GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2008 🢒 TopKick C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Cooling 🢒 Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement

Removal Procedure

    Object Number: 1867403 Size: SH
  1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement .
  2. Loosen the charge air cooler inlet pipe clamp (1) at the charge air cooler.

    3. 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.

  3. Remove the charge air cooler inlet pipe (3) from the charge air cooler.
  4. Loosen the charge air cooler inlet pipe clamp (2) at the turbocharger.

    5. 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 charge air cooler inlet pipe (3) from the turbocharger.
  6. Cover the turbocharger opening with tape in order to prevent entry of objects.

    7. Object Number: 1867490 Size: SH
  7. Using a pick or a small flat-bladed screwdriver, remove and discard the quick connect fitting clip (1) from the charge air cooler outlet pipe.

    8. Object Number: 1867404 Size: SH
  8. Loosen the charge air cooler outlet pipe clamp (2) at the charge air cooler.
  9. Remove the charge air cooler outlet pipe from the charge air cooler.
  10. Remove the charge air cooler outlet pipe (3) from the intake air valve.

Installation Procedure

    Object Number: 1867404 Size: SH
  1. Install a NEW quick connect fitting clip to the charge air cooler pipe (3).
  2. Install the charge air cooler outlet pipe to the intake air valve.
  3. Install the charge air cooler outlet pipe to the charge air cooler.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Tighten the charge air cooler outlet pipe clamp (2) at the charge air cooler.

    5. Tighten
    Tighten the clamp to 8 N·m (71 lb in).


    Object Number: 1867403 Size: SH
  5. Remove the tape covering the turbocharger opening.
  6. Install the charge air cooler inlet pipe (3) to the turbocharger.
  7. Install the charge air cooler inlet pipe (3) to the charge air cooler.
  8. Tighten the charge air cooler inlet pipe clamp (2) at the turbocharger.

    9. Tighten
    Tighten the clamp to 8 N·m (71 lb in).

  9. Tighten the charge air cooler inlet pipe clamp (1) at the charge air cooler.

    10. Tighten
    Tighten the clamp to 8 N·m (71 lb in).

  10. Install the air cleaner. Refer to Air Cleaner Assembly Replacement .