GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2009 🢒 TopKick C-Series (Conventional) C4/C5 🢒 Preface 🢒 Dangers, Warnings, and Cautions 🢒 Charge Air Cooler Replacement

Removal Procedure

    Object Number: 1867403 Size: SH
  1. Remove the following, if equipped:
    2. • Fixed grille--Refer to Grille Replacement.
    • A/C condenser--Refer to Air Conditioning Condenser Replacement.
    • Auxiliary transmission cooler--Refer to Transmission Fluid Auxiliary Cooler Replacement.
  2. Loosen the charge air cooler inlet pipe clamp (1) at the charge air cooler.
  3. Remove the charge air cooler inlet pipe (3) from the charge air cooler.

    4. Object Number: 1867404 Size: SH
  4. Loosen the charge air cooler outlet pipe clamp (2) at the charge air cooler.
  5. Remove the charge air cooler outlet pipe (3) from the charge air cooler.

    6. Object Number: 1867406 Size: SH
  6. Remove the charge air cooler bolts/nuts.
  7. Remove the charge air cooler from the radiator support.

Installation Procedure

    Object Number: 1867406 Size: SH
  1. Position and install the charge air cooler to the radiator support.

    2. Caution: Refer to Fastener Caution in the Preface section.

  2. Install the charge air cooler bolts/nuts.

    3. Tighten
    Tighten the bolts/nuts to 25 N·m (18 lb ft).


    Object Number: 1867404 Size: SH
  3. Install the charge air cooler outlet pipe (3) to the charge air cooler.
  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. Install the charge air cooler inlet pipe (3) to the charge air cooler.
  6. Tighten the charge air cooler inlet pipe clamp (1) at the charge air cooler.

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

  7. Install the following, if equipped:
    8. • Fixed grille--Refer to Grille Replacement.
    • A/C condenser--Refer to Air Conditioning Condenser Replacement.
    • Auxiliary transmission cooler--Refer to Transmission Fluid Auxiliary Cooler Replacement.