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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1023 (Engine Mechanical - 6.6L (Lb7) (Repair Instructions 1 Of 4)) >> Repair Instructions (On-Vehicle & Off Vehicle - Part 1) >> On-Vehicle Repair Instructions >> Charged Air Cooler Hoses/Pipes Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the charged air cooler inlet duct. The duct is marked for correct installation.
  2. Install the clamp (3) on the charged air cooler inlet duct but do not tighten.
  3. Install the charged air cooler inlet duct to the charged air cooler aligning the marks (2) on the hoses.
    4. Fig 1: View Of Charged Air Cooler Aligning Marks & Clamps
    GM877283Courtesy of GENERAL MOTORS CORP.
  4. Remove the tape from the turbocharger openings.
  5. Install the charged air cooler inlet duct to the turbocharger.
  6. Align the mark on the duct (2) with the mark on the turbocharger.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Position the clamp (1) as shown for proper clearance.

    Tighten:  Tighten the clamp to 6 N.m (53 lb in).

    8. Fig 2: View Of Charged Air Cooler Inlet Duct & Clamps
    GM877281Courtesy of GENERAL MOTORS CORP.
  8. Assemble the hose and pipe, if required.
  9. Install the charged air cooler outlet duct (2).
  10. Working through the right wheelhouse, tighten the charged air cooler outlet duct clamp (1) at the charged air cooler.
    11. Fig 3: View Of Charged Air Cooler Outlet Duct & Clamp
    GM877289Courtesy of GENERAL MOTORS CORP.
  11. Install the charged air cooler outlet duct to the intake.
  12. Align the mark on the duct (3) with the mark on the intake.
  13. Position the clamp (1) as shown for proper clearance.

    Tighten:  Tighten the clamp to 6 N.m (53 lb in).

    14. Fig 4: View Of Charged Air Cooler Outlet Duct & Clamps
    GM877275Courtesy of GENERAL MOTORS CORP.
  14. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls - 6.6 L.
  15. Install the left or right wheelhouse inner panel. Refer to Wheelhouse Panel Replacement in Body Front End.
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