GM Service Manual Online
For 1990-2009 cars only

Charged Air Cooler Hoses/Pipes Replacement Driver Side

Removal Procedure


    Object Number: 1334380  Size: SH
  1. Remove the left wheelhouse panel. Refer to Wheelhouse Panel Replacement.
  2. Important: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.

  3. Loosen the left charged air cooler inlet duct connector to turbocharger 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.

  5. Remove the left charged air cooler inlet duct connector (4) from the turbocharger.

  6. Object Number: 877283  Size: SH
  7. Working through the left wheelhouse, loosen the charged air cooler inlet duct clamp (3) at the charged air cooler.
  8. Remove the left charged air cooler inlet duct.

Installation Procedure


    Object Number: 877283  Size: SH

    Important: Do not over tighten the charged air cooler pipe clamps. If the clamp is overtightened, the pipe may become distorted allowing separation of the hose from the pipe. Make sure the charged air cooler pipe/hoses are properly orientated.

  1. Working through the left wheelhouse, install the charged air cooler inlet duct.
  2. Hand tighten the left charged air cooler inlet duct clamp (3) at the charged air cooler.
  3. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1334381  Size: SH

    Important: Do not over tighten the charged air cooler pipe clamps. If the clamp is overtightened, the pipe may become distorted allowing separation of the hose from the pipe. Make sure the charged air cooler pipe/hoses are properly orientated.

  4. Install the left charged air cooler outlet duct to the intake.
  5. Tighten the charged air cooler outlet duct to intake hose clamps.
  6. Tighten
    Tighten the clamps to 8 N·m (70 lb in).

  7. Install the left wheelhouse panel. Refer to Wheelhouse Panel Replacement.

Charged Air Cooler Hoses/Pipes Replacement Passenger Side

Removal Procedure


    Object Number: 1653035  Size: SH
  1. Remove the right wheelhouse panel. Refer to Wheelhouse Panel Replacement .
  2. Using a pick or a small flat-bladed screwdriver, remove and discard the quick connect fitting clip from the charged air cooler outlet duct.
  3. Remove the charged air cooler outlet duct from the intake.

  4. Object Number: 1653039  Size: SH
  5. Working through the right wheelhouse, Using the pick or a small flat-bladed screwdriver, remove and discard the quick connect fitting clip from the charged air cooler outlet duct.
  6. Remove the charged air cooler outlet duct from the charged air cooler.

Installation Procedure


    Object Number: 1653039  Size: SH
  1. Install NEW quick connect fitting clips to the charged air cooler.
  2. Working through the right wheelhouse, install the charged air cooler outlet duct to the charged air cooler.

  3. Object Number: 1653035  Size: SH
  4. Install the charged air cooler outlet duct to the intake.
  5. Install the right wheelhouse panel. Refer to Wheelhouse Panel Replacement .