GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2009 🢒 TopKick C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Cooling 🢒 Engine Oil Cooler Replacement

Removal Procedure
  1. Remove the ECU bracket with the harness attached.
  2. Remove the PCV hose assembly.
  3. Remove the EGR pipe assembly.
  4. Remove the fuel leak off pipe.
  5. Remove the fuel pipes.
  6. Remove the injection pipe.
  7. Remove the fuel filter. Refer to Fuel Filter Replacement.
  8. Remove the fuel feed pipe from the fuel supply pump.
  9. Remove the fuel return pipe.
  10. Loosen the coupling bolts.
  11. Remove the boost air pipe, intake cover to injection pump governor.
  12. Loosen the fuel supply pump fixing bolts.
  13. Remove the fuel supply pump.
  14. Remove the EGR duct.
  15. Remove the fan guide bracket.
  16. Loosen the oil cooler bolts evenly from the outside to inside.

    17. Object Number: 1986934 Size: SH
  17. Remove the oil cooler assembly (2) from the cylinder block (1).
    18. • Install the removed bolts (3) to the replacer hole and remove the oil cooler.
    • Clean the sealing surface of the block and remove sealant residue.

Installation Procedure

    Object Number: 1682283 Size: SH

    Note: Install the oil cooler within 15 minutes of applying sealant.

  1. Install the oil cooler assembly with new gaskets (1) to the cylinder block.
    2. • Clean the sealing surface of the oil cooler.
    • Apply Three Bond No. 1207C/1216C or equivalent to the groove of the oil cooler assembly.

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1986938 Size: SH
  2. Install oil cooler fixing bolts in sequence.

    3. Tighten
    Tighten the oil cooler fixing bolts to 19 N·m (14 lb ft) in the sequence shown.

  3. Install the fan guide bracket.
  4. Install the EGR duct.
  5. Install the injection pump.
  6. Install the fuel feed pipe to the fuel supply pump.

    7. Tighten
    Tighten the fuel feed pipe bolts to 27 N·m (20 lb ft).

  7. Install the fuel return pipe.

    8. Tighten
    Tighten the fuel return pipe bolts to 34 N·m (25 lb ft).

  8. Install the air boost pipe, injection pump governor to the intake cover.
  9. Install the fuel filter to the bracket.

    10. Tighten
    Tighten the fuel filter bolts to 39 N·m (29 lb ft).

  10. Install the injection pipes.

    11. Tighten
    Tighten the sleeve nuts to 29 N·m (22 lb ft).

  11. Install the fuel return pipe.

    12. Tighten
    Tighten the fuel return pipe bolts to 37 N·m (27 lb ft).

  12. Install the fuel pipe, fuel filter to injection pump.
  13. Install the fuel pipe, fuel pump to fuel filter.

    14. Tighten
    Tighten the bolts to 39 N·m (29 lb ft).

  14. Install the fuel leak off pipe.

    15. Tighten

    1. Tighten the cylinder head side bolts to 29 N·m (22 lb ft).
    2. Tighten the filter side bolts to 25 N·m (18 lb ft).
  15. Install the EGR pipe assembly.
  16. Install the PCV hose assembly.
  17. Install the ECU bracket with the harness attached.