GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Chevy K Silverado - 4WD 🢒 Engine 🢒 Engine Mechanical - 6.6L (LLY) 🢒 Charged Air Cooler Replacement

Removal Procedure

    Object Number: 697513 Size: SH
  1. Remove the charged air cooler hoses/pipes. Refer to Charged Air Cooler Hoses/Pipes Replacement .
  2. Remove the radiator. Refer to Radiator Replacement .
  3. Remove the charged air cooler bolts.

    4. Important: Do not damage the charged air cooler fins while removing.

  4. Remove the charged air cooler.
    5. 4.1. Disengage the bottom mounts from the radiator support.
    4.2. Remove the left side from the radiator support.
    4.3. Angle up the right side and rotate in order to remove.
  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:
    7. • 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.

Installation Procedure

    Object Number: 697513 Size: SH
  1. Install the charged air cooler.
    2. 1.1. Angle in the left side.
    1.2. Slide to the left.
    1.3. Move in the right side.

    Notice: Refer to Fastener Notice in the Preface section.

    1.4. Position bottom insulators in the radiator support.
  2. Install the charged air cooler bolts.

    3. Tighten
    Tighten the bolts to 21 N·m (15 lb ft).

  3. Install the radiator. Refer to Radiator Replacement .
  4. Install the charged air cooler hoses/pipes. Refer to Charged Air Cooler Hoses/Pipes Replacement .