PPEpower 2020-2024 Heat Exchanger for GM 3.0L Duramax Intercooler Installation Guide

: August 6, 2024
: PPEpower

Table of Contents

PPEpower 2020-2024 Heat Exchanger for GM 3.0L Duramax Intercooler
Product Usage Instructions
FAQ
CONTENTS
Tools needed
Disassembly
DISCLAIMER OF LIABILITY
LIMITATION OF WARRANTY
Documents / Resources

PPEpower 2020-2024 Heat Exchanger for GM 3.0L Duramax Intercooler

PPEpower-2020-2024-Heat-Exchanger-for-GM-3-0L-Duramax-Intercooler-
PRODUCT

Specifications

Product Name: Heat Exchanger for GM 3.0L Duramax Intercooler (119010300)
Compatibility: GM 3.0L Duramax engines from 2020-2024

Product Usage Instructions

Disassembly

Turn off the vehicle and allow it to cool down.
Remove the skid plate below the electric fans using a 13 mm socket.
Disengage inserts securing the air deflector under the charge air coolant heat exchanger bottom bracket.
Pinch and disconnect the coolant inlet hose spring clamp, then remove the hose from the heat exchanger inlet.
Remove the hood release lever with a T-15 bit.
Pop all clips securing the intake air splash shield and remove the shield using a U-groove clip-removing tool.
Unbolt the hood release latch bracket using a 13 mm socket.
Disconnect the horn and horn bracket with a 10 mm socket.
Remove the left and right diagonal braces with a 15 mm socket.
Disconnect the coolant outlet hose spring clamp and hose from the heat exchanger.
Unbolt the heat exchanger support brackets on both sides.
Lift and remove the factory heat exchanger.

Installation

Install C-nuts to the PPE heat exchanger, two on each side.
Insert the PPE heat exchanger from the top opening, ensuring bottom supports are fully seated in fan shroud slots.
Reconnect the inlet and outlet hoses, securing both clamps.
Re-install diagonal braces, horn bracket, hood release latch bracket, intake air splash shield, and hood release lever.
Add coolant to the charge air cooler coolant reservoir to the factory-recommended fill level.
Drive the truck for at least 15-20 minutes to purge air in the charge air coolant loop, then top off the coolant to the recommended level again.

FAQ

Q: How long does it take to install the heat exchanger?

A: The installation process typically takes around 1-2 hours depending on experience level and tools available.

Q: Can I reuse the coolant when disconnecting hoses?

A: Yes, you can save and reuse the coolant if it is still in good condition.

Tools needed

T-15 torx bit
10 mm socket
13 mm socket
15 mm socket
U-groove clip-removing tool
Plier

Disassembly

Turn the vehicle off and allow time to cool down before installing.
With a 13 mm socket, remove the skid plate below the electric fans. (FIG 1)
Disengage the inserts that secure the air deflector under the charge air coolant heat exchanger bottom bracket. This will allow for the heat exchanger removal in later steps. (FIG 2, FIG 3)
Draining the coolant: Using a plier, pinch and disengage the coolant inlet hose spring clamp located at the lower driver side of the heat exchanger. Then disconnect the coolant hose from the heat exchanger inlet. Save coolant if reusing. (FIG 4)
With a T-15 bit, remove the hood release lever.
Using a U-groove clip removing tool, pop all the clips that secure the intake air splash shield, and remove the shield (FIG 5)
Using a 13 mm socket, unbolt the two screws securing the hood release latch bracket, and leave it on top of the upper tie bar (FIG 6). Do not disconnect the hood open sensor wire from the latch.
Using a 10 mm socket, disconnect the horn and horn bracket from the tie bar.
Using a 15 mm socket, remove the left and right diagonal braces located right in front of the transmission cooler. (FIG 7)
Disengage the coolant outlet hose spring clamp and disconnect the hose from the heat exchanger. This is located at the upper passenger side of the heat exchanger. Use paper towels to avoid spillage.
Using a 10 mm socket, unbolt the left and right heat exchanger support brackets. There are four bolts on each side, two for the heat exchanger and two for the radiator. If it is too hard to access the passenger-side radiator-bracket bolts, unbolt the passenger-side transmission cooler bolt and lift the transmission cooler for more room.
Lift the factory heat exchanger straight up and maneuver it out from the opening created by removing the intake air splash shield.
- Installation
Install the four C-nuts to the PPE heat exchanger, two on each side.
Drop in the PPE heat exchanger from the top opening created by removing the intake air splash shield. Make sure that the bottom supports are fully seated in the fan shroud slots. (FIG 8, FIG 9)
Reconnect the inlet and outlet hoses, and reengage both clamps.
Re-install the diagonal braces, horn bracket, hood release latch bracket, intake air splash shield, and hood release lever.
Add coolant to the charge air cooler coolant reservoir (the smaller reservoir). Add coolant to the factory-recommended fill level marked on the side of the reservoir (FIG 10).
Drive the truck for at least 15-20 minutes to purge the air in the charge air coolant loop, then top off the coolant to the factory-recommended fill level again.

DISCLAIMER OF LIABILITY

Performance products can increase horsepower above and beyond factory specifications. Additional horsepower creates more stress on the drive-train components, which could result in drive-train failure.
Note regarding emissions-related, non-E.O.-legal products: THESE PRODUCTS ARE LEGAL IN CALIFORNIA ONLY FOR RACING VEHICLES THAT MAY NEVER BE USED, OR REGISTERED OR LICENSED FOR HIGHWAY OR OFF-ROAD USE.
This agreement sets forth the terms and conditions for the use of PPE products. The installation of this product indicates that the Buyer has read and understands this agreement and accepts the terms and conditions.

PPE (Pacific Performance Engineering)

Inc., its distributors, employees, and dealers (the “Seller”) shall not be responsible for the product’s proper use and service.
The buyer hereby waives all liability claims. The Buyer hereby acknowledges no reliance on the Seller’s skill or judgment to select or furnish goods suitable for any particular purpose and that there are no liabilities that extend beyond the description on the face hereof, and the Buyer hereby waives all remedies or liabilities expressed or implied, arising by law or otherwise (including without any obligation of the Seller concerning fitness, merchantability, and consequential damages), or whether or not occasioned by the Seller’s negligence.
The Seller disclaims any warranty and expressly disclaims any liability for personal injury or damages. The Buyer acknowledges and agrees that the disclaimer of any liability for personal injury is a material term for this agreement and the Buyer agrees to indemnify the Seller and to hold the Seller harmless from any claim related to the item of equipment purchased. Under no circumstances will the Seller be liable for any damages or expenses because of the use or sale of any such equipment.
The Seller assumes no liability regarding the improper installation or misapplication of its products. It is the installer’s responsibility to check for proper installation and if in doubt, contact the manufacturer.
The Buyer is solely responsible for all warranty issues from the manufacturer.

LIMITATION OF WARRANTY

The Seller gives Limited Warranty as to description, quality, merchantability, and fitness for a particular purpose, productiveness, or any other matter of Seller’s product sold herewith. The Seller shall not be responsible for the product’s proper use and service and the Buyer hereby waives all rights other than those expressly written herein. This warranty shall not be extended, altered, or varied except by a written instrument signed by Seller and Buyer.
Limited lifetime warranty on all PPE cast aluminum products, and PPE Transmission Coolers. Three (3) year limited warranty on PPE Manifolds and Up-Pipes Kits, and OEM-Length.
Up-Pipes. One (1) year limited warranty on all other PPE products from the date of sale to the original buyer and limited solely to the parts contained within the product kit. All products that are in question of Warranty must be returned prepaid to the Seller and must be accompanied by a dated proof of purchase receipt. All Warranty claims are subject to approval by the Seller. Under no circumstances will the Seller be liable for any labor charged or travel time incurred
in diagnosis for defects, removal, or re-installation – of this product or any other contingent expenses. Under no circumstances will the Seller be liable for any damage or expenses incurred because of the use or sale of any such equipment.
If the buyer does not agree with this agreement: the buyer may promptly return this product, in a new and unused condition in its original packaging, with a dated proof of purchase to the place of purchase within ten (10) days from the date of purchase for a full refund.
The installation of this product indicates that the buyer has read and understands this agreement and accepts its terms and conditions. PPEpower.com

Documents / Resources

| PPEpower 2020-2024 Heat Exchanger for GM 3.0L Duramax Intercooler [pdf] Installation Guide
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