GM 12622238 Cooler Assembly, Charging Air

Disconnect the cable from the negative battery terminal, then remove the cross brace. Lift each side of the engine cover up and off the ball studs, and remove it from the vehicle. Raise the vehicle and support it securely on jackstands, then remove the splash shield, bumper cover, and radiator inlet duct. Place a drain pan under the intercooler and loosen the intercooler radiator drain plug located at the lower left corner of the intercooler radiator. Locate the quick-connect fittings for the intercooler hoses, remove the retaining clips, and separate the hoses from the fittings. Disconnect the PCV fresh air tube and dirty air tube, as well as the electrical connectors from the supercharger air inlet and outlet pressure sensors, the intake Air Temperature sensor, and the barometric pressure sensor. Remove the intercooler cover bolts, using a 1/4 inch-drive extension and flex-socket for the rear bolts if necessary, then remove the cover and gasket, taking care to cover the opening to prevent dirt from contaminating the rotors. Do not reuse the intercooler cover gaskets. Remove the intercooler outlet fasteners and slide the outlet out from the cover and cooler. Turn the intercooler cover upside down, remove the intercooler mounting bolts, and take the cooler off the cover. Replace the outlet-to-cooler O-rings with new ones. Ensure the mating surfaces of the intercooler cover and supercharger are perfectly clean before installing the intercooler cover, using brake system cleaner for this purpose. Install the intercooler with new O-rings to the cover and tighten the bolts to the specified torque. Attach the intercooler outlet to the intercooler fittings, ensuring the O-rings are not damaged, and tighten the outlet-to-cover bolts to the specified torque. Remove any rag or tape used to cover the supercharger opening and install the gasket, followed by a new intercooler cover gasket to the cover. Install the intercooler cover and bolts, tightening them in sequence to the specified torque, then install and tighten the intercooler radiator drain plug. Refill and bleed the intercooler system, and complete the installation in reverse order of removal, ensuring to clean any spilled coolant, start the engine to check for proper operation and coolant leaks, and install the engine covers.

Rotate the charge air cooler fill port fitting clockwise until the fill cap is on top, then remove the cap.