GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Kodiak C-Series (Conventional) C6/C7/C8 🢒 Engine 🢒 Engine Controls - 7.8L 🢒 Charge Air Cooler Replacement

Removal Procedure
  1. If equipped, remove the following:
    2. • Fixed grill
    • A/C condenser
    • Auxiliary oil cooler
    • Auxiliary transmission cooler
  2. If equipped, disconnect the air compressor intake hose on the charge air intake pipe at the snap-to-connect fitting.

    3. Object Number: 799719 Size: SH
  3. Remove the clamps from the charge air intake hose.

    4. Object Number: 820393 Size: SH
  4. Remove the hose from the intake manifold inlet pipe and the charge air cooler.
  5. Remove the clamps from the air inlet hose.

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

    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. Object Number: 820393 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).

  6. If equipped, connect the air compressor intake hose to the charge air intake pipe at the snap-to-connect fitting.

    7. Object Number: 799719 Size: SH
  7. If equipped, install the following:
    8. • Fixed grill
    • A/C condenser
    • Auxiliary oil cooler
    • Auxiliary transmission cooler