cooler Replacement .

    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. Remove the condenser mounting bracket.

    7. Object Number: 803034 Size: SH
  7. Remove the mounting bolts from the charger air cooler to the radiator.
  8. 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: Refer to Fastener Notice in the Preface section.

  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. Install the condenser mounting bracket.
  5. Install the hose assembly to the charge air cooler and the intake manifold inlet pipe.
  6. Tighten the hose clamps.

    7. Tighten
    Tighten the hose clamps to 8 N·m (71 lb in).


    Object Number: 799719 Size: SH
  7. If equipped, install the following:
    8. • Fixed grill, refer to Grille Replacement .
    • A/C condenser, refer to Condenser Replacement .
    • Auxiliary transmission cooler, refer to Transmission Fluid Auxiliary Cooler Replacement .