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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 997 (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 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 charged air cooler hoses. Refer to Charged Air Cooler Hoses/Pipes Replacement .
  2. Remove the radiator. Refer to Radiator Replacement (EXC 8.1L) or Radiator Replacement (8.1L) in Engine Cooling.
  3. Remove the charged air cooler bolts.
  4. Remove the charged air cooler.
    IMPORTANT: Do not damage the charged air cooler fins while removing.
    1. Lift the bottom mounts from the radiator support.
    2. Remove the left side from the radiator support.
    3. Angle up the right side and turn to remove.
    5. Fig 1: View Of Charged Air Cooler & Bolts
    GM697513Courtesy of GENERAL MOTORS CORP.
  5. Clean the charged air cooler by flushing with mild soap and water. Do not use stream pressure to clean.
  6. Inspect the charged air cooler for the following damage:
    • Damaged fins
    • Cracked or distorted hose connections
    • Broken or loose welds
    • Leaks in the core or the tank connections
  7. Replace the charged air cooler if damage is found.
  8. Inspect the charged air cooler mounting insulators and replace if required.
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