Heating, Ventilation and Air Conditioning Cadillac XLR I

Fastener Tightening Specifications

Fastener Tightening Specifications

Refrigerant System Capacities

Refrigerant System Capacities

Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information

1. The identification of the control modules which are not communicating.
2. The identification of any stored diagnostic trouble codes (DTCs) and their status.

The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis.

Leak Testing

Tools Required

1. J 39400-A Halogen Leak Detector
2. J 41447 R-134A A/C Tracer Dye-Box of 24. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
3. J 42220 Universal 12V Leak Detection Lamp. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
4. J 43872 Fluorescent Dye Cleaner. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
5. J 46297 A/C Dye Injector Kit. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
6. J 46297-12 Replacement Dye Cartridges. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

Refrigerant Leak Testing

The fluorescent dye mixes and flows with the polyalkylene glycol (PAG) oil throughout the refrigerant system.

Verifying some passive leaks may require using the J 39400-A , even though the A/C system contains fluorescent dye.

The only time that adding additional fluorescent dye is required is after flushing the A/C system.

Fluorescent Leak Detector

Fluorescent dye will assist in locating any leaks in the A/C system.

1. Condensation on the evaporator core or the refrigerant lines may wash the PAG oil and fluorescent dye away from the actual leak. Condensation may also carry dye through the HVAC module drain.
2. Leaks in the A/C system will be indicated in a light green or yellow color when using the leak detection lamp. Use the leak detection lamp in the following areas: All fittings or connections that use seal washers or O-rings All of the A/C components The A/C compressor shaft seal The A/C hoses and pressure switches The HVAC module drain tube, if the evaporator core is suspected of leaking The service port sealing caps The sealing cap is the primary seal for the service ports.
3. Follow the instructions supplied with the J 42220 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
4. To prevent false diagnosis in the future, thoroughly clean the residual dye from any area where leaks were found. Use a rag and the approved J 43872 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

Fluorescent Dye Injection

1. Not all of the fluorescent dyes are compatible with PAG oil. Some types of dye decrease the oil viscosity or may chemically react with the oil.
2. R-134A leak detection dye requires time to work. Depending upon the leak rate, a leak may not become visible for between 15 minutes and 7 days.
3. To prevent false diagnosis, thoroughly clean any residual dye from the service port with a rag and the approved fluorescent dye cleaner J 43872 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

Halogen Leak Detector

Ensure that the vehicle has at least 0.45 kg (1 lb) of refrigerant in the A/C refrigeration system in order to perform a leak test. Refer to Refrigerant Recovery and Recharging for recharging the A/C system.

Clean and dry all surfaces in order to prevent a false warning. Liquids will damage the detector.

Follow the instructions supplied with the J 39400-A .

Test Description

This test measures the operating efficiency of the A/C system under the following conditions

1. The current ambient air temperature
2. The current relative humidity
3. The high side pressure of the A/C system
4. The low side pressure of the A/C system
5. The temperature of the air being discharged into the passenger compartment

The numbers below refer to the step numbers on the diagnostic table.

1. 1: This step determines if the A/C system has at least the minimum refrigerant charge required to operate the system without damage.
2. 2: This step measures the performance of the A/C system.
3. 3: This step allows for vehicle variations as well as high ambient temperatures.

Air Conditioning (A/C) System Performance Test (4.4L)

Scheme 39

A/C Performance Table

This test measures the operating efficiency of the A/C system under the following conditions

1. The current ambient air temperature
2. The current relative humidity
3. The high side pressure of the A/C system
4. The low side pressure of the A/C system
5. The temperature of the air being discharged into the passenger compartment

The numbers below refer to the step numbers on the diagnostic table.

1. 1: This step determines if the A/C system has at least the minimum refrigerant charge required to operate the system without damage.
2. 2: This step measures the performance of the A/C system.
3. 3: This step is to allow for vehicle variations as well as high ambient temperatures.

Air Conditioning (A/C) System Performance Test (4.6L)

Scheme 40

A/C Performance Table

Air Conditioning (A/C) Diagnostics - Pressure Zone A

Air Conditioning (A/C) Diagnostics - Pressure Zone A

Air Conditioning (A/C) Diagnostics - Pressure Zone B

Air Conditioning (A/C) Diagnostics - Pressure Zone B

Air Conditioning (A/C) Diagnostics - Pressure Zone C

Air Conditioning (A/C) Diagnostics - Pressure Zone C

Air Conditioning (A/C) Diagnostics - Pressure Zone D

Air Conditioning (A/C) Diagnostics - Pressure Zone D

Heating Performance Diagnostic

Heating Performance Diagnostic

Defrosting Insufficient

Defrosting Insufficient

Noise Diagnosis - Blower Motor

Noise Diagnosis - Blower Motor

Noise Diagnosis - Air Conditioning (A/C) System

Noise Diagnosis - Air Conditioning (A/C) System

Noise Diagnosis - HVAC Module

Noise Diagnosis - HVAC Module

Odor Diagnosis

Odor Diagnosis

Eliminating Air Conditioning Odor

Odors may be emitted from the air conditioning system primarily at start up in hot, humid climates. The following conditions may cause the odor

1. Debris is present in the HVAC module
2. Microbial growth on the evaporator core

When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. To remove odors of this type, the microbial growth must be eliminated. Perform the following procedure

Deodorize the evaporator core using Deodorizing Aerosol Kit.

Perform the following steps in order to deodorize the A/C system

1. Ensure that the plenum which draws outside air into the HVAC module is clear of debris.
2. Disable the A/C compressor clutch operation by disconnecting the clutch coil electrical connector.
3. Dry the evaporator core by performing the following steps: Start the engine. Select the warmest temperature setting. Select the recirculation mode. Run the blower motor on high for 10 minutes.
4. Locate an area in the air conditioning duct between the blower motor and the evaporator core downstream of the blower motor.
5. Drill a 3.175 mm (0.125 in) hole where the hole will not interfere with or damage the following components: The blower motor The evaporator core Any other operating part the of system
6. Wear safety goggles and latex gloves in order to perform the following actions: Select the maximum blower speed. Insert the deodorizer extension tube into the hole to the mark on the extension tube. Use short spray bursts and vary the direction of spray for a 2-3 minute period of time.
7. Shut the engine OFF. Allow the vehicle to sit for 3-5 minutes.
8. Seal the 3.175 mm (0.125 in) hole with body sealer or RTV gasket compound.
9. Start the engine.
10. Operate the blower motor on high for 15-20 minutes to dry.
11. Reconnect the A/C compressor clutch coil electrical connector.
12. Verify proper A/C clutch operation.

Refrigerant Recovery and Recharging

Tools Required

1. J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
2. J 45037 A/C Oil Injector. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

Note. R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure.

Note. To avoid system damage use only R-134a dedicated tools when servicing the A/C system.

Note. Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result.

Note. R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing.

The J 43600 is a complete air conditioning service center for R-134a. See Special Tools . The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant.

The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system.

The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain.

Refer to the J 43600 ACR 2000 manual for operation and setup instruction. See Special Tools . Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount.

A/C Refrigerant System Oil Charge Replenishing

If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . See Special Tools . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities .

Flushing

Tools Required

1. J 41447 R-134A A/C Tracer Dye - Box of 24. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
2. J 42220 Universal 12V Leak Detection Lamp. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
3. J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
4. J 45268 A/C Flushing Adapter Kit. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

Flushing is intended to remove the following

1. Contaminated PAG oil
2. Desiccant, following a desiccant bag failure
3. Overcharge of PAG oil
4. Refrigerant contamination

Forward Flushing Setup

1. Install both J 45268-9 (2) onto the J 45268-10 (3).
2. Install the J 45268-7 (4) onto the suction side of the J 45268-10 (3).
3. Install the J 45268-8 (1) onto the discharge side of the J 45268-10 (3).

Reverse Flushing Setup

1. Install both J 45268-9 (2) onto the J 45268-10 (3).
2. Install the J 45268-8 (1) onto the suction side of the J 45268-10 (3).
3. Install the J 45268-7 (4) onto the discharge side of the J 45268-10 (3).

Scheme 41

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the TXV. Refer to «Thermal Expansion Valve Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the stud onto the J 45268-115.
4. Install new sealing washers onto the evaporator core. Refer to «Sealing Washer Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install J 45268-115 in place of the TXV.
6. Install TXV mounting bolts. Tighten: Tighten the bolts to 7 N.m (62 lb in).
7. Install new washers onto the rear evaporator line assembly. Refer to «Sealing Washer Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Connect the rear evaporator line assembly to the J 45268-115.
9. Install the TXV block fitting nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
10. Remove the A/C compressor. Refer to «Compressor Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Remove the A/C refrigerant filter. Refer to «Air Conditioning (A/C) Refrigerant Filter Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
12. Service the filter with ACDelco P/N GF 470, before each flush.
13. Install the J 45268-10 to the compressor hose assembly.
14. Connect the J 45268-1 flush filter to the J 45268-7 flush adapter.
15. Connect the blue hose from the J 43600 to J 45268-1 flush filter adapter. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
16. Connect the red hose from the J 43600 to J 45268-8 flush adapter. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
17. Flush the A/C system. Follow the instructions supplied with the J 43600 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
18. Disconnect the red hose from the J 43600 to J 45268-8 flush adapter. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
19. Disconnect the blue hose from the J 43600 to J 45268-1 flush filter adapter. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
20. Disconnect the J 45268-1 flush filter from the J 45268-10 flush adapter.
21. Remove the J 45268-10 from the compressor hose assembly.
22. If you will reinstall the removed A/C compressor, perform the following procedure: Remove the A/C compressor drain plug. Drain the PAG oil from the A/C compressor. Rotate the compressor input shaft to assist in draining the PAG oil from the compressor. Install the A/C compressor drain plug. Tighten: Tighten the drain plug to 15 N.m (11 lb ft). Add the total system capacity of PAG oil to the crankcase of the A/C compressor. Refer to «Refrigerant System Capacities»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) . IMPORTANT: Flushing will remove the fluorescent leak detection dye from the A/C system. Add one bottle of J 41447 directly to the A/C compressor. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
23. Install the A/C compressor. Refer to «Compressor Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
24. Install the A/C refrigerant filter. Refer to «Air Conditioning (A/C) Refrigerant Filter Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
25. Remove the TXV block fitting nut.
26. Disconnect the rear evaporator line assembly from the J 45268-115.
27. Remove the TXV bolts retaining the J 45268-115.
28. Remove the J 45268-115.
29. Inspect the TXV for debris. Clean or replace as needed.
30. Install the TXV. Refer to «Thermal Expansion Valve Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
31. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
32. Leak test the fittings using J 42220 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

Draining Procedure

1. Remove the compressor crankcase oil drain bolt and drain the refrigerant oil from the crankcase and rear head ports into a clean, graduated container.
2. Rotate the compressor shaft to assist in draining the compressor.
3. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
4. Properly discard the used refrigerant oil.
5. Clean the graduated cylinder.
6. Remove the compressor crankcase oil drain bolt and drain the refrigerant oil from the crankcase and rear head ports into a clean, graduated container.
7. Rotate the compressor shaft to assist in draining the compressor.

Balancing Procedure

1. Refer to the amount of refrigerant oil recorded during the compressor removal.
2. If the amount of oil recorded from the removed compressor is less than or equal to 75 ml (2.5 fl. oz), add 75 ml of the new PAG oil back into the new compressor through the compressor oil drain bolt hole.
3. If the amount of oil recorded from the removed compressor is greater than 75 ml (2.5 fl. oz), add the equivalent amount of the new PAG oil back into the new compressor through the compressor oil drain bolt hole.
4. Install the compressor oil drain bolt. Tighten: Tighten the bolt to 15 N.m (11 lb ft).
5. Rotate the clutch driver three times to lubricate the internal compressor components.
6. If necessary, refer to «Refrigerant System Capacities»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the A/C compressor hose assembly. Refer to «Compressor Hose Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Remove the stabilizer shaft. Refer to «Stabilizer Shaft Replacement»(/cadillac/xlr/i-2003-2009/remont/suspension-front/#front-suspension-system) .
4. Remove the RH lower shock absorber mounting bolts. Refer to «Shock Absorber Replacement (W/F55)»(/cadillac/xlr/i-2003-2009/remont/suspension-front/#front-suspension-system__shock-absorber-replacement-wf55) .
5. Separate the RH upper ball joint from the RH upper control arm. Refer to «Upper Control Arm Replacement»(/cadillac/xlr/i-2003-2009/remont/suspension-front/#front-suspension-system) .
6. Remove the LH wheel and tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/cadillac/xlr/i-2003-2009/remont/wheel-tire-system/#tires-and-wheels) .
7. Remove the LH lower shock absorber mounting bolts. Refer to «Shock Absorber Replacement (W/F55)»(/cadillac/xlr/i-2003-2009/remont/suspension-front/#front-suspension-system__shock-absorber-replacement-wf55) .
8. Disconnect the RH ESC position sensor harness connector.
9. Disconnect the RH ESC sensor link from the control arm link stud.
10. Remove the RH ESC position sensor mounting bolt.
11. Remove the RH ESC position sensor from the vehicle.
12. Remove the RH brake pipe to front suspension crossmember mounting bolt.
13. Support the LH side of the front crossmember.
14. Support the RH side of the front crossmember with a transmission jack.
15. Remove the front crossmember mounting nuts.
16. Lower the LH side of the front crossmember approximately 0.375 in (10.0 mm).
17. Lower the RH side of the front crossmember approximately 2.00 in (51.0 mm).
18. Disconnect the A/C compressor electrical connector.
19. Remove the A/C compressor mounting bolts (1, 2, 3).
20. Remove the A/C compressor from the vehicle.
21. If replacing the A/C compressor, balance the compressor. Refer to «Compressor Oil Balancing»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Installation Procedure

1. Install the A/C compressor to the vehicle.
2. Position the A/C compressor onto the A/C compressor bracket and install the A/C compressor mounting bolts (1, 2, 3) and torque in sequence. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Connect the A/C compressor electrical connector.
4. Raise the front crossmember into the proper position.
5. Install the front crossmember mounting nuts. Tighten: Tighten the nuts to 110 N.m (81 lb ft).
6. Remove the transmission jack from under the vehicle
7. Install the RH brake pipe to front crossmember mounting bolt. Tighten: Tighten the bolt to 3 N.m (26 lb in).
8. Install the ESC position sensor to the vehicle.
9. Install the ESC position sensor mounting bolt. Tighten: Tighten the bolt to 3 N.m (26 lb in).
10. Connect the ESC sensor link to the control arm link stud.
11. Connect the RH ESC position sensor harness connector.
12. Install the LH lower shock absorber mounting bolts. Refer to «Shock Absorber Replacement (W/F55)»(/cadillac/xlr/i-2003-2009/remont/suspension-front/#front-suspension-system__shock-absorber-replacement-wf55) .
13. Install the LH wheel and tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/cadillac/xlr/i-2003-2009/remont/wheel-tire-system/#tires-and-wheels) .
14. Install the RH upper ball joint to the RH upper control arm. Refer to «Upper Control Arm Replacement»(/cadillac/xlr/i-2003-2009/remont/suspension-front/#front-suspension-system) .
15. Install the RH lower shock absorber mounting bolts. Refer to «Shock Absorber Replacement (W/F55)»(/cadillac/xlr/i-2003-2009/remont/suspension-front/#front-suspension-system__shock-absorber-replacement-wf55) .
16. Install the stabilizer shaft. Refer to «Stabilizer Shaft Replacement»(/cadillac/xlr/i-2003-2009/remont/suspension-front/#front-suspension-system) .
17. Install the compressor hose assembly. Refer to «Compressor Hose Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
18. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
19. Leak test the fittings of the A/C components using J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/xlr/i-2003-2009/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
3. Remove the right front wheel and tire from the vehicle. Refer to «Tire and Wheel Removal and Installation»(/cadillac/xlr/i-2003-2009/remont/wheel-tire-system/#tires-and-wheels) .
4. Disconnect the RH ESC position sensor harness connector.
5. Disconnect the ESC sensor link from the control arm link stud.
6. Remove the ESC position sensor mounting bolt.
7. Remove the ESC position sensor from the vehicle.
8. Disconnect the front RH ABS electrical connector from the engine cradle and reposition aside.
9. Remove the high pressure relief valve.
10. Cap or tape the A/C compressor.

1. Remove the cap or tape from the A/C compressor.
2. Install the high pressure relief valve. Tighten: Tighten the valve to 8 N.m (70 lb in).
3. Connect the front RH ABS electrical connector to the engine cradle.
4. Install the ESC position sensor to the vehicle.
5. Install the ESC position sensor mounting bolt. Tighten: Tighten the bolt to 3 N.m (26 lb in).
6. Connect the ESC sensor link to the control arm link stud.
7. Connect the RH ESC position sensor harness connector.
8. Install the right front wheel and tire to the vehicle. Refer to «Tire and Wheel Removal and Installation»(/cadillac/xlr/i-2003-2009/remont/wheel-tire-system/#tires-and-wheels) .
9. Lower the vehicle.
10. Evacuate and recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
11. Leak test the fittings of the component using J 39400-A .

1. Remove the seal washer from the A/C refrigerant component.
2. Inspect the seal washer for any signs of damage.
3. Inspect the A/C refrigerant components for damage or burrs. Repair or replace as necessary.
4. Discard the sealing washer.

1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer.
2. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
3. Carefully install the new seal washer onto the A/C refrigerant component.
4. The washer must completely bottom against the surface of the fitting.
5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.

1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure.
2. Remove the O-ring seal from the A/C refrigerant component.
3. Inspect the O-ring seal for signs of damage.
4. Inspect the A/C refrigerant components for damage or burrs. Repair or replace as necessary.
5. Discard the O-ring seal.

1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary.
2. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components.
3. Lightly coat the new O-ring seal and thread fitting with mineral base 525 viscosity refrigerant oil.
4. Carefully slide the new O-ring seal onto the A/C refrigerant component.
5. The O-ring seal must be fully seated.
6. Assemble the A/C components. Refer to the appropriate repair procedure.

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Locate the A/C coupling assembly's locking tab access slots (1).
3. Carefully insert a small flat bladed screwdriver into the first locking tab access slot and gently lift the locking tab to release the lock.
4. Carefully insert a small flat bladed screwdriver into the second locking tab access slot and gently lift the locking tab to release the lock.
5. Open and remove the A/C coupling assembly from the A/C refrigerant component.

1. Install the A/C coupling assembly to the A/C refrigerant component.
2. Close the A/C coupling assembly.
3. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
4. Leak test the fittings of the component using J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the radiator support. Refer to «Radiator Support Replacement»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the A/C compressor hose assembly bolt (1) from the A/C condenser fitting.
4. Disconnect the A/C compressor hose assembly from the A/C condenser fitting.
5. Remove and discard the sealing washer.
6. Cap or tape off the A/C condenser fitting.
7. Disconnect and remove the A/C tube connector from the evaporator outlet tube and A/C compressor hose assembly. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Disconnect the evaporator outlet tube (1) from the A/C compressor hose assembly (2).
9. Cap or tape off the evaporator outlet tube (1).
10. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/xlr/i-2003-2009/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
11. Remove the right front tire and wheel assembly from the vehicle. Refer to «Tire and Wheel Removal and Installation»(/cadillac/xlr/i-2003-2009/remont/wheel-tire-system/#tires-and-wheels) .
12. Remove the A/C compressor hose assembly to A/C compressor retaining nut (3).
13. Disconnect the A/C compressor hose assembly (2) from the A/C compressor.
14. Remove and discard the sealing washers.
15. Cap or tape off the A/C compressor.
16. Remove the power steering pump. Refer to «Power Steering Pump Replacement (RPO LH2)»(/cadillac/xlr/i-2003-2009/remont/manual-power-steering/#power-steering-system) or «Power Steering Pump Replacement (RPO LC3)»(/cadillac/xlr/i-2003-2009/remont/manual-power-steering/#power-steering-system) .
17. Lower the vehicle.
18. Remove the A/C compressor hose assembly (2) from the vehicle.

1. Install the A/C compressor hose assembly (2) to the vehicle.
2. Install the power steering pump. Refer to «Power Steering Pump Replacement (RPO LH2)»(/cadillac/xlr/i-2003-2009/remont/manual-power-steering/#power-steering-system) or «Power Steering Pump Replacement (RPO LC3)»(/cadillac/xlr/i-2003-2009/remont/manual-power-steering/#power-steering-system) .
3. Raise and support the vehicle.
4. Remove cap or tape from the A/C compressor.
5. Install new sealing washers onto the compressor hose assembly. Refer to «Sealing Washer Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Connect the A/C compressor hose assembly (2) to the A/C compressor.
7. Install the A/C compressor hose assembly to A/C compressor retaining nut (3). Tighten: Tighten the nut to 20 N.m (15 lb ft).
8. Install the right front tire and wheel assembly to the vehicle. Refer to «Tire and Wheel Removal and Installation»(/cadillac/xlr/i-2003-2009/remont/wheel-tire-system/#tires-and-wheels) .
9. Lower the vehicle.
10. Remove cap or tape from the evaporator outlet tube (1).
11. Install a new O-rings onto the evaporator outlet tube (1). Refer to «O-Ring Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
12. Connect the evaporator outlet tube (1) to the A/C compressor hose assembly (2).
13. Install the A/C tube connector to the evaporator outlet tube and A/C compressor hose assembly. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
14. Remove cap or tape from the A/C condenser fitting.
15. Install a new sealing washer onto the compressor hose assembly. Refer to «Sealing Washer Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
16. Connect the A/C compressor hose assembly to the A/C condenser fitting.
17. Install the A/C compressor hose assembly bolt (1) to the A/C condenser fitting. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
18. Install the radiator support. Refer to «Radiator Support Replacement»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system) .
19. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
20. Leak test the fittings of the component using J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the battery. Refer to «Battery Replacement»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Disconnect and remove the A/C tube connector (1) at the evaporator rear line assembly. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Disconnect the front evaporator inlet line from the body retaining clip (1).
5. Disconnect the refrigerant pressure sensor electrical connector (2).
6. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/xlr/i-2003-2009/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
7. Remove the front evaporator inlet line to A/C condenser lower bolt.
8. Disconnect the front evaporator line inlet from the A/C condenser.
9. Remove and discard the sealing washer.
10. Cap or tape off the A/C condenser.
11. Lower the vehicle.
12. Disconnect the front evaporator inlet line from the evaporator rear line assembly.
13. Remove and discard the O-rings.
14. Cap or tape the evaporator rear line assembly.
15. Disconnect the surge tank outlet hose and the inlet heater hose from the underhood junction box retainer clip (1).
16. Remove the front evaporator inlet line from the vehicle.

1. Install the front evaporator inlet line to the vehicle.
2. Connect the surge tank outlet hose and the inlet heater hose to the underhood junction box retainer clip (1).
3. Remove cap or tape from the evaporator rear line assembly.
4. Install new O-rings to the rear evaporator line assembly. Refer to «O-Ring Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Connect the front evaporator inlet line to the evaporator rear line assembly.
6. Raise the vehicle.
7. Remove cap or tape from the A/C condenser.
8. Install a new sealing washer to the front evaporator inlet line. Refer to «Sealing Washer Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. Connect the front evaporator inlet line to the A/C condenser.
10. Install the front evaporator inlet line to A/C condenser lower bolt. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
11. Lower the vehicle.
12. Connect the front evaporator inlet line to the body retaining clip (1).
13. Connect the refrigerant pressure sensor electrical connector (2).
14. Connect the A/C tube connector (1) at the evaporator rear line assembly. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
15. Install the battery. Refer to «Battery Replacement»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
16. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
17. Leak test the fittings of the component using J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the battery. Refer to «Battery Replacement»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Remove the intake manifold. Refer to «Intake Manifold Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-46l-lh2-1-of-5) .
4. Disconnect the front evaporator inlet line from the body retaining clip (1).
5. Disconnect the refrigerant pressure sensor electrical connector (2).
6. Disconnect and remove the A/C tube connectors from the evaporator rear line assembly. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
7. Disconnect the front evaporator inlet line from the evaporator rear line assembly.
8. Remove and discard O-rings.
9. Cap or tape the front evaporator inlet line.
10. Disconnect the A/C compressor line from the evaporator rear line assembly.
11. Remove and discard the O-rings.
12. Cap or tape the front evaporator line and A/C compressor line.
13. Remove the heater pipe bracket retaining nut (1) from the cowl stud.
14. Remove the TXV block fitting nut (2).
15. Disconnect the evaporator rear line assembly from the TXV (3).
16. Disconnect the evaporator rear line assembly from the retainer bracket.
17. Remove the rear evaporator line assembly from the vehicle.
18. Remove and discard the seal washers.
19. Cap or tape the TXV (3).

1. Remove the cap or tape from the TXV (3).
2. Install new seal washers to the evaporator rear line assembly. Refer to «Sealing Washer Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the evaporator rear line assembly to the vehicle.
4. Connect the evaporator rear line assembly to the retainer bracket.
5. Connect the evaporator rear line assembly to the TXV (3).
6. Install the TXV block fitting nut (2). Tighten: Tighten the nut to 20 N.m (15 lb ft).
7. Install the heater pipe bracket retaining nut (1) to the cowl stud. Tighten: Tighten the nut to 10 N.m (7 lb ft).
8. Remove cap or tape from the front evaporator line and A/C compressor line.
9. Install new O-rings to the rear evaporator line assembly. Refer to «O-Ring Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
10. Connect the A/C compressor line to the evaporator rear line assembly.
11. Connect the front evaporator line to the evaporator rear line assembly.
12. Connect the A/C tube connectors onto the evaporator rear line assembly. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
13. Connect the refrigerant pressure sensor electrical connector (2).
14. Connect the front evaporator inlet line to the body retaining clip (1).
15. Install the intake manifold. Refer to «Intake Manifold Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-46l-lh2-1-of-5) .
16. Install the battery. Refer to «Battery Replacement»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
17. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
18. Leak test the fittings of the component using J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/xlr/i-2003-2009/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
3. Remove the front evaporator inlet line to A/C condenser bolt.
4. Disconnect the front evaporator inlet line from the A/C condenser.
5. Cap or tape off the A/C condenser port.
6. Remove A/C refrigerant filter from the front evaporator inlet line.
7. Remove and discard the seal washer from the front evaporator inlet line.
8. Cap or tape off the front evaporator inlet line.

1. Remove the cap or the tape from the front evaporator inlet line.
2. Install a new seal washer to the front evaporator inlet line. Refer to «Sealing Washer Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the A/C refrigerant filter to the front evaporator inlet line.
4. Remove the cap or tape from the A/C condenser.
5. Connect the front evaporator inlet line to the condenser.
6. Install the front evaporator inlet line to condenser bolt. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
7. Lower the vehicle.
8. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
9. Leak test the fittings of the component using J 39400-A .

J 43244 Relay Puller Pliers

1. Remove the electrical center cover.
2. Locate the compressor relay. Refer to «Electrical Center Identification Views»(/cadillac/xlr/i-2003-2009/remont/electrical-component-locations/#wiring-systems-component-views) to locate the electrical center where the compressor relay exists.
3. Using the J 43244 (1) position the tool on opposing corners of the compressor relay (2).
4. Remove the compressor relay (2) from the electrical center.

1. Install the compressor relay (2) in the same position as removed.
2. Install the electrical center cover.

Air Conditioning Refrigerant Service Valve Core Replacement

Tools Required

1. J 39400-A Halogen Leak Detector
2. J 46246 Valve Core Tool. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Using the J 46246 , remove the valve core from the service port. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

1. Install the valve core to the service port.
2. Using the J 46246 , tighten the valve core. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Tighten: Tighten the valve core to 11 N.m (97 lb in).
3. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
4. Leak test the fittings of the component using J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the rear evaporator line assembly. Refer to «Air Conditioning Evaporator Rear Tube Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Remove the TXV to evaporator core mounting bolts.
4. Disconnect the TXV from the evaporator and remove from the vehicle.
5. Remove and discard the evaporator core seal washers.
6. Cap or tape off the evaporator core.

1. Remove the cap or tape from the evaporator core.
2. Install new seal washers to the evaporator core. Refer to «Sealing Washer Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the TXV to the evaporator core.
4. Install the TXV to evaporator core mounting bolts. Tighten: Tighten the bolts to 7 N.m (62 lb in).
5. Install the rear evaporator line assembly. Refer to «Air Conditioning Evaporator Rear Tube Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
7. Leak test the fittings of the component using J 39400-A .

J 39400-A Halogen Leak Detector

1. Disconnect the A/C refrigerant pressure sensor electrical connector.
2. Remove the A/C refrigerant pressure sensor from the front evaporator line.
3. Remove and discard the O-ring seal from the A/C refrigerant sensor port.

1. Install a new O-ring seal onto the A/C refrigerant pressure sensor port. Refer to «O-Ring Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the A/C refrigerant pressure sensor to the front evaporator line. Tighten: Tighten the sensor to 5 N.m (44 lb in).
3. Connect the A/C refrigerant pressure sensor electrical connector.
4. Leak test the fittings of the component using J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the upper radiator support. Refer to «Radiator Support Replacement»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the A/C compressor hose assembly to A/C condenser fitting bolt (1).
4. Disconnect the A/C compressor hose assembly from the A/C condenser fitting.
5. Remove and discard the seal washer.
6. Cap or tape the A/C compressor hose assembly.
7. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/xlr/i-2003-2009/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
8. Remove the front evaporator inlet line bolt from the A/C condenser.
9. Disconnect the front evaporator inlet line from the A/C condenser.
10. Remove and discard the seal washer.
11. Cap or tape the front evaporator inlet line.
12. Lower the vehicle.
13. Remove the LH radiator air baffle upper retainer pin (1).
14. Remove the RH radiator air baffle upper retainer pin (1).
15. Raise the A/C condenser along the radiator to release the A/C condenser tabs from the radiator slots.
16. Remove the A/C condenser from the vehicle.

1. If replacing the condenser, add the specified amount of PAG oil directly to the condenser. Refer to «Refrigerant System Capacities»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .
2. Position the A/C condenser into the vehicle.
3. Lower the A/C condenser to secure the A/C condenser tabs into the radiator slots.
4. Remove the RH radiator air baffle upper retainer pin (1).
5. Remove the LH radiator air baffle upper retainer pin (1).
6. Raise and support the vehicle.
7. Remove the cap or tape from the front evaporator inlet line.
8. Install a new seal washer onto the front evaporator inlet line. Refer to «Sealing Washer Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. Connect the front evaporator inlet line to the A/C condenser.
10. Install the front evaporator inlet line bolt. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
11. Lower the vehicle.
12. Remove the cap or tape from the A/C compressor hose assembly.
13. Install a new seal washer to the A/C compressor hose assembly. Refer to «Sealing Washer Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
14. Connect the A/C compressor hose assembly to the A/C condenser.
15. Install the A/C compressor hose assembly to A/C condenser bolt (1). Tighten: Tighten the bolt to 16 N.m (12 lb ft).
16. Install the upper radiator support. Refer to «Radiator Support Replacement»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system) .
17. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
18. Leak test the fittings of the component using J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-static) or «Cooling System Draining and Filling (GE 47716)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-ge) in Engine Cooling.
3. Remove the heater pipe assembly. Refer to «Heater Pipes Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Remove the engine wire harness bracket bolt.
5. Disconnect engine wire harness electrical connector and reposition aside.
6. Remove the evaporator drain tube (1) from the HVAC module.
7. Remove the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
8. Remove the retainers from the upper defogger duct on the left side window.
9. Disconnect and remove the upper defogger outlet duct.
10. Disconnect the HUD electrical connector.
11. Remove the HUD retaining nuts.
12. Remove the screw that secures the HUD to the steering column bracket.
13. Remove the retainer from the lower defogger outlet duct.
14. Disconnect and remove the outlet duct from the defroster duct.
15. Remove the retainer securing the floor air outlet duct to the lower I/P beam.
16. Disconnect the floor air outlet duct from the rear floor air outlet duct.
17. Remove the floor air outlet duct.
18. Remove the retaining screws from the floor air outlet duct.
19. Remove the outlet duct.
20. Remove the retainers from the upper outlet duct on the right side window defogger.
21. Disconnect and remove the defogger upper outlet duct from the defogger lower outlet duct.
22. Disconnect the defogger lower outlet duct from the knee bolster bracket.
23. Disconnect the defogger lower outlet duct from the defroster duct.
24. Remove the defogger lower outlet duct.
25. Remove the knee bolster bracket. Refer to «Passenger Knee Bolster Bracket Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
26. Remove the retaining screws from the floor air outlet duct.
27. Remove the air outlet duct.
28. Remove the defroster duct retaining screws.
29. Remove the defroster duct.
30. Disconnect the blower motor electrical connector.
31. Remove the blower motor retaining screws.
32. Remove the blower motor from the HVAC module.
33. Remove the retaining and sealing nuts from the cowl.
34. Remove the retaining bolts from the upper I/P cross vehicle beam.
35. Completely loosen the studs on the HVAC module.
36. Loosen the front LH recirculation housing retaining screw.
37. Disconnect the recirculation actuator electrical connector.
38. Disconnect the HVAC module wiring harness from the recirculation housing.
39. Remove the remaining recirculation housing retaining screws.
40. Remove the recirculation housing from the HVAC module.
41. Reposition the center console wiring harness and the corresponding electrical connectors to the sides of the HVAC module and forward of the lower tie bar.
42. Carefully remove the HVAC module from the vehicle.
43. Remove and discard the air inlet, drain and plumbing seals from the HVAC module.

1. If a new HVAC module is being installed, add the specified amount of PAG oil to the evaporator core. Refer to «Refrigerant System Capacities»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .
2. Install the HVAC module studs. Tighten: Tighten the studs to 4 N.m (35 lb in).
3. Install new air inlet, drain and plumbing seals to the HVAC module.
4. Inspect the dash-mat for proper alignment to the cowl. Align if necessary.
5. Install the HVAC module into the vehicle.
6. Reposition the center console wire harness and the corresponding electrical connectors rearward of the lower tie bar.
7. Install the recirculation housing to the HVAC module.
8. Install the recirculation housing retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
9. Connect the HVAC module wiring harness to the recirculation housing.
10. Connect the recirculation actuator electrical connector.
11. Tighten the front LH recirculation housing retaining screw. Tighten: Tighten the screw to 1.6 N.m (14 lb in).
12. Align the following components to the corresponding openings on the cowl: The heater core block fitting The evaporator block fitting The HVAC module drain The HVAC module studs
13. Install the bolts retaining the HVAC module to the upper I/P cross vehicle beam. Tighten: Tighten the bolts to 5 N.m (44 lb in).
14. Install new HVAC module retaining and sealing nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
15. Install the blower motor to the HVAC module.
16. Install the blower motor retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
17. Connect the blower motor electrical connector.
18. Install the defroster duct to the HVAC module.
19. Install the defroster duct retaining screws. Tighten: Tighten the screws to 10 N.m (89 lb in).
20. Install the right floor air outlet duct.
21. Install the floor air outlet duct retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
22. Install the knee bolster bracket. Refer to «Passenger Knee Bolster Bracket Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
23. Install the lower outlet duct to the side window defogger.
24. Connect the lower outlet duct on the side window defogger to the defroster duct.
25. Connect the defogger lower outlet duct to the knee bolster bracket.
26. Connect the defogger upper outlet duct to the defogger lower outlet duct.
27. Install the retainers to the defogger upper outlet duct.
28. Install the left rear floor air outlet duct.
29. Install the floor air outlet duct retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
30. Install the air outlet duct.
31. Connect the left floor air outlet duct to the left rear floor air outlet duct.
32. Install the retainer securing the left floor air outlet duct to the lower I/P beam.
33. Connect the window defogger lower outlet duct to the defroster duct.
34. Install the defogger lower outlet duct retainer.
35. Install the screw that secures the HUD to the steering column bracket. Tighten: Tighten the screw to 3 N.m (27 lb in).
36. Install the HUD retaining nuts. Tighten: Tighten the nuts to 5 N.m (44 lb in).
37. Connect the HUD electrical connector.
38. Connect the defogger upper outlet duct.
39. Install the retainers to the upper defogger duct.
40. Install the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
41. Install the evaporator drain tube (1) to the HVAC module.
42. Connect engine wire harness electrical connector.
43. Install the engine wire harness bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb ft).
44. Install the heater pipe assembly. Refer to «Heater Pipes Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
45. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-static) or «Cooling System Draining and Filling (GE 47716)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-ge) in Engine Cooling.
46. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
47. Leak test the fittings of the component using J 39400-A .

J 39400-A Halogen Leak Detector

1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove and discard the HVAC module assembly foam seal.
3. Remove the TXV mounting bolts.
4. Remove the TXV from the evaporator core.
5. Remove and discard the sealing washers.
6. Disconnect the discharge temperature management (DTM) sensor electrical connectors.
7. Disconnect the HVAC module wiring harness retainer pin (2) from the HVAC module.
8. Disconnect the wiring harness from the heater core cover wire harness retainer (1) and reposition the wiring harness aside.
9. Disconnect the wiring harness from the heater core cover wire harness retainer (3) and reposition the wiring harness aside.
10. Remove the heater cover screws.
11. Remove the heater cover from the HVAC module.
12. Remove the heater core from the HVAC module.
13. Remove the HVAC module case retaining screws.
14. Separate the HVAC module upper case from the HVAC module lower case.
15. Remove the evaporator core from the HVAC module.

1. If replacing the evaporator core, add the specified amount of PAG oil directly to the evaporator core. Refer to «Refrigerant System Capacities»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .
2. Install a new side seal to the evaporator core.
3. Install a new upper seal to the evaporator core.
4. Install 2 new lower seals to the evaporator core.
5. Install the evaporator core to the HVAC module.
6. Install the HVAC module upper case to the HVAC module lower case.
7. Install the HVAC module case retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
8. Install a new foam seal to the heater core.
9. Install the heater core to the HVAC module.
10. Install the heater cover to the HVAC module.
11. Install the heater cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
12. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (1).
13. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (3).
14. Connect the HVAC module wiring harness retainer pin (2) to the HVAC module.
15. Connect the discharge temperature management (DTM) sensor electrical connectors.
16. Install new sealing washers to the evaporator core. Refer to «Sealing Washer Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
17. Install the TXV to the evaporator core.
18. Install the TXV to mounting bolts. Tighten: Tighten the bolts to 7 N.m (62 lb in).
19. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-46l-lh2-1-of-5) .
2. Remove the engine wire harness bracket bolt.
3. Disconnect engine wire harness electrical connector and reposition aside.
4. Remove the HVAC module drain tube (1) from the HVAC module.

1. Install the HVAC module drain tube (1) to the HVAC module.
2. Connect engine wire harness electrical connector.
3. Install the engine wire harness bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the intake manifold. Refer to «Intake Manifold Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-46l-lh2-1-of-5) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-static) or «Cooling System Draining and Filling (GE 47716)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-ge) .
2. Remove the battery. Refer to «Battery Replacement»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Disengage tension on the heater inlet hose clamp at the heater pipe assembly.
4. Disconnect the heater inlet hose from the heater pipe assembly.
5. Disconnect the heater inlet hose from the underhood junction box retainer clip (1).
6. Disengage tension on the heater inlet hose clamp at the water pump.
7. Disconnect the heater inlet hose (1) from the water pump.
8. Remove the heater inlet hose from the vehicle.

1. Install the heater inlet hose on to the vehicle.
2. Connect the heater inlet hose (1) to the water pump.
3. Engage tension on the heater inlet hose clamp at the water pump.
4. Connect the heater inlet hose to the underhood junction box retainer clip (1).
5. Connect the heater inlet hose to the heater pipe assembly.
6. Engage tension on the heater inlet hose clamp at the heater pipe assembly.
7. Install the battery. Refer to «Battery Replacement»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
8. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-static) or «Cooling System Draining and Filling (GE 47716)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-ge) .

J 38185 Spring Hose Clamp Pliers

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-static) or «Cooling System Draining and Filling (GE 47716)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-ge) .
3. Remove the rear evaporator line assembly. Refer to «Air Conditioning Evaporator Rear Tube Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Release and reposition the heater inlet and outlet hose clamps using the J 38185 .
5. Separate the heater hoses from heater pipes.
6. Cap or plug the open heater hoses.
7. Remove the heater pipe assembly to heater core retaining bolt (1).
8. Disconnect the heater pipe assembly from the heater pipe bracket retainer.
9. Disconnect the heater pipe assembly from the heater core.
10. Remove the heater pipe assembly from the vehicle.
11. Remove and discard the sealing washers.
12. Cap or plug the heater core.

1. Remove the cap or plug from the heater core.
2. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the heater pipe assembly and the heater core.
3. Lightly coat the new seal washers with coolant.
4. Carefully slide the new sealing washers onto the heater pipe assembly until properly seated.
5. Install the heater pipe assembly into position in the vehicle.
6. Install the heater pipe assembly to the heater core.
7. Install the heater pipe assembly retaining bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
8. Remove cap or plug from the heater hoses.
9. Connect heater inlet and outlet hoses to the heater pipe assembly.
10. Install the heater hose clamps into position using the J 38185 .
11. Install the rear evaporator line assembly. Refer to «Air Conditioning Evaporator Rear Tube Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
12. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-static) or «Cooling System Draining and Filling (GE 47716)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-ge) .

1. Disengage the passenger compartment air filter housing cover retainer clips (1).
2. Remove the passenger compartment air filter housing cover.
3. Remove the passenger compartment air filter from the housing.

1. Install the passenger compartment air filter into the housing.
2. Install the passenger compartment air filter housing cover.
3. Engage the passenger compartment air filter housing cover retainer clips (1).

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-static) or «Cooling System Draining and Filling (GE 47716)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-ge) in Engine Cooling.
3. Remove the heater pipe assembly. Refer to «Heater Pipes Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Remove the engine wire harness bracket bolt.
5. Disconnect engine wire harness electrical connector and reposition aside.
6. Remove the evaporator drain tube (1) from the HVAC module.
7. Remove the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
8. Remove the retainers from the upper defogger duct on the left side window.
9. Disconnect and remove the upper defogger outlet duct.
10. Disconnect the HUD electrical connector.
11. Remove the HUD retaining nuts.
12. Remove the screw that secures the HUD to the steering column bracket.
13. Remove the retainer from the lower defogger outlet duct.
14. Disconnect and remove the outlet duct from the defroster duct.
15. Remove the retainer securing the floor air outlet duct to the lower I/P beam.
16. Disconnect the floor air outlet duct from the rear floor air outlet duct.
17. Remove the floor air outlet duct.
18. Remove the retaining screws from the floor air outlet duct.
19. Remove the outlet duct.
20. Remove the retainers from the upper outlet duct on the right side window defogger.
21. Disconnect and remove the defogger upper outlet duct from the defogger lower outlet duct.
22. Disconnect the defogger lower outlet duct from the knee bolster bracket.
23. Disconnect the defogger lower outlet duct from the defroster duct.
24. Remove the defogger lower outlet duct.
25. Remove the knee bolster bracket. Refer to «Passenger Knee Bolster Bracket Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
26. Remove the retaining screws from the floor air outlet duct.
27. Remove the air outlet duct.
28. Remove the defroster duct retaining screws.
29. Remove the defroster duct.
30. Disconnect the blower motor electrical connector.
31. Remove the blower motor retaining screws.
32. Remove the blower motor from the HVAC module.
33. Remove the retaining and sealing nuts from the cowl.
34. Remove the retaining bolts from the upper I/P cross vehicle beam.
35. Loosen the front LH recirculation housing retaining screw.
36. Disconnect the recirculation actuator electrical connector.
37. Remove the recirculation actuator screws.
38. Remove the recirculation actuator.
39. Disconnect the HVAC module wiring harness from the recirculation housing (1).
40. Remove the remaining recirculation housing retaining screws.
41. Remove the recirculation housing from the HVAC module.
42. Disconnect and remove the air inlet door from the recirculation housing.
43. Remove and discard the foam seal from the recirculation housing.

1. Install a new foam seal to the recirculation housing.
2. Install the air inlet door to the recirculation housing.
3. Install the recirculation housing to the HVAC module.
4. Install the recirculation housing retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
5. Connect the HVAC module wiring harness to the recirculation housing (1).
6. Install the recirculation actuator.
7. Install the recirculation actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
8. Connect the recirculation actuator electrical connector.
9. Tighten the front LH recirculation housing retaining screw. Tighten: Tighten the screw to 1.6 N.m (14 lb in).
10. Align the following components to the corresponding openings on the cowl: The heater core joint fitting The evaporator joint fitting The HVAC module drain The HVAC module studs
11. Install the bolts retaining the HVAC module to the upper I/P cross vehicle beam. Tighten: Tighten the bolts to 5 N.m (44 lb in).
12. Install new HVAC module retaining and sealing nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
13. Install the blower motor to the HVAC module.
14. Install the blower motor retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
15. Connect the blower motor electrical connector.
16. Install the defroster duct to the HVAC module.
17. Install the defroster duct retaining screws. Tighten: Tighten the screws to 10 N.m (89 lb in).
18. Install the right floor air outlet duct.
19. Install the floor air outlet duct retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
20. Install the knee bolster bracket. Refer to «Passenger Knee Bolster Bracket Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
21. Install the lower outlet duct to the side window defogger.
22. Connect the lower outlet duct on the side window defogger to the defroster duct.
23. Connect the defogger lower outlet duct to the knee bolster bracket.
24. Connect the defogger upper outlet duct to the defogger lower outlet duct.
25. Install the retainers to the defogger upper outlet duct.
26. Install the left rear floor air outlet duct.
27. Install the floor air outlet duct retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
28. Install the air outlet duct.
29. Connect the left floor air outlet duct to the left rear floor air outlet duct.
30. Install the retainer securing the left floor air outlet duct to the lower I/P beam.
31. Connect the window defogger lower outlet duct to the defroster duct.
32. Install the defogger lower outlet duct retainer.
33. Install the screw that secures the HUD to the steering column bracket. Tighten: Tighten the screw to 3 N.m (27 lb in).
34. Install the HUD retaining nuts. Tighten: Tighten the nuts to 5 N.m (44 lb in).
35. Connect the HUD electrical connector.
36. Connect the defogger upper outlet duct.
37. Install the retainers to the upper defogger duct.
38. Install the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
39. Install the evaporator drain tube (1) to the HVAC module.
40. Connect engine wire harness electrical connector.
41. Install the engine wire harness bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
42. Install the heater pipe assembly. Refer to «Heater Pipes Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
43. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-static) or «Cooling System Draining and Filling (GE 47716)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-ge) in Engine Cooling.
44. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
45. Leak test the fittings of the component using J 39400-A .

1. Remove the RH insulator panel. Refer to «Instrument Panel Insulator Panel Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
2. Disconnect the blower motor electrical connector.
3. Remove the blower motor retaining screws.
4. Remove the blower motor from the HVAC module.

1. Install the blower motor to the HVAC module.
2. Install the blower motor retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
3. Connect the blower motor electrical connector.
4. Install the RH insulator panel. Refer to «Instrument Panel Insulator Panel Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.

1. Remove the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
2. Remove the retainers from the RH defogger upper outlet duct.
3. Disconnect and remove the RH defogger upper outlet duct from the RH defogger lower outlet duct.
4. Disconnect the RH defogger lower outlet duct from the SIR bracket.
5. Disconnect the RH defogger lower outlet duct from the defroster duct.
6. Remove the RH defogger lower outlet duct.
7. Remove the windshield defroster duct retaining screws.
8. Disconnect the defroster duct from the LH defogger lower outlet duct.
9. Remove the defroster duct.

1. Install the defroster duct.
2. Connect the defroster duct to the LH defogger lower outlet duct.
3. Install the retaining screws to the windshield defroster duct. Tighten: Tighten the screws to 10 N.m (89 lb in).
4. Install the RH defogger lower outlet duct.
5. Connect the RH defogger lower outlet duct to the defroster duct.
6. Connect the RH defogger lower outlet duct to the SIR bracket.
7. Connect the RH defogger upper outlet duct to the RH defogger lower outlet duct.
8. Install the retainers to the RH defogger upper outlet duct.
9. Install the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.

1. Remove the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
2. Remove the screws retaining the air distribution duct to the underside of the I/P assembly.
3. Remove the air distribution duct.
4. Remove the DTM sensors from the air distribution duct.

1. Install the DTM sensors to the air distribution duct.
2. Install the air distribution duct into position on the I/P assembly.
3. Install the retaining screws to the underside of the I/P assembly. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
4. Install the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.

1. Remove the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
2. Remove the retainers from the side window upper defogger duct.
3. Disconnect and remove the defogger upper outlet duct.
4. Disconnect the HUD electrical connector.
5. Remove the HUD retaining nuts.
6. Remove the screw that secures the HUD to the steering column bracket.
7. Remove the defogger lower outlet duct retainer.
8. Disconnect and remove the defogger lower outlet duct from the defroster duct.

1. Install the defogger lower outlet duct.
2. Connect the defogger lower outlet duct to the defroster duct.
3. Install the retainer to the defogger lower outlet duct.
4. Install the screw that secures the HUD to the steering column bracket. Tighten: Tighten the screw to 3 N.m (27 lb in).
5. Install the HUD retaining nuts. Tighten: Tighten the nuts to 5 N.m (44 lb in).
6. Connect the HUD electrical connector.
7. Install and connect the defogger upper outlet duct to the defogger lower outlet duct.
8. Install the retainers to the upper defogger duct.
9. Install the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.

1. Remove the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
2. Remove the retainers from the defogger upper outlet duct.
3. Disconnect and remove the defogger upper outlet duct from the defogger lower outlet duct.
4. Disconnect the defogger lower outlet duct from the SIR bracket.
5. Disconnect the defogger lower outlet duct from the defroster duct.
6. Remove the defogger lower outlet duct.

1. Install the defogger lower outlet duct.
2. Connect the defogger lower outlet duct to the defroster duct.
3. Connect the defogger lower outlet duct to the SIR bracket.
4. Connect the defogger upper outlet duct to the defogger lower outlet duct.
5. Install the retainers to the defogger upper outlet duct.
6. Install the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.

1. Remove the LH lower insulator panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
2. Remove the retainer securing the LH floor air outlet duct to the lower I/P beam.
3. Disconnect the LH floor air outlet duct from the LH rear floor air outlet duct.
4. Remove the LH floor air outlet duct.

1. Install the LH floor air outlet duct.
2. Connect the LH floor air outlet duct to the LH rear floor air outlet duct.
3. Install the retainer securing the LH floor air outlet duct to the lower I/P beam.
4. Remove the LH lower insulator panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.

1. Remove the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
2. Remove the retaining screws from the right floor air outlet duct.
3. Disconnect the air outlet duct from the HVAC module.
4. Remove the air outlet duct.

1. Install the air outlet duct.
2. Connect the air outlet duct to the HVAC module.
3. Install the air outlet duct retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
4. Install the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.

1. Remove the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
2. Remove the retainer securing the left floor air outlet duct to the lower I/P beam.
3. Disconnect the air outlet duct from the air outlet duct.
4. Remove the air outlet duct retaining screws.
5. Disconnect the air outlet duct from the HVAC module.
6. Remove the air outlet duct.

1. Install the air outlet duct.
2. Connect the air outlet duct to the HVAC module.
3. Install the air outlet duct retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
4. Connect the left floor air outlet duct to the left rear floor air outlet duct.
5. Install the retainer securing the air outlet duct to the lower I/P beam.
6. Install the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(/cadillac/xlr/i-2003-2009/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.

J 39400-A Halogen Leak Detector

1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove and discard the HVAC module assembly foam seal.
3. Disconnect the LH air temperature actuator electrical connector.
4. Remove the LH air temperature actuator screws.
5. Remove the LH air temperature actuator.
6. Disconnect the RH air temperature actuator electrical connector.
7. Remove the RH air temperature actuator screws.
8. Remove the RH air temperature actuator.
9. Disconnect the discharge temperature management (DTM) sensor electrical connectors.
10. Disconnect the HVAC module wiring harness retainer pin (2) from the HVAC module.
11. Disconnect the wiring harness from the heater core cover wire harness retainer (1) and reposition the wiring harness aside.
12. Disconnect the wiring harness from the heater core cover wire harness retainer (3) and reposition the wiring harness aside.
13. Remove the heater cover screws.
14. Remove the heater cover from the HVAC module.
15. Remove the heater core from the HVAC module.
16. Remove the HVAC module case retaining screws.
17. Separate the HVAC module upper case from the HVAC module lower case.
18. Lift up on the LH and RH air temperature doors to disconnect from one another.
19. Remove the RH air temperature door from the HVAC module.

1. Install the RH air temperature door to the HVAC module.
2. Lift up on the LH and RH air temperature doors to connect to one another.
3. Install the HVAC module upper case to the HVAC module lower case.
4. Install the HVAC module case retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
5. Install a new foam seal to the heater core.
6. Install the heater core to the HVAC module.
7. Install the heater cover to the HVAC module.
8. Install the heater cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
9. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (1).
10. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (3).
11. Connect the HVAC module wiring harness retainer pin (2) to the HVAC module.
12. Connect the discharge temperature management (DTM) sensor electrical connectors.
13. Install the RH air temperature actuator.
14. Install the RH air temperature actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
15. Connect the RH air temperature actuator electrical connector.
16. Install the LH air temperature actuator.
17. Install the LH air temperature actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
18. Connect the LH air temperature actuator electrical connector.
19. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

J 39400-A Halogen Leak Detector

1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove and discard the HVAC module assembly foam seal.
3. Disconnect the LH air temperature actuator electrical connector.
4. Remove the LH air temperature actuator screws.
5. Remove the LH air temperature actuator.
6. Disconnect the RH air temperature actuator electrical connector.
7. Remove the RH air temperature actuator screws.
8. Remove the RH air temperature actuator.
9. Disconnect the discharge temperature management (DTM) sensor electrical connectors.
10. Disconnect the HVAC module wiring harness retainer pin (2) from the HVAC module.
11. Disconnect the wiring harness from the heater core cover wire harness retainer (1) and reposition the wiring harness aside.
12. Disconnect the wiring harness from the heater core cover wire harness retainer (3) and reposition the wiring harness aside.
13. Remove the heater cover screws.
14. Remove the heater cover from the HVAC module.
15. Remove the heater core from the HVAC module.
16. Remove the HVAC module case retaining screws.
17. Separate the HVAC module upper case from the HVAC module lower case.
18. Lift up on the LH and RH air temperature doors to disconnect from one another.
19. Remove the LH air temperature door from the HVAC module.

1. Install the LH air temperature door to the HVAC module.
2. Lift up on the LH and RH air temperature doors to connect to one another.
3. Install the HVAC module upper case to the HVAC module lower case.
4. Install the HVAC module case retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
5. Install a new foam seal to the heater core.
6. Install the heater core to the HVAC module.
7. Install the heater cover to the HVAC module.
8. Install the heater cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
9. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (1).
10. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (3).
11. Connect the HVAC module wiring harness retainer pin (2) to the HVAC module.
12. Connect the discharge temperature management (DTM) sensor electrical connectors.
13. Install the RH air temperature actuator.
14. Install the RH air temperature actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
15. Connect the RH air temperature actuator electrical connector.
16. Install the LH air temperature actuator.
17. Install the LH air temperature actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
18. Connect the LH air temperature actuator electrical connector.
19. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Disconnect the LH air temperature actuator electrical connector.
3. Remove the LH actuator retaining screws.
4. Remove the LH actuator.
5. Disconnect the mode actuator electrical connector.
6. Disconnect the RH air temperature actuator electrical connector.
7. Remove the actuator support bracket retaining screws.
8. Remove the actuator support bracket and actuators.
9. Remove the mode valve assembly retaining screws.
10. Disconnect the HVAC module wiring harness retainer pin (1) from the HVAC module.
11. Disconnect the wiring harness from the heater core cover wire harness retainer (2) and reposition the wiring harness aside.
12. Disconnect the discharge temperature management (DTM) sensor electrical connectors.
13. Remove the heater core cover screws.
14. Remove the heater core cover.
15. Remove the mode valve assembly.

1. Install the mode valve assembly.
2. Install the heater core cover.
3. Install the heater core cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
4. Connect the wiring harness to the heater core cover wire harness retainer (2).
5. Connect the HVAC module wiring harness retainer pin (1) to the HVAC module.
6. Connect the discharge temperature management (DTM) sensor electrical connectors.
7. Install the mode valve assembly retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
8. Install the actuator support bracket and actuators to the HVAC module.
9. Install the actuator support bracket retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
10. Connect the RH air temperature actuator electrical connector.
11. Connect the mode actuator electrical connector.
12. Install the LH actuator.
13. Install the LH actuator retaining screws.
14. Connect the LH air temperature actuator electrical connector.
15. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the air inlet assembly. Refer to «Air Inlet Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Disconnect and remove the recirculation door from the air inlet housing.

1. Install the recirculation door to the air inlet housing.
2. Install the air inlet assembly. Refer to «Air Inlet Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Disconnect the HVAC module wiring harness retainer pin (2) from the HVAC module.
3. Disconnect the wiring harness from the heater core cover wire harness retainer (1) and reposition the wiring harness aside.
4. Disconnect the wiring harness from the heater core cover wire harness retainer (3) and reposition the wiring harness aside.
5. Disconnect the discharge temperature management (DTM) sensor electrical connectors.
6. Remove the DTM sensors.
7. Remove the heater core cover screws.
8. Remove the heater core cover.

1. Install the heater core cover.
2. Install the heater core cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
3. Install the DTM sensors.
4. Connect the discharge temperature management (DTM) sensor electrical connectors.
5. Connect the wiring harness to the heater core cover wire harness retainer (1).
6. Connect the wiring harness to the heater core cover wire harness retainer (3).
7. Connect the HVAC module wiring harness retainer pin (2) to the HVAC module.
8. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove and discard the HVAC module assembly foam seal.
3. Disconnect the discharge temperature management (DTM) sensor electrical connectors.
4. Disconnect the HVAC module wiring harness retainer pin (2) from the HVAC module.
5. Disconnect the wiring harness from the heater core cover wire harness retainer (1) and reposition the wiring harness aside.
6. Disconnect the wiring harness from the heater core cover wire harness retainer (3) and reposition the wiring harness aside.
7. Remove the heater cover screws.
8. Remove the heater cover from the HVAC module.
9. Remove the heater core from the HVAC module.

1. Install a new foam seal to the heater core.
2. Install the heater core to the HVAC module.
3. Install the heater cover to the HVAC module.
4. Install the heater cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
5. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (1).
6. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (3).
7. Connect the HVAC module wiring harness retainer pin (2) to the HVAC module.
8. Connect the discharge temperature management (DTM) sensor electrical connectors.
9. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Special Tools

Special Tools Illustration Tool Number/Description J 38185 Hose Clamp Pliers J 39400-A Halogen Leak Detector J 41447 R-134a A/C Tracer Dye - Box of 24 J 42220 Universal 12V Leak Detection Lamp J 43244 Relay Puller Pliers J 43600 ACR2000 Air Conditioning Service Center J 43872 Fluorescent Dye Cleaner J 45037 A/C Oil Injector J 45268 A/C Flush Adapter Kit J 46246 Valve Core Tool J 46297 A/C Dye Injector Kit J 46297-12 Replacement Dye Cartridges

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

See also:
• Diagnostic System Check - Vehicle
• Scan Tool Output Controls
• Symptoms - HVAC Systems - Automatic
• Moving Parts and Hot Surfaces Caution
• Cooling System Description and Operation
• Engine Fails To Reach Normal Operating Temperature
• HVAC Compressor Clutch Does Not Engage
• Drive Belt Excessive Wear Diagnosis
• Drive Belt Falls Off and Excessive Wear Diagnosis
• Drive Belt Tensioner Diagnosis
• Drive Belt Tensioner Diagnosis
• Drive Belt Replacement - Accessory
• Air Conditioning Compressor and Power Steering Pump Belt Replacement
• Vibration Analysis - Engine
• Instrument Panel Carrier Replacement
• Loss of Coolant (LH2)
• Loss of Coolant (LC3)
• Oil Leak Diagnosis
• Fluid Leak Diagnosis
• Power Steering Fluid Leaks
• Fastener Notice
• Stabilizer Shaft Replacement
• Shock Absorber Replacement (W/F55)
• Tire and Wheel Removal and Installation
• Lifting and Jacking the Vehicle
• Power Steering Pump Replacement (RPO LH2)
• Battery Replacement
• Electrical Center Identification Views
• Cooling System Draining and Filling (Static Fill)
• Cooling System Draining and Filling (GE 47716)
• Special Tools
• Refrigerant Recovery and Recharging
• Leak Testing
• Air Conditioning (A/C) Diagnostics - Pressure Zone A
• Air Conditioning (A/C) System Performance Test (4.4L)
• Flushing
• Refrigerant System Capacities
• Heating Performance Diagnostic