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.

This procedure takes it that the front bumper cover has been already taken off for intercooler system drainage. First, raise the engine cover to the extent that it will no longer be connected to the ballstuds, before moving it to the front and off the engine. Then, turn the bleed screw which is placed at the top right side of intercooler radiator anti-clockwise. Turn the intercooler fill port fitting in a clockwise manner until the fill cap is in a position whereby it sits on top then unscrew the cap, pour coolant and water blend of 50/50 until coolant is observed dripping from the bleeder, then screw the bleeder tight. After fitting the cap, turn the engine on and let the engine run for one minute; then switch off and let the coolant in the fitting to settle down for the next one minute before removing the cap. Pour in more 50/50 coolant mixture until it is near the top of the fitting again, and do as the steps above again if needed. Twist the cap open to avoid the occurrence of bubbles, wait for approximately fifteen minutes to add more solutions, when necessary and twist the cap shut. This should be done until coolant level within the fitting cannot bubbles and remains steady.