Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 2072 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 6.6L (LMM) - REPAIR INSTRUCTIONS)REPAIR INSTRUCTIONSCHARGE AIR COOLER REPLACEMENTINSTALLATION PROCEDURE

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation Procedure

WARNING: This page is about a different car, the 2010 GMC Sierra, 2010 GMC Cab & Chassis Sierra, 2010 Chevrolet Silverado, and 2010 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: View Of Charge Air Cooler & Bolts

Courtesy of GENERAL MOTORS CORP.

Install the charge air cooler.
1. Angle in the left side.
2. Slide to the left.
3. Move in the right side.
4. Position bottom insulators in the radiator support.
  CAUTION: Refer to Fastener Caution .
Install the charge air cooler bolts.
Tighten: Tighten the bolts to 21 N.m (15 lb ft).
Install the radiator. Refer to Radiator Replacement (LMM) or Radiator Replacement (4.3L, 4.8L, 5.3L, and 6.0L) .
Install the charge air cooler inlet and outlet pipes. Refer to Charge Air Cooler Inlet Pipe Replacement and Charge Air Cooler Outlet Pipe Replacement .
Install the upper tie bar. Refer to Front End Upper Tie Bar Replacement .

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.