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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 >> Removal Procedure

Removal 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. Remove the left or right wheelhouse inner panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls - 6.6 L.
  3. Loosen the charged air cooler outlet duct to intake hose clamp (1).
    4. IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  4. Remove the charged air cooler outlet duct from the intake.
    5. Fig 1: View Of Charged Air Cooler Outlet Duct & Clamps
    GM877275Courtesy of GENERAL MOTORS CORP.
  5. Working through the right wheelhouse, loosen the charged air cooler outlet duct clamp at the charged air cooler.
  6. Remove the charged air cooler outlet duct.
    7. Fig 2: View Of Charged Air Cooler Outlet Duct & Clamp
    GM877289Courtesy of GENERAL MOTORS CORP.
  7. Disassemble the hose and pipe, if required.
  8. Loosen the charged air cooler inlet duct to turbocharger clamp (1).
    9. IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.
  9. Remove the charged air cooler inlet duct from the turbocharger.
    10. Fig 3: View Of Charged Air Cooler Inlet Duct & Clamps
    GM877281Courtesy of GENERAL MOTORS CORP.
  10. Loosen the charged air cooler inlet duct clamp (3) at the charged air cooler.
    11. Fig 4: View Of Charged Air Cooler Aligning Marks & Clamps
    GM877283Courtesy of GENERAL MOTORS CORP.
  11. Remove the charged air cooler inlet duct. The duct can be removed as one piece with the left wheelhouse inner panel removed.
  12. Disassemble the hose and pipe, if required.
  13. Inspect the hoses for cuts or tears.
  14. Inspect the pipes for damage.
  15. Replace the hose or pipe if damage is found.
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