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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1306 (Engine Controls And Fuel - 6.6L - Introduction (1 Of 2)) >> Repair Instructions >> Charge Air Cooler Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2009 GMC Sierra, 2009 GMC Cab & Chassis Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Charged Air Cooler & Bolts
    GM697513Courtesy of GENERAL MOTORS CORP.
  1. Remove the upper tie bar. Refer to Front End Upper Tie Bar Replacement .
  2. Remove the charge air cooler inlet and outlet pipes. Refer to Charge Air Cooler Inlet Pipe Replacement  and Charge Air Cooler Outlet Pipe Replacement .
  3. Remove the radiator. Refer to Radiator Replacement (4.3L, 4.8L, 5.3L, and 6.0L) or Radiator Replacement (HP2) or Radiator Replacement (LMM) .
  4. Remove the charge air cooler bolts.
    NOTE: Do not damage the charged air cooler fins while removing.
  5. Remove the charge air cooler.
    1. Disengage the bottom mounts from the radiator support.
    2. Remove the left side from the radiator support.
    3. Angle up the right side and rotate in order to remove.
  6. Clean the charge air cooler by flushing with mild soap and water. Do not use stream pressure to clean.
  7. Inspect the charge 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
  8. Replace the charge air cooler if damage is found.
  9. Inspect the charged air cooler mounting insulators and replace if required.
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