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Home >> Cadillac >> 2006 >> STS Base, 3.6 7, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine Mechanical - 4.4L (1 Of 5)) >> On-Vehicle Repair Instructions (Part 1) >> Charge Air Cooler Front Manifold Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Remove the hood. Refer to Hood Replacement .
  2. Remove the engine sight shield. Refer to Intake Manifold Sight Shield Replacement .
  3. Remove the front supercharger inlet duct assembly. Refer to Supercharger Inlet Duct Assembly Replacement .
  4. Drain the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling (Static Fill) or Charge Air Cooling System Draining and Filling (Vac N Fill) .
    5. IMPORTANT: Do not allow coolant to contact the supercharger drive belt.
    Place a shop rag under the front portion of the supercharger to catch any remaining coolant.
    Fig 1: Charge Air Cooler Front Manifold Assembly
    GM1614613Courtesy of GENERAL MOTORS CORP.
  5. Remove the charge air cooler hoses from the front section of the charge air cooler front manifold.
  6. Remove the bolts (1) and remove the front portion of the supercharger front manifold (2). Discard the manifold O-ring seals.
    7. Fig 2: Supercharger Bypass Regulator Solenoid Valve
    GM1644303Courtesy of GENERAL MOTORS CORP.
  7. Remove the supercharger bypass regulator solenoid valve and bracket. Refer to Supercharger Bypass Regulator Solenoid Valve Replacement .
    8. IMPORTANT: The remaining section of the front manifold and the rear manifold must be serviced together. If only one manifold is serviced, there is a possibility of unseating the O-ring seals on the opposite manifold.
    Fig 3: Charge Air Cooler Front Manifold Bolts
    GM1644344Courtesy of GENERAL MOTORS CORP.
  8. Remove the charge air cooler front manifold bolts.
    9. Fig 4: Charge Air Cooler Front Manifold
    GM1644346Courtesy of GENERAL MOTORS CORP.
  9. Remove the charge air cooler front manifold.
    10. Fig 5: Charge Air Cooler Front Manifold Gasket
    GM1644347Courtesy of GENERAL MOTORS CORP.
  10. Remove and discard the charge air cooler front manifold gasket.
    11. Fig 6: Charge Air Cooler Cooling Tube Front O-Rings
    GM1644351Courtesy of GENERAL MOTORS CORP.
  11. Remove and discard the charge air cooler cooling tube front O-rings.
    12. Fig 7: Charge Air Cooler Cooling Tube Front Spacers
    GM1644352Courtesy of GENERAL MOTORS CORP.
  12. Remove the charge air cooler cooling tube front spacers if required.
    13. Fig 8: Charge Air Cooler Rear Manifold Bolts
    GM1644357Courtesy of GENERAL MOTORS CORP.
  13. Remove the charge air cooler rear manifold bolts.
    14. Fig 9: Charge Air Cooler Rear Manifold
    GM1644359Courtesy of GENERAL MOTORS CORP.
  14. Remove the charge air cooler rear manifold.
    15. Fig 10: Charge Air Cooler Rear Manifold Gaskets
    GM1644361Courtesy of GENERAL MOTORS CORP.
  15. Remove and discard the charge air cooler rear manifold gaskets.
    16. Fig 11: Charge Air Cooler Cooling Tube Rear O-Rings
    GM1644367Courtesy of GENERAL MOTORS CORP.
  16. Remove and discard the charge air cooler cooling tube rear O-rings.
    17. Fig 12: Charge Air Cooler Cooling Tube Rear Spacers
    GM1644368Courtesy of GENERAL MOTORS CORP.
  17. Remove the charge air cooler cooling tube rear spacers, if required.
  18. Remove the inboard and outboard charge air cooling tubes, if required. Refer to Charge Air Cooler Cooling Tube Replacement .
  19. Clean and inspect the charge air cooler manifolds and cooling tubes. Refer to Supercharger Cleaning and Inspection .
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