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Engine Mechanical - 4.4l (5 of 5) Cadillac XLR I

Mechanical ~2920 words

Supercharger Installation - Off Vehicle

Tools Required

  1. EN 46109 Guide Pins. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  2. EN-47748 Supercharger Lifting Fixture. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  3. EN-47833 Supercharger Service Holding Fixture. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  1. Install the NEW supercharger gaskets.
  2. Install the 8 mm (0.31 in) EN 46109 into cylinder head supercharger mounting bolt holes at opposing corners. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  3. Lift the supercharger assembly off of the table using appropriate lifting equipment.
  4. Remove the EN-47833 from the supercharger. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  5. Install the supercharger using the EN-47748 with appropriate lifting equipment. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  6. As the supercharger is lowered into place carefully align the EN 46109 with the corner mounting holes of the supercharger. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  7. Remove the EN-47748 from the supercharger. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  8. Remove the EN 46109 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  9. Loosely install the supercharger bolts.
  10. Tighten the supercharger bolts in sequence as shown. Tighten: Tighten the supercharger bolts in sequence to 25 N.m (18 lb ft).
  11. Place the fuel injector rail assembly into position and align each fuel injector with the fuel injector bores in the supercharger.
  12. Place the fuel injection rail crossover tube into the clip (1) and fasten.
  13. Install the fuel injection rail studs. Tighten: Tighten the fuel injection rail studs to 10 N.m (89 lb in).
  14. Connect the dirty air positive crankcase ventilation (PCV) tube (1) to the right camshaft cover.
  15. Install the bracket with sensors and tubes.
  16. Connect the supercharger inlet absolute pressure sensor vacuum tube connection (1) to the supercharger fitting.
  17. Connect the manifold absolute pressure (MAP) sensor vacuum tube connection (1) to the supercharger fitting.
  18. Install the fuel injector sight shield cover ball studs. Tighten: Tighten the fuel injection sight shield cover ball studs to 10 N.m (89 lb in).
  19. Install the NEW charge air cooler coolant front manifold O-rings.
  20. Install the charge air cooler coolant front manifold.
  21. Install the charge air cooler coolant front manifold bolts. Tighten: Tighten the charge air cooler coolant front manifold bolts to 25 N.m (18 lb ft).
  22. Install and connect the clean air positive crankcase ventilation (PCV) tube to the left camshaft cover.

Air Conditioning (A/C) Compressor Installation - Off Vehicle

  1. Place the air conditioner bracket in position to the engine.
  2. Install the air conditioner bracket bolts. Ensure the longer bolt (1) is installed in the upper rear position and the shorter bolts (2) are installed in the remaining positions.
  3. Tighten the air conditioner bracket bolts in the sequence shown. Tighten: Tighten the air conditioner bracket rear upper bolt (1) to 50 N.m (37 lb ft). Tighten the air conditioner bracket lower bolt (2) to 50 N.m (37 lb ft). Tighten the air conditioner bracket front upper bolt (3) to 50 N.m (37 lb ft). Tighten the air conditioner bracket center bolt (4) to 50 N.m (37 lb ft).
  4. Place the air conditioner compressor in position to the air conditioner bracket.
  5. Loosely install the air conditioner compressor bolts. Ensure the longer bolts (1) are installed in the upper front and rear positions and the shorter bolt (2) is installed in the lower front position.
  6. Tighten the air conditioner compressor bolts in the sequence shown. Tighten: Tighten the air conditioner upper front bolt (1) to 25 N.m (18 lb ft). Tighten the air conditioner compressor lower front bolt (2) to 25 N.m (18 lb ft). Tighten the air conditioner compressor rear bolt (3) to 25 N.m (18 lb ft).

Power Steering Pump Installation - Off Vehicle

  1. Place the power steering pump in position to the engine.
  2. Install the power steering pump bolts.
  3. Tighten the power steering pump bolts. Tighten: Tighten the power steering pump bolts to 25 N.m (18 lb ft).
  4. Lubricate the splines (1) on the power steering pump shaft with G/M P/N 1051344 (Canadian P/N 993037).
  5. Install the power steering pulley in position on the power steering pump.
  6. Install the power steering pulley bolts. Ensure the short bolts (1) are installed in the upper and inboard positions and the longer bolt (2) is installed in the lower outboard position.
  7. Tighten the bolts in the sequence shown (1-3). Tighten: Tighten the power steering pulley bolts in sequence (1-3) to 50 N.m (37 lb ft).

Generator Installation - Off Vehicle

  1. Position the generator rear brace to the engine.
  2. Install the generator rear brace bolt finger tight.
  3. Install the generator/drive belt idler pulley mounting stud. Tighten: Tighten the generator/drive belt idler pulley mounting stud to 12 N.m (118 lb in).
  4. Install the generator over the generator/drive belt idler pulley mounting stud.
  5. Install the upper front generator bolt finger tight through the generator and into the rear generator brace.
  6. Install the drive belt idler pulley and bracket over the generator/drive belt idler pulley stud and the drive belt idler pulley bolt through the generator.
  7. Install the nut on the generator/drive belt idler pulley mounting stud.
  8. Tighten the generator and drive belt idler pulley bolts and nut in the sequence shown. Tighten: Tighten the front upper generator bolt (1) to 50 N.m (37 lb ft). Tighten the generator/drive belt idler pulley stud nut (2) to 50 N.m (37 lb ft). Tighten the drive belt idler pulley bolt (3) to 50 N.m (37 lb ft).
  9. Tighten the rear generator brace bolt. Tighten: Tighten the rear generator brace bolt (1) to 50 N.m (37 lb ft).
  10. Install the NEW generator coolant hose sealing rings.
  11. Install the hose into the fitting in the engine front cover.
  12. Install the cooling hose assembly onto the generator port.
  13. Install the bolt through the cooling hose assembly into the generator. Tighten: Tighten the bolt to 27 N.m (19 lb ft).

Generator and Water Pump

Supercharger

  1. Install the supercharger drive belt idler pulley.
  2. Tighten the supercharger drive belt idler pulley bolt. Tighten: Tighten the supercharger drive belt idler pulley bolt to 50 N.m (37 lb ft).
  1. Select the generator drive belt tensioner (1).
  2. Place the generator drive belt tensioner in position to the left camshaft position actuator housing. Ensure to properly locate the generator drive belt tensioner anchor pin in the recess (1) in the left camshaft position actuator housing.
  3. Install the generator drive belt tensioner bolt. Tighten: Tighten the generator drive belt tensioner bolt to 50 N.m (37 lb ft).

A/C Compressor and Power Steering Pump

Refer to the A/C Compressor and Power Steering Pump Drive Belt Installation in the Drive Belt Installation .

  1. Select the supercharger drive belt tensioner (2).
  2. Place the supercharger drive belt tensioner in position to the right camshaft position actuator housing. Ensure to properly locate the supercharger drive belt tensioner anchor pin in the recess (1) in the right camshaft position actuator housing.
  3. Install the supercharger drive belt tensioner bolt. Tighten: Tighten the supercharger drive belt tensioner bolt to 50 N.m (37 lb ft).
  1. Install the A/C compressor and power steering pump drive belt around the crankshaft balancer inner pulley and the power steering pump inner pulley.
  2. Route the A/C compressor and power steering pump drive belt in front of the A/C compressor in order to create access (1) for the installation of the A/C compressor and power steering pump drive belt tensioner.
  3. Place the A/C compressor and power steering pump drive belt tensioner into position.
  4. Loosely install the upper bolt into the A/C compressor and power steering pump drive belt tensioner.
  5. Loosely install the lower bolt into the A/C compressor and power steering pump drive belt tensioner.
  6. Tighten both A/C compressor and power steering pump drive belt tensioner bolts (1, 2). Tighten: Tighten the A/C compressor and power steering pump drive belt tensioner upper (1) and lower (2) bolts to 25 N.m (18 lb ft).
  7. Insert a 1/2 inch drive breaker bar into the A/C compressor and power steering pump drive belt tensioner.
  8. Rotate the breaker bar clockwise (1) in order to allow the installation of the A/C compressor and power steering pump drive belt around the A/C compressor (2).
  9. Ensure the A/C compressor and power steering pump drive belt is properly seated in all the pulleys.
  10. Slowly release the A/C compressor and power steering pump drive belt tensioner back to its original position. This will apply tension to the A/C compressor and power steering pump drive belt.
  11. Remove the breaker bar.
  12. After installation, inspect the A/C compressor and power steering pump drive belt for proper routing and the correct alignment.
  1. Insert a 1/2 inch drive breaker bar into the generator and water pump drive belt tensioner.
  2. Rotate the breaker bar clockwise in order to allow the installation of the generator and water pump drive belt.
  3. Route the generator and water pump drive belt around the crankshaft balancer outer pulley, the generator and water pump drive belt idler pulley, the generator pulley, the generator and water pump drive belt tensioner pulley and the water pump pulley.
  4. Ensure the generator and water pump drive belt is properly seated in all the pulleys.
  5. Slowly release the generator and water pump drive belt tensioner back to its original position. This will apply tension to the generator and water pump drive belt.
  6. Remove the breaker bar.
  7. After installation, inspect the generator and water pump drive belt for proper routing and the correct alignment.
  1. Insert a 1/2 inch drive breaker bar into the supercharger drive belt tensioner.
  2. Rotate the breaker bar clockwise in order to allow the installation of the supercharger drive belt.
  3. Route the supercharger drive belt around the supercharger pulley, the supercharger drive belt idler pulley, the power steering outer pulley and the supercharger drive belt tensioner pulley.
  4. Ensure the supercharger drive belt is properly seated in all the pulleys.
  5. Slowly release the supercharger drive belt tensioner back to its original position. This will apply tension to the supercharger drive belt.
  6. Remove the breaker bar.
  7. After installation, inspect the supercharger drive belt for proper routing and the correct alignment.
  8. Place the power steering pump reservoir into position.
  9. Install the power steering pump reservoir bracket nuts. Tighten: Tighten the power steering pump reservoir bracket nut to 10 N.m (89 lb in).
  10. Install the power steering pump reservoir hose.

Exhaust Manifold Installation - Right Side - Off Vehicle

  1. Install the right engine mount bracket.
  2. Install the right engine mount bracket bolts. Tighten: Tighten the engine mount bracket bolts to 58 N.m (43 lb ft).
  3. Install the engine mount heat shield to the engine mount.
  4. Install the right engine mount.
  5. Install the right engine mount upper nut. Tighten: Tighten the engine mount upper nut to 58 N.m (43 lb ft).
  6. Install the right exhaust manifold studs to the right cylinder head. Tighten: Tighten the exhaust manifold studs to 6 N.m (53 lb in).
  7. Install the NEW right exhaust manifold gasket.
  8. Install the right exhaust manifold.
  9. Install the right exhaust manifold bolts to the right cylinder head and bell housing.
  10. Tighten the exhaust manifold bolts and nuts in the sequence shown. Tighten: Tighten the exhaust manifold bolts and nuts to 25 N.m (18 lb ft).
  11. Install the right exhaust manifold bolt to the bell housing. Tighten: Tighten the right exhaust manifold bolt to 50 N.m (37 lb ft).
  12. Install the right exhaust manifold heat shield.
  13. Install the right exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).

Exhaust Manifold Installation - Left Side - Off Vehicle

  1. Install the bell housing.
  2. Install the bell housing bolts. Tighten: Tighten the bell housing bolts to 50 N.m (37 lb ft).
  3. Install the right engine flywheel housing cover.
  4. Install the right engine flywheel housing cover bolts. Tighten: Tighten the exhaust manifold studs to 10 N.m (89 lb in).
  5. Install the left engine flywheel housing cover.
  6. Install the left engine mount bracket.
  7. Install the left engine mount bracket bolts. Tighten: Tighten the engine mount bracket bolts to 58 N.m (43 lb ft).
  8. Install the engine mount heat shield to the engine mount.
  9. Install the left engine mount.
  10. Install the left engine mount upper nut. Tighten: Tighten the engine mount upper nut to 58 N.m (43 lb ft).
  11. Install the left exhaust manifold studs to the left cylinder head. Tighten: Tighten the exhaust manifold studs to 6 N.m (53 lb in).
  12. Install the NEW left exhaust manifold gasket.
  13. Install the left exhaust manifold.
  14. Install the left exhaust manifold bolts to the left cylinder head and bell housing.
  15. Tighten the exhaust manifold bolts and nuts in the sequence shown. Tighten: Tighten the exhaust manifold bolts and nuts to 25 N.m (18 lb ft).
  16. Tighten the left exhaust manifold bolt to the bell housing. Tighten: Tighten the left exhaust manifold bell housing bolt to 50 N.m (37 lb ft).
  17. Install the left exhaust manifold heat shield.
  18. Install the left exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).

Left Side Harness Connections

  1. Install the engine wiring harness to the engine block.
  2. Connect the engine wiring harness starter connector to the starter wiring harness.
  3. Connect the engine wiring harness to the left side fuel injectors.
  4. Connect the engine wiring harness to the left camshaft cover.
  5. Connect the engine wiring harness to the left coil assembly harness.
  6. Connect the engine wiring harness to the evaporative emissions (EVAP) canister purge solenoid.
  7. Connect the engine wiring harness to the throttle body.
  8. Connect the engine wiring harness to the left camshaft position actuators.
  9. Connect the engine wiring harness to the left camshaft position sensors.
  10. Connect the engine wiring harness to the supercharger charge air bypass regulator solenoid valve.
  11. Connect the starter motor wiring harness to the generator stud.
  12. Install the nut attaching the starter motor wiring harness to the generator stud. Tighten: Tighten the generator stud nut to 20 N.m (15 lb ft).
  13. Connect the engine wiring harness to the generator.
  14. Connect the engine wiring harness to the oil pressure sensor.

Right Side Harness Connections

  1. Connect the engine wiring harness to the knock and crankshaft position sensor wiring harness.
  2. Connect the engine wiring harness to the engine coolant temperature (ECT) sensor at the rear of the right cylinder head.
  3. Connect the engine wiring harness to the right side fuel injectors.
  4. Connect the engine wiring harness to the right camshaft cover.
  5. Connect the engine wiring harness to right coil assembly harness.
  6. Connect the engine wiring harness to the supercharger inlet absolute pressure sensor (1), barometric pressure (BARO) sensor (2), and manifold absolute pressure (MAP) sensor (3).
  7. Connect the engine wiring harness to the intake air temperature (IAT) sensor 2.
  8. Connect the engine wiring harness to the right camshaft position actuators.
  9. Connect the engine wiring harness to right camshaft position sensors.
  10. Connect the engine wiring harness to the air conditioning compressor.
  11. Connect the engine wiring harness to the engine oil level switch/temperature sensor.

Supercharger Inlet Duct Installation - Off Vehicle

  1. Install the throttle body duct seal.
  2. Install the rear air duct.
  3. Align the tab (1) on the throttle body duct seal with the notch (2) in the rear inlet duct.
  4. Tighten the front screw clamp (1) on the throttle body duct seal. Tighten: Tighten the screw clamps to 3.25 N.m (29 lb in).
  5. Tighten the rear screw clamp (2) on the throttle body duct seal. Tighten: Tighten the screw clamps to 3.25 N.m (29 lb in).
  6. Install the inlet duct seals.
  7. Install and connect the clean air positive crankcase ventilation (PCV) hose to the left camshaft cover fitting.
  8. Install the front air duct.
  9. Lift the front of the front air duct in order to access the clean air PCV hose connector at the bottom of the front air duct.
  10. Connect the clean air PCV hose (1) to the front air duct.
  11. In order to leave clearance for the intake manifold sight shield align the left inlet duct seal and clamps (1) as shown.
  12. In order to leave clearance for the intake manifold sight shield align the right inlet duct seal and clamps (1) as shown.
  13. Tighten the front screw clamps (1) on the inlet duct seals. Tighten: Tighten the screw clamps 3.25 N.m (29 lb in).
  14. Tighten the rear screw clamps (2) on the inlet duct seals. Tighten: Tighten the screw clamps to 3.25 N.m (29 lb in).
  15. Install the supercharger inlet duct ball stud nuts. Tighten: Tighten the supercharger inlet duct ball stud nuts to 10 N.m (89 lb in).
  16. Install and connect the evaporative emissions (EVAP) hose.

Engine Prelubing - Off Vehicle

Tools Required

  1. EN-47971 Oil Pressure Gage Adapter. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  2. J 45299 Engine Preluber. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  1. Remove the engine oil filter.
  2. Install the EN-47971 onto the oil filter adapter. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  3. Install the 1/8 NPT fitting from the J 45299 into the port on the EN-47971 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  4. Install the J 45299 flexible hose to the fitting. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  5. Open the valve of the J 45299 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  6. Pump the handle of the J 45299 in order to flow a minimum of 1-1. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .9 liters (1-2 quarts) of fresh clean engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
  7. Close the valve of the J 45299 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  8. Remove the J 45299 flexible hose. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  9. Remove the fitting from the EN-47971 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  10. Remove the EN-47971 from the oil filter adapter. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
  11. Ensure the NEW oil filter is filled with clean fresh engine oil.
  12. Install the NEW oil filter. Tighten: Tighten the oil filter to 32 N.m (24 lb ft).

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