GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2007 🢒 G5 🢒 Engine 🢒 Engine Cooling 🢒 Charge Air Cooler Radiator Replacement

Tools Required

GE-47622 Hose Clamp Pliers

Removal Procedure
  1. Drain the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling .

    2. Object Number: 1382071 Size: SH
  2. Using GE-47622 compress the charge air cooler radiator inlet hose clamp at the charge air cooler radiator.
  3. Remove the charge air cooler radiator inlet hose from the charge air cooler radiator.

    4. Object Number: 1382066 Size: SH
  4. Using GE-47622 compress the auxiliary water pump inlet hose clamp at the charge air cooler radiator.
  5. Remove the auxiliary water pump inlet hose from the charge air cooler radiator.

    6. Object Number: 1413270 Size: SH
  6. Remove the pushpin fasteners from the air dam.
  7. Remove the air dam.

    8. Object Number: 877658 Size: SH
  8. Remove the condenser bolts.

    9. Object Number: 877659 Size: SH
  9. Slide the condenser down to disengage the upper mounting tabs from the radiator.
  10. Reposition the condenser to allow access to the charge air cooler radiator.

    11. Object Number: 1413203 Size: SH
  11. Remove the mounting bolt from the lower left side of the charge air cooler radiator.

    12. Object Number: 1413202 Size: SH
  12. Remove the mounting bolt from the lower right side of the charge air cooler radiator.

    13. Object Number: 1402987 Size: SH
  13. Slide the charge air cooler down to disengage the upper mounting tab from the radiator.
  14. Remove the charge air cooler radiator.

Installation Procedure

    Object Number: 1402987 Size: SH
  1. Install the charge air cooler radiator.
  2. Slide the charge air cooler up to engage the upper mounting tab to the radiator.

    3. Object Number: 1413202 Size: SH
  3. Install the mounting bolt to the lower right side of the charge air cooler radiator.

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


    Object Number: 1413203 Size: SH
  4. Install the mounting bolts to the lower left side of the charge air cooler radiator.

    5. Tighten
    Tighten the bolts to 10 N·m (88 lb in).


    Object Number: 877659 Size: SH
  5. Slide the condenser up to engage the upper mounting tabs into the radiator.

    6. Object Number: 877658 Size: SH
  6. Install the condenser bolts.

    7. Tighten
    Tighten the bolts to 10 N·m (88 lb in).


    Object Number: 1413270 Size: SH
  7. Install the air dam with the pushpin fasteners.

    8. Object Number: 1382066 Size: SH
  8. Install the auxiliary water pump inlet hose to the charge air cooler radiator.
  9. Using GE-47622 compress the auxiliary water pump inlet hose clamp at the charge air cooler radiator.
  10. Install the charge air cooler radiator inlet hose to the charge air cooler radiator.

    11. Object Number: 1382071 Size: SH
  11. Using GE-47622 compress the charge air cooler radiator inlet hose clamp at the charge air cooler radiator.
  12. Fill the cooling system. Refer to Charge Air Cooling System Draining and Filling .