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Reference Information Cadillac XLR I

Engine Controls - 4.4l - Introduction (2 of 2) ~4061 words

Reference Information

Special Tools Required

  1. J 36850 Transjel Lubricant. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
  2. J 42960-2 Fuel Flapper Door Holder. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
  3. J 45004 Fuel Drain Hose. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
CAUTIONNever drain or store fuel in an open container. Always use an approved fuel storage container in order to reduce the chance of fire or explosion.
CAUTIONPlace a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these precautions may result in personal injury.
CAUTIONDrain the fuel tank to at least 3/4 of a tank before removing the fuel sender retaining ring or fuel sender access panel in order to avoid possible fuel spillage. Failing to follow this procedure could result in personal injury.
  1. Remove the fuel filler cap.
  2. Install the J 42960-2 (1) into the fuel fill pipe in order to hold the door open. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
  3. Insert the J 45004 (2) into the fuel tank until the hose reaches the bottom of the fuel tank. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
  4. Use an air operated pump device in order to drain the fuel into an approved gasoline container.
  5. Simultaneously twist and pull in order to remove the J 45004 from the fuel tank. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
  6. Remove the driveline support assembly. Refer to «Driveline Support Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/driveshaft-universal-joints/#propeller-shaft) .
  7. Remove the crossover tube/hose from the right hand fuel tank. Refer to «Fuel Tank Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  8. Drain the fuel through the fuel tank crossover connection using a hand or an air operated fuel pump device and the J 45004 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__fuel-pressure-relief) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  4. 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) .
  5. Remove the left rear tire. Refer to «Tire and Wheel Removal and Installation»(/cadillac/xlr/i-2003-2009/remont/wheel-tire-system/#tires-and-wheels) .
  6. Remove the left rear wheelhouse liner panel. Refer to «Rear Wheelhouse Liner Panel Replacement»(/cadillac/xlr/i-2003-2009/remont/exterior-body-panels/#body-rear-end) .
  7. Remove both mufflers. Refer to «Exhaust Muffler Replacement - Left Side»(/cadillac/xlr/i-2003-2009/remont/exhaust/#engine-exhaust-system) and «Exhaust Muffler Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/exhaust/#engine-exhaust-system) .
  8. Remove the driveline support assembly. Refer to «Driveline Support Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/driveshaft-universal-joints/#propeller-shaft) .
  9. Disconnect the fuel fill hose and the recirculation line from the fill pipe.
  10. Disconnect the fuel pump jumper harness connector.
  11. Disconnect the fuel feed pipe (4) at the rear of the left fuel tank. Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-46l-lh2-introduction-2-of-2) .
  12. Cap the fuel pipes to prevent fuel system contamination.
  13. Loosen the fuel tank strap in order to drop the tank approximately one inch.
  14. Disengage the crossover tube connector position assurance (CPA) retainer by pulling the tab (1) outward and rotate.
  15. Rotate crossover tube collar counterclockwise to disengage.
  16. Disconnect the crossover tube from the left fuel tank by pulling straight out.
  17. Disconnect the evaporative emission (EVAP) crossover pipe (2) quick connect fitting at the left fuel tank.
  18. Cap the EVAP pipe to prevent system contamination.
  19. Remove the fuel tank strap mount bolts.
  20. Remove the fuel tank strap from the vehicle.
  21. Remove the fuel tank.
  1. Install the fuel tank.
  2. Install the fuel tank strap to the vehicle.
  3. Install the fuel tank strap bolts loosely leaving the tank hanging approximately 1 inch.
  4. Remove the cap from the EVAP pipe.
  5. Connect the EVAP crossover pipe (2) quick connect fitting at the left fuel tank.
  6. Lubricate the crossover tube to fuel tank connection O-rings (1-4) with P/N 1051717 rubber lubricant.
  7. Lubricate the crossover tube O-ring mating surfaces (1, 3 and 4) with P/N 1051717 rubber lubricant.
  8. Connect the crossover tube to the left fuel tank using the features previously noted.
  9. Rotate the crossover tube collar (5) clockwise to engage the tangs.
  10. Rotate the crossover tube CPA retainer counter-clockwise past the collar latching tang and push the tab (1) into the locked position.
  11. Test the crossover tube to fuel tank connection by attempting to rotate the crossover tube collar counterclockwise.
  12. Tighten the fuel tank strap bolts. Tighten: Tighten the bolts to 25 N.m (18 lb in).
  13. Remove the cap from the fuel pipes.
  14. Connect the fuel feed pipe (4) at the rear of the left fuel tank. Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  15. Connect the fuel pump jumper harness connector.
  16. Connect the fuel fill hose and the recirculation line to the fill tube. Tighten: Tighten the clamp to 3.5 N.m (31 lb in).
  17. Install the driveline support assembly. Refer to «Driveline Support Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/driveshaft-universal-joints/#propeller-shaft) .
  18. Install both mufflers. Refer to «Exhaust Muffler Replacement - Left Side»(/cadillac/xlr/i-2003-2009/remont/exhaust/#engine-exhaust-system) and «Exhaust Muffler Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/exhaust/#engine-exhaust-system) .
  19. Install the left rear wheelhouse liner panel. Refer to «Rear Wheelhouse Liner Panel Replacement»(/cadillac/xlr/i-2003-2009/remont/exterior-body-panels/#body-rear-end) .
  20. Install the left rear tire. Refer to «Tire and Wheel Removal and Installation»(/cadillac/xlr/i-2003-2009/remont/wheel-tire-system/#tires-and-wheels) .
  21. Lower the vehicle.
  22. Refuel the fuel tank.
  23. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
  24. Perform the following procedure in order to test for leaks: Turn ON the ignition switch, for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  25. Program the transmitters. Refer to «Transmitter Programming (Domestic and Japan)»(/cadillac/xlr/i-2003-2009/remont/door-locks-anti-theft-systems/#keyless-entry-system__transmitter-programming-domestic-and-japan) or «Transmitter Programming (Export - Including Canada)»(/cadillac/xlr/i-2003-2009/remont/door-locks-anti-theft-systems/#keyless-entry-system__transmitter-programming-export-including-canada) .

J 37088-A Fuel Line Disconnect Tool

  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__fuel-pressure-relief) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  4. 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) .
  5. Remove the right rear tire. Refer to «Tire and Wheel Removal and Installation»(/cadillac/xlr/i-2003-2009/remont/wheel-tire-system/#tires-and-wheels) .
  6. Remove the right rear wheelhouse liner panel. Refer to «Rear Wheelhouse Liner Panel Replacement»(/cadillac/xlr/i-2003-2009/remont/exterior-body-panels/#body-rear-end) .
  7. Remove the evaporative emission (EVAP) canister access cover.
  8. Disconnect the fuel level vent valve (FLVV) hose (1) at the EVAP canister (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  9. Disconnect the fuel pump module harness connector.
  10. Remove the crossover tube from the clamp located above the transmission.
  11. Disengage the crossover tube connector position assurance (CPA) retainer by pulling the tab (1) outward and rotate.
  12. Rotate crossover tube collar counterclockwise to disengage.
  13. Disconnect the crossover tube from the right fuel tank by pulling the tube straight out of the fuel tank connection.
  14. Disconnect the EVAP crossover pipe (2) quick connect fitting at the right fuel tank. Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  15. Cap the EVAP pipe to prevent system contamination.
  16. Remove the fuel tank strap mount bolts.
  17. Remove the fuel tank strap from the vehicle.
  18. Remove the fuel tank.
  1. Install the fuel tank.
  2. Install the fuel tank strap to the vehicle.
  3. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  4. Remove the cap from the EVAP pipe.
  5. Connect the EVAP crossover pipe (2) quick connect fitting at the right fuel tank. Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  6. Lubricate the crossover tube to fuel tank connection O-rings (1-4) with P/N 1051717 rubber lubricant.
  7. Lubricate the crossover tube O-ring mating surfaces (1, 3 and 4) with P/N 1051717 rubber lubricant.
  8. Connect the crossover tube to the right fuel tank using the features previously noted.
  9. Rotate the crossover tube collar (5) clockwise to engage the tangs.
  10. Rotate the crossover tube CPA retainer counterclockwise past the collar latching tang and push the tab (1) into the locked position.
  11. Test the crossover tube to fuel tank connection by attempting to rotate the crossover tube collar counterclockwise.
  12. Tighten the fuel tank strap bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  13. Snap the crossover tube into the clamp located above the transmission.
  14. Connect the fuel pump module harness connector.
  15. Connect the FLVV hose (1) at the EVAP Canister (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  16. Install the EVAP canister access cover.
  17. Install the driveline support assembly. Refer to «Driveline Support Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/driveshaft-universal-joints/#propeller-shaft) .
  18. Install the right rear wheelhouse liner panel. Refer to «Rear Wheelhouse Liner Panel Replacement»(/cadillac/xlr/i-2003-2009/remont/exterior-body-panels/#body-rear-end) .
  19. Install the right rear tire. Refer to «Tire and Wheel Removal and Installation»(/cadillac/xlr/i-2003-2009/remont/wheel-tire-system/#tires-and-wheels) .
  20. Refuel the fuel tank.
  21. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
  22. Perform the following procedure in order to test for leaks: Turn ON the ignition switch, for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  23. Program the transmitters. Refer to «Transmitter Programming (Domestic and Japan)»(/cadillac/xlr/i-2003-2009/remont/door-locks-anti-theft-systems/#keyless-entry-system__transmitter-programming-domestic-and-japan) or «Transmitter Programming (Export - Including Canada)»(/cadillac/xlr/i-2003-2009/remont/door-locks-anti-theft-systems/#keyless-entry-system__transmitter-programming-export-including-canada) .
  1. Lower the driveline support assembly. Refer to the appropriate steps in the driveline support replacement procedure. Refer to «Driveline Support Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/driveshaft-universal-joints/#propeller-shaft) .
  2. Remove the crossover tube (1) from the clamp (2) located above the transmission.
  3. Disengage the left crossover tube connector position assurance (CPA) retainer by pulling the tab (1) outward and rotate.
  4. Rotate crossover tube collar (3) counterclockwise to disengage.
  5. Disconnect the crossover tube from the left fuel tank by pulling the tube straight out of the fuel tank connection.
  6. Repeat these steps for the right side tank.
  1. Lubricate the right crossover tube to fuel tank connection O-rings (1-4) with P/N 1051717 rubber lubricant.
  2. Lubricate the crossover tube O-ring mating surfaces (1,3 and 4) with P/N 1051717 rubber lubricant.
  3. Connect the crossover tube to the right fuel tank using the features previously noted.
  4. Rotate the crossover tube collar clockwise to engage the tangs.
  5. Rotate the crossover tube CPA retainer counterclockwise past the collar latching tang and push the tab (1) into the locked position.
  6. Test the crossover tube to fuel tank connection by attempting to rotate the crossover tube collar counterclockwise.
  7. Repeat these steps for the left side fuel tank.
  8. Snap the crossover tube into the clamp located above the transmission.
  9. Install the driveline support assembly. Refer to «Driveline Support Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/driveshaft-universal-joints/#propeller-shaft) .
  1. Remove the right rear wheelhouse liner panel. Refer to «Rear Wheelhouse Liner Panel Replacement»(/cadillac/xlr/i-2003-2009/remont/exterior-body-panels/#body-rear-end) .
  2. Remove the evaporative emission (EVAP) canister access cover.
  3. Disconnect the fuel tank pressure sensor electrical connector (1) located on the right side fuel tank module.
  4. Remove the fuel tank pressure sensor (2) by carefully prying the sensor out of the fuel tank.
  1. Lubricate the fuel tank pressure sensor rubber grommet with clean engine oil in order to aid in installation.
  2. Install the fuel tank pressure sensor (1) into the top of the fuel tank module.
  3. Connect the fuel tank pressure sensor electrical connector (1).
  4. Install the EVAP canister access cover.
  5. Install the right rear wheelhouse liner panel. Refer to «Rear Wheelhouse Liner Panel Replacement»(/cadillac/xlr/i-2003-2009/remont/exterior-body-panels/#body-rear-end) .
  1. Remove the fuel filler cap.
  2. Remove the left rear wheelhouse liner panel. Refer to «Rear Wheelhouse Liner Panel Replacement»(/cadillac/xlr/i-2003-2009/remont/exterior-body-panels/#body-rear-end) in Body Rear End.
  3. Disconnect the fuel fill hose (1) and the vent hose (2) from the fuel tank fill and vent pipe.
  4. Cap the open ends of the fuel fill hose (1) and the vent hose (2).
  5. Disconnect the fuel system ground strap.
  6. Remove the fuel tank fill and vent pipe from the fuel filler pocket.
  1. Install the fuel tank fill and vent pipe to the fuel filler pocket. Tighten: Tighten the fuel tank fill and vent pipe bolts to 3.5 N.m (31 lb in).
  2. Connect the fuel fill pipe ground strap. Tighten: Tighten the fuel fill pipe ground strap bolt to 4.0 N.m (35 lb in).
  3. Uncap the openings on the fuel fill hose (1) and the vent hose (2).
  4. Connect the fuel fill hose (1) and the vent hose (2) to the fuel tank fill and vent pipe. Tighten: Tighten the fuel fill hose clamp to 3.5 N.m (31 lb in).
  5. Install the left rear wheelhouse liner panel. Refer to «Rear Wheelhouse Liner Panel Replacement»(/cadillac/xlr/i-2003-2009/remont/exterior-body-panels/#body-rear-end) in Body Rear End.
  6. Install the fuel filler cap.
  1. Remove the left fuel tank. Refer to «Fuel Tank Replacement - Left Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  2. Remove the fuel fill hose (1) from the fuel tank.
  3. Cap the open end of the fuel tank.
  1. Uncap the opening on the fuel tank.
  2. Install the fuel fill hose (1) to the fuel tank. Tighten: Tighten the fuel fill hose clamp to 3.5 N.m (31 lb in).
  3. Install the left fuel tank. Refer to «Fuel Tank Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .

J39765-A Fuel Sender Lock Ring Tool. See Special Tools .

  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
  2. Remove the left fuel tank. Refer to «Fuel Tank Replacement - Left Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  3. Place the fuel tank on a suitable work surface.
  4. Disconnect the fuel pump electrical jumper harness from the fuel pump module.
  5. Disconnect the fuel feed line from the retainer on the side of the fuel tank.
  6. Using the J39765-A (1), remove the fuel pump module locking ring (2), by turning the J39765-A in a counterclockwise direction. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
  7. Carefully remove the fuel pump module (2) half way from the fuel tank, with the internal fuel lines connected. Use care to prevent damage to the fuel sender float arm.
  8. Disconnect the jet line quick-connect fitting from the fuel pump module inner port.
  9. Remove the jet line from the module cup and retainer. This line has no connector.
  10. Remove the fuel pump module O-ring (3) from the fuel tank opening.
  1. Install a new fuel pump module O-ring (3) to the fuel tank opening.
  2. Place mechanics wire around the internal fuel lines in the fuel tank. This will permit line access once the pump module is inserted into the fuel tank.
  3. Install the pump module (2) into the fuel tank half way, using care not to damage the float arm.
  4. Using the mechanics wire, gently pull the fuel lines up through the fuel pump module opening.
  5. Place the fuel line with no connector through the retainer and into the module cup.
  6. Connect the fuel line quick-connect fitting to the fuel pump module inner port.
  7. Remove the mechanics wire from the internal fuel lines.
  8. Install the fuel pump module lock ring (1) into position on the fuel tank module.
  9. Align the fuel tank module to the installed position.
  10. Compress the fuel pump module into the fuel tank.
  11. Using the J39765-A (1), fully lock the fuel pump module lock ring (2) in place, by turning the J39765-A in a clockwise direction. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
  12. Connect the fuel supply line into the clip on the side of the fuel tank.
  13. Using a digital multimeter, verify the full and empty readings resistance reading of the fuel pump module. Turn the fuel tank upside down to achieve the full tank reading. Resistance: Empty tank reading 40 ohms resistance Full tank reading 250 ohms resistance
  14. Connect the fuel pump jumper harness to the fuel pump module.
  15. Install the left fuel tank. Refer to «Fuel Tank Replacement - Left Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  16. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
  17. Perform the following procedure in order to test for leaks: Turn ON the ignition switch, for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  18. Program the transmitters. Refer to «Transmitter Programming (Domestic and Japan)»(/cadillac/xlr/i-2003-2009/remont/door-locks-anti-theft-systems/#keyless-entry-system__transmitter-programming-domestic-and-japan) or «Transmitter Programming (Export - Including Canada)»(/cadillac/xlr/i-2003-2009/remont/door-locks-anti-theft-systems/#keyless-entry-system__transmitter-programming-export-including-canada) .

J39765-A Fuel Sender Lock Ring Tool. See Special Tools .

  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
  2. Remove the right fuel tank. Refer to «Fuel Tank Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  3. Place the fuel tank on a suitable work surface.
  4. Disconnect the evaporative emissions (EVAP) purge line (4) from the fuel tank module.
  5. Disconnect the fuel tank module harness connector (5).
  6. Disconnect the fuel tank pressure (FTP) sensor harness connector (1).
  7. If replacing the fuel tank module, remove the FTP sensor (2). Refer to «Fuel Tank Pressure Sensor Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-46l-lh2-introduction-2-of-2) .
  8. Using the J39765-A (1), remove the fuel tank module locking ring (2), by rotating the J39765-A in a counterclockwise direction. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
  9. Carefully remove the fuel tank module (2) from the fuel tank half way with the jet lines connected. Ensure not to damage the fuel level float arm.
  10. Disconnect the internal fuel line quick-connect fittings from the fuel tank module ports, noting the location of the lines for installation.
  11. Remove the fuel tank module from the fuel tank using care not to damage the fuel level float arm.
  12. Remove the fuel tank module O-ring (3) from the fuel tank opening.
  1. Install a NEW fuel tank module O-ring (3) to the fuel tank opening.
  2. Pull the internal fuel lines up through the fuel tank module opening and connect the internal fuel line quick-connect fittings to the fuel tank module ports in the location noted during disassembly.
  3. Install the fuel tank module lock ring (1) into position on the fuel tank module.
  4. Install the fuel tank module into the fuel tank, using care not to damage the fuel level sensor arm.
  5. Compress and align the fuel tank module.
  6. Using the J39765-A (1), fully lock the fuel tank module lock ring (2) in place, by rotating the J39765-A in a clockwise direction. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
  7. Using a digital multimeter, verify the full and empty readings resistance reading of the fuel tank module. Turn the fuel tank upside down to achieve the full tank reading. Resistance: Empty 40 ohms resistance Full 250 ohms resistance
  8. Install the FTP sensor (2), if previously removed. Refer to «Fuel Tank Pressure Sensor Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  9. Connect the FTP sensor harness connector (1).
  10. Connect the fuel tank module harness connector (5).
  11. Connect the EVAP purge line (4) to the fuel tank module.
  12. Install the right fuel tank. Refer to «Fuel Tank Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
  14. Perform the following procedure in order to test for leaks: Turn ON the ignition switch, for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  15. Program the transmitters. Refer to «Transmitter Programming (Domestic and Japan)»(/cadillac/xlr/i-2003-2009/remont/door-locks-anti-theft-systems/#keyless-entry-system__transmitter-programming-domestic-and-japan) or «Transmitter Programming (Export - Including Canada)»(/cadillac/xlr/i-2003-2009/remont/door-locks-anti-theft-systems/#keyless-entry-system__transmitter-programming-export-including-canada) .
  1. Remove the left fuel tank module (2). Refer to «Fuel Tank Fuel Pump Module Replacement - Left Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  2. Remove the fuel pump module O-ring (3) from the fuel tank opening.
  3. Press down on the locking tab and remove the level sensor (1) from the module.
  4. Make a note of the wire location in relation to the internal connector.
  5. Remove the level sensor wires from the internal connector. Refer to «Delphi Connectors (Weather Pack)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Push To Seat)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Pull To Seat)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Micro-Pack 100W)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Micro .64)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (12-Way)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) .
  1. Install the level sensor wires to the internal connector in the proper location. Refer to «Delphi Connectors (Weather Pack)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Push To Seat)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Pull To Seat)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Micro-Pack 100W)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Micro .64)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (12-Way)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) .
  2. Install the new level sensor (1) into the module by sliding it down until the lock tab clicks.
  3. Ensure that the wires are in the slot below the sensor and the sensor is installed properly.
  4. Install a NEW fuel pump module O-ring (3) to the fuel tank opening.
  5. Install the left fuel tank module (2) to the fuel tank. Refer to «Fuel Tank Fuel Pump Module Replacement - Left Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  6. Using a digital multimeter, verify the full and empty readings resistance reading of the fuel pump module. Turn the fuel tank upside down to achieve the full tank reading. Resistance: Empty tank reading 40 ohms resistance Full tank reading 250 ohms resistance
  7. Install the left fuel tank. Refer to «Fuel Tank Replacement - Left Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  1. Remove the fuel tank module (2) from the fuel tank. Refer to «Fuel Tank Fuel Pump Module Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  2. Remove the fuel tank module O-ring (3) from the fuel tank opening.
  3. Press down on the locking tab and remove the fuel level sensor (1) from the fuel tank module.
  4. Make a note of the wire location in relation to the internal connector.
  5. Remove the level sensor wires from the internal connector. Refer to «Delphi Connectors (Weather Pack)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Push To Seat)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Pull To Seat)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Micro-Pack 100W)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Micro .64)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (12-Way)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) .
  1. Install the fuel level sensor wires to the internal connector in the proper location. Refer to «Delphi Connectors (Weather Pack)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Push To Seat)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Pull To Seat)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Micro-Pack 100W)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (Micro .64)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) or «Delphi Connectors (12-Way)»(/cadillac/xlr/i-2003-2009/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing) .
  2. Install the fuel level sensor (1) to the fuel tank module by sliding it down until the lock tab clicks.
  3. Ensure that the wires are in the slot below the sensor and the sensor is installed properly.
  4. Install a NEW fuel tank module O-ring (3) to the fuel tank opening.
  5. Install the fuel tank module (2) to the fuel tank. Refer to «Fuel Tank Fuel Pump Module Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  6. Using a digital multimeter, verify the full and empty readings resistance reading of the fuel tank module. Turn the fuel tank upside down to achieve the full tank reading. Resistance: Empty 40 ohms resistance Full 250 ohms resistance
  7. Connect the fuel tank pressure (FTP) sensor harness connector (1).
  8. Connect the fuel pump module harness connector (5).
  9. Connect the evaporative emission (EVAP) purge line (4) to the fuel pump module.
  10. Install the right fuel tank. Refer to «Fuel Tank Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
  2. Remove the engine sight shield. Refer to «Intake Manifold Sight Shield Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
  3. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__fuel-pressure-relief) .
  4. Disconnect the fuel feed hose (3) from the chassis fuel feed pipe (2). Refer to «Metal Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  5. Cap the engine compartment fuel feed pipe.
  6. Disconnect the chassis fuel and evaporative emission (EVAP) pipe retainer (1) from the upper front of dash mounting stud (3).
  7. Raise 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 exhaust intermediate pipe. Refer to «Intermediate Pipe Replacement»(/cadillac/xlr/i-2003-2009/remont/exhaust/#engine-exhaust-system) .
  9. Remove the driveline tunnel closeout panel. Refer to «Driveline Tunnel Closeout Panel Replacement»(/cadillac/xlr/i-2003-2009/remont/driveshaft-universal-joints/#propeller-shaft) .
  10. Disconnect the chassis fuel pipe (5) from the underbody retainers (6).
  11. Remove the chassis fuel pipe.
IMPORTANTFollow the same routing as the original pipe. Secure the pipe in order to prevent chafing. Do not kink or bend the pipe.
  1. Install the chassis fuel pipe (5) into the underbody retainers (6).
  2. Connect the chassis fuel feed pipe.
  3. Install the driveline tunnel closeout panel. Refer to «Driveline Tunnel Closeout Panel Replacement»(/cadillac/xlr/i-2003-2009/remont/driveshaft-universal-joints/#propeller-shaft) .
  4. Install the exhaust intermediate pipe. Refer to «Intermediate Pipe Replacement»(/cadillac/xlr/i-2003-2009/remont/exhaust/#engine-exhaust-system) .
  5. Lower the vehicle.
  6. Remove the cap from the engine compartment fuel feed pipe.
  7. Connect the chassis fuel and EVAP pipe retainer (1) at the upper front of dash mounting stud (3). Tighten: Tighten the fuel and EVAP pipe retainer nut to 6 N.m (53 lb in).
  8. Connect the fuel feed hose (3) to the chassis fuel feed pipe (2). Refer to «Metal Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  9. Tighten the fuel filler cap.
  10. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
  11. Perform the following procedure in order to inspect for leaks: Turn the ignition switch ON for 2 seconds. Turn the ignition switch OFF for 10 seconds. Turn the ignition switch ON. Inspect for fuel leaks.
  12. Install the engine sight shield. Refer to «Intake Manifold Sight Shield Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
  1. Disconnect the negative battery cable.
  2. Remove the engine sight shield. Refer to «Intake Manifold Sight Shield Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
  3. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__fuel-pressure-relief) .
  4. Remove the secondary lock and disconnect the quick-connect fitting at the fuel rail (1). Refer to «Metal Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  5. Remove the secondary lock and disconnect the quick-connect fitting at the chassis fuel pipe (2). Refer to «Metal Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  6. Remove engine compartment fuel feed hose (3).
  7. Cap the chassis fuel pipe and the fuel rail pipe in order to prevent possible fuel system contamination.
  8. Inspect the hose for bends, for kinks, for chafing, and for cracks. Replace the hose as required.
  1. Remove the caps from the chassis fuel pipe and the fuel rail pipe.
  2. Connect the fuel feed hose (3) to the chassis fuel pipe (2), and install the secondary lock. Refer to «Metal Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  3. Connect the fuel feed hose (2) to the fuel rail (1), and install the secondary lock. Refer to «Metal Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
  4. Tighten the fuel filler cap.
  5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
  6. Perform the following procedure in order to inspect for leaks: Turn the ignition switch ON for 2 seconds. Turn the ignition switch OFF for 10 seconds. Turn the ignition switch ON. Inspect for fuel leaks.
  7. Install the engine sight shield. Refer to «Intake Manifold Sight Shield Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
  8. Program the transmitters. Refer to «Transmitter Programming (Domestic and Japan)»(/cadillac/xlr/i-2003-2009/remont/door-locks-anti-theft-systems/#keyless-entry-system__transmitter-programming-domestic-and-japan) or «Transmitter Programming (Export - Including Canada)»(/cadillac/xlr/i-2003-2009/remont/door-locks-anti-theft-systems/#keyless-entry-system__transmitter-programming-export-including-canada) .