GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2009 🢒 Sierra Denali 🢒 Body Repair 🢒 Bolted Exterior Body Panels and Closures 🢒 Charge Air Cooler Replacement

Removal Procedure

    Object Number: 697513 Size: SH
  1. Remove the upper tie bar. Refer to Front End Upper Tie Bar Replacement.
  2. Remove the charge air cooler inlet and outlet pipes. Refer to Charge Air Cooler Inlet Pipe Replacement and Charge Air Cooler Outlet Pipe Replacement.
  3. Remove the radiator. Refer to Radiator Replacement.
  4. Remove the charge air cooler bolts.

    5. Note: Do not damage the charged air cooler fins while removing.

  5. Remove the charge air cooler.
    6. 5.1. Disengage the bottom mounts from the radiator support.
    5.2. Remove the left side from the radiator support.
    5.3. Angle up the right side and rotate in order to remove.
  6. Clean the charge air cooler by flushing with mild soap and water. Do not use stream pressure to clean.
  7. Inspect the charge air cooler for the following damage:
    8. • Damaged fins
    • Cracked or distorted hose connections
    • Broken or loose welds
    • Leaks in the core or the tank connections
  8. Replace the charge air cooler if damage is found.
  9. Inspect the charged air cooler mounting insulators and replace if required.

Installation Procedure

    Object Number: 697513 Size: SH
  1. Install the charge air cooler.
    2. 1.1. Angle in the left side.
    1.2. Slide to the left.
    1.3. Move in the right side.

    Caution: Refer to Fastener Caution in the Preface section.

    1.4. Position bottom insulators in the radiator support.
  2. Install the charge air cooler bolts.

    3. Tighten
    Tighten the bolts to 21 N·m (15 lb ft).

  3. Install the radiator. Refer to Radiator Replacement.
  4. Install the charge air cooler inlet and outlet pipes. Refer to Charge Air Cooler Inlet Pipe Replacement and Charge Air Cooler Outlet Pipe Replacement.
  5. Install the upper tie bar. Refer to Front End Upper Tie Bar Replacement.