GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2006 🢒 ION 🢒 Engine 🢒 Engine Cooling 🢒 Charge Air Cooler Outlet Hose Replacement

Tools Required
    • SA9111E Hose Clamp Pliers
    • GE-47622 Hose Clamp Pliers

Removal Procedure

    Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

  1. Place a drain pan under the front and the center of the vehicle.

    2. Object Number: 1402994 Size: SH
  2. Using GE-47622 compress the outlet hose clamp at the charge air cooler.
  3. Remove the outlet hose from the charge air cooler.
  4. Remove the bolts from the charge air cooler reservoir.

    5. Object Number: 1380591 Size: SH
  5. Reposition the reservoir and the hose assembly up to gain access to the hose clamp.
  6. Using SA9111E reposition the outlet hose clamp close to the opposite end of the hose.
  7. Remove the charge air cooler outlet hose from the reservoir.

Installation Procedure

    Object Number: 1380591 Size: SH
  1. Install the charge air cooler hose to the reservoir.
  2. Reposition the hose clamp to secure the hose using SA9111E .
  3. Install the bolts to the charge air cooler reservoir.

    4. Object Number: 1402994 Size: SH
  4. Using GE-47622 compress the hose clamp to secure the hose.
  5. Install the charge air cooler outlet hose to the charge air cooler.
  6. Fill the cooling system. Refer to Charge Air Cooling System Draining and Filling .