GM Service Manual Online
For 1990-2009 cars
Makes 🢒 Chevrolet 🢒 2004 🢒 C-Series Medium Duty Truck C6/7/8 - Mexico 🢒 Engine 🢒 Engine Controls - 7.2L (Caterpillar) 🢒 Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement

Removal Procedure
  1. Remove the air cleaner . Refer to Air Cleaner Replacement .

    2. Important: After removing the turbocharger air ducts hoses, cover the turbocharger, the air inlet duct, and the charged air cooler openings with tape to prevent entry of objects.

  2. Remove the air cleaner duct from the air cleaner and the turbocharger.

    3. Object Number: 868020 Size: SH
  3. Loosen both charged air cooler outlet duct to intake manifold tube hose clamps.

    4. Important: Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

  4. Remove the hose from the charged air cooler outlet duct to intake manifold tube.

    5. Object Number: 799718 Size: SH
  5. Remove the charged air cooler outlet hose and pipe assembly from the vehicle.
  6. Disassemble the hose and pipe assembly as required.

    7. Object Number: 820393 Size: SH
  7. Loosen the charged air cooler inlet duct to turbocharger clamp.

    8. Important: Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.

  8. Remove the charged air cooler inlet duct to turbocharger cool air outlet hose from the turbocharger.

    9. Object Number: 799719 Size: SH
  9. Loosen the charged air cooler inlet duct to charged air cooler clamp.
  10. Remove the charged air cooler inlet hose and pipe assembly from the vehicle. The assembly can be removed as one piece with the left front fender wheelhouse inner panel removed.
  11. Disassemble the hose and pipe assembly as required.
  12. Inspect the hoses for cuts or tears.
  13. Inspect the pipes for damage.
  14. Replace the hose or pipe if damage is found.

Installation Procedure

    Object Number: 799719 Size: SH
  1. Install the charged air cooler inlet hose to the pipe. The hose is marked for correct installation.
  2. Install the hose clamps on the charged air cooler inlet hose but do not tighten.
  3. Install the charged air cooler inlet hose to the charged air cooler aligning the marks on the hoses.

    4. Object Number: 820393 Size: SH
  4. Install the upper hose on the charged air cooler inlet pipe.
  5. Install the clamps on the hose assembly but do not tighten.
  6. Install the charged air cooler inlet duct to turbocharger cool air outlet hose to the turbocharger.

    7. Notice: Refer to Fastener Notice in the Preface section.

  7. Position all of the clamps as shown for proper clearance.

    8. Tighten
    Tighten the charged air cooler hose clamps to 6 N·m (53 lb in).


    Object Number: 799718 Size: SH
  8. Install the lower hose on the charged air cooler outlet pipe. The hose is marked for correct installation.
  9. Install the clamps on the outlet hose but do not tighten.

    10. Object Number: 868020 Size: SH
  10. Install the charged air cooler outlet duct to intake manifold tube hose.

    11. The hose is marked DUCT which connects to the charged air cooler outlet duct.

    The hose is marked ENG which connects to the intake manifold tube.

    Align the marks on the hose with the alignment marks on the pipe and duct.

  11. Position all of the clamps as shown for proper clearance.

    12. Tighten
    Tighten the charged air cooler hose clamps to 6 N·m (53 lb in).

  12. Inspect the routing of the charged air cooler ducts to ensure they are not contacting anything. Adjust the ducts if necessary.
  13. Install the air cleaner . Refer to Air Cleaner Replacement .
  14. Install the air cleaner outlet duct to turbocharger. Align the duct to the air cleaner.

    15. Tighten
    Tighten the charged air cooler outlet duct clamps to 6 N·m (53 lb in).

  15. If equipped, install the following:
    16. • The auxiliary transmission cooler.
    • The auxiliary oil cooler.
    • Fixed grill.