GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Kodiak C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Mechanical - 6.6L 🢒 Charged Air Cooler Replacement

Removal Procedure
  1. Remove the stationary grill, if equipped.
  2. Remove aux oil cooler, if equipped.
  3. Remove aux trans cooler, if equipped.
  4. Remove the A/C condenser, if equipped.
  5. Remove both charged air cooler hose assemblies. Refer to Charged Air Cooler Hoses/Pipes Replacement .

    6. Object Number: 803034 Size: SH
  6. Remove the 2 bolts and 2 nuts retaining the charged air cooler to the radiator support.

    7. Important: Do not damage the charged air cooler fins while removing.

  7. Remove the charged air cooler.
    8. 7.1. Lift the bottom mounts from the radiator support.
    7.2. Remove the left side from the radiator support.
    7.3. Angle up the right side and turn to remove.
  8. Clean the charged air cooler by flushing with mild soap and water. Do not use stream pressure to clean.
  9. Inspect the charged air cooler for the following damage:
    10. • Damaged fins
    • Cracked or distorted hose connections
    • Broken or loose welds
    • Leaks in the core or the tank connections
  10. Replace the charged air cooler if damage is found.
  11. Inspect the charged air cooler mounting insulators and replace if required.

Installation Procedure

    Object Number: 803034 Size: SH
  1. Install the charged air cooler to the radiator support.
    2. 1.1. Angle in the left side.
    1.2. Slide to the left.
    1.3. Move in the right side.
    1.4. Position bottom insulators in the radiator support.

    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 retaining bolts and nuts for the charged air cooler.

    3. Tighten
    Tighten the charged air cooler bolts to 23 N·m (15 lb ft).

  3. Install both charged air cooler hose assemblies. Refer to Charged Air Cooler Hoses/Pipes Replacement .
  4. Install the A/C condenser.
  5. Install aux oil cooler.
  6. Install trans cooler.
  7. Install the stationary grill.