Engine Controls - 4.4l - Introduction (2 of 2) Cadillac XLR I

Temperature Versus Resistance

Temperature Versus Resistance

Altitude Versus Barometric Pressure

Altitude Versus Barometric Pressure

Ignition System Specifications

Ignition System Specifications

Fastener Tightening Specifications

Fastener Tightening Specifications

Emissions Related DTCs

Action Taken When the DTC Sets - Type A

1. The control module illuminates the malfunction indicator lamp (MIL) when the diagnostic runs and fails.
2. The control module records the operating conditions at the time the diagnostic fails. The control module stores this information in the Freeze Frame/Failure Records.

Action Taken When the DTC Sets - Type B

1. The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails.
2. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records.

Conditions for Clearing the MIL/DTC - Type A or Type B

1. The control module turns OFF the malfunction indicator lamp (MIL) after 4 consecutive ignition cycles that the diagnostic runs and does not fail.
2. A current DTC, Last Test Failed, clears when the diagnostic runs and passes.
3. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic.
4. Clear the MIL and the DTC with a scan tool.

Non-Emissions Related DTCs

Action Taken When the DTC Sets - Type C

1. The control module stores the DTC information into memory when the diagnostic runs and fails.
2. The malfunction indicator lamp (MIL) will not illuminate.
3. The control module records the operating conditions at the time the diagnostic fails. The control module stores this information in the Failure Records.
4. The driver information center, if equipped, may display a message.

Conditions for Clearing the DTC - Type C

1. A current DTC Last Test Failed clears when the diagnostic runs and passes.
2. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other non-emission related diagnostic.
3. Clear the DTC with a scan tool.

Conditions for Clearing the DTC - Type X

Diagnostic Trouble Code (DTC) Types

Diagnostic Trouble Code (DTC) Types

Scheme 78

Scheme 79

Engine Controls Schematic Icons

Engine Controls Schematic Icons Icon Icon Definition NOTE: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. IMPORTANT: Twisted-pair wires provide an effective shield that helps protect sensitive electronic components from electrical interference. If the wires were covered with shielding, install new shielding. In order to prevent electrical interference from degrading the performance of the connected components, you must maintain the proper specification when making any repairs to the twisted-pair wires shown : The wires must be twisted a minimum of 9 turns per 31 cm (12 in) as measured anywhere along the length of the wires The outside diameter of the twisted wires must not exceed 6.0 mm (0.25 in)

Scheme 80

Scheme 81

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Scheme 84

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Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Engine Control Module Connector End Views

Engine Control Module (ECM) - C1

Scheme 105

Engine Control Module Connector End Views

Engine Control Module (ECM) - C2

Engine Control Module (ECM) - C3

Engine Control Module Connector End Views

Engine Control Module (ECM) - C3

Scheme 106

Engine Controls Connector End Views

Accelerator Pedal Position (APP) Sensor

Scheme 107

Engine Controls Connector End Views

Barometric Pressure (BARO) Sensor

Scheme 108

Engine Controls Connector End Views

Camshaft Position (CMP) Actuator Solenoid Bank 1 Exhaust

Camshaft Position (CMP) Actuator Solenoid Bank 1 Intake

Engine Controls Connector End Views

Camshaft Position (CMP) Actuator Solenoid Bank 1 Intake

Camshaft Position (CMP) Actuator Solenoid Bank 2 Exhaust

Engine Controls Connector End Views

Camshaft Position (CMP) Actuator Solenoid Bank 2 Exhaust

Camshaft Position (CMP) Actuator Solenoid Bank 2 Intake

Engine Controls Connector End Views

Camshaft Position (CMP) Actuator Solenoid Bank 2 Intake

Scheme 109

Engine Controls Connector End Views

Camshaft Position (CMP) Sensor Bank 1 Exhaust

Camshaft Position (CMP) Sensor Bank 1 Intake

Engine Controls Connector End Views

Camshaft Position (CMP) Sensor Bank 1 Intake

Camshaft Position (CMP) Sensor Bank 2 Exhaust

Engine Controls Connector End Views

Camshaft Position (CMP) Sensor Bank 2 Exhaust

Camshaft Position (CMP) Sensor Bank 2 Intake

Engine Controls Connector End Views

Camshaft Position (CMP) Sensor Bank 2 Intake

Scheme 110

Engine Controls Connector End Views

Charge Air Cooler (CAC) Coolant Pump

Scheme 111

Engine Controls Connector End Views

Charged Air Cooler Pump Relay

Crankshaft Position (CKP) Sensor

Engine Controls Connector End Views

Crankshaft Position (CKP) Sensor

Scheme 112

Engine Controls Connector End Views

Engine Coolant Temperature (ECT) Sensor

Scheme 113

Engine Controls Connector End Views

Engine Oil Pressure (EOP) Sensor

Scheme 114

Engine Controls Connector End Views

Evaporative Emissions (EVAP) Canister Purge Valve

Scheme 115

Engine Controls Connector End Views

Evaporative Emissions (EVAP) Canister Vent Solenoid

Scheme 116

Engine Controls Connector End Views

Fuel Injector 1

Fuel Injector 2

Engine Controls Connector End Views

Fuel Injector 2

Fuel Injector 3

Engine Controls Connector End Views

Fuel Injector 3

Fuel Injector 4

Engine Controls Connector End Views

Fuel Injector 4

Fuel Injector 5

Engine Controls Connector End Views

Fuel Injector 5

Fuel Injector 6

Engine Controls Connector End Views

Fuel Injector 6

Fuel Injector 7

Engine Controls Connector End Views

Fuel Injector 7

Fuel Injector 8

Engine Controls Connector End Views

Fuel Injector 8

Scheme 117

Engine Controls Connector End Views

Fuel Pump and Sender Assembly

Scheme 118

Engine Controls Connector End Views

Fuel Tank Pressure Sensor

Scheme 119

Engine Controls Connector End Views

Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1

Scheme 120

Engine Controls Connector End Views

Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2

Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1

Engine Controls Connector End Views

Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1

Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2

Engine Controls Connector End Views

Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2

Scheme 121

Engine Controls Connector End Views

Ignition Coil - 1

Ignition Coil - 2

Engine Controls Connector End Views

Ignition Coil - 2

Ignition Coil - 3

Engine Controls Connector End Views

Ignition Coil - 3

Ignition Coil - 4

Engine Controls Connector End Views

Ignition Coil - 4

Ignition Coil - 5

Engine Controls Connector End Views

Ignition Coil - 5

Ignition Coil - 6

Engine Controls Connector End Views

Ignition Coil - 6

Ignition Coil - 7

Engine Controls Connector End Views

Ignition Coil - 7

Ignition Coil - 8

Engine Controls Connector End Views

Ignition Coil - 8

Scheme 122

Engine Controls Connector End Views

Intake Air Temperature (IAT) Sensor 2

Scheme 123

Engine Controls Connector End Views

Intake Air Temperature (IAT) / Mass Air Flow (MAF) Sensor

Scheme 124

Engine Controls Connector End Views

Knock Sensor (KS) Bank 1

Knock Sensor (KS) Bank 2

Engine Controls Connector End Views

Knock Sensor (KS) Bank 2

Manifold Absolute Pressure (MAP) Sensor

Engine Controls Connector End Views

Manifold Absolute Pressure (MAP) Sensor

Scheme 125

Engine Controls Connector End Views

Secondary Fuel Sender Assembly

Super Charger Inlet Air Pressure (SCIAP) Sensor

Engine Controls Connector End Views

Super Charger Inlet Air Pressure (SCIAP) Sensor

Scheme 126

Engine Controls Connector End Views

Throttle Actuator Control Module

Scheme 127

Engine Controls Connector End Views

Vacuum Bypass Valve

Diagnostic Code Index

DIAGNOSTIC CODE INDEX

Engine Control Module Replacement

Engine control module (ECM) service should normally consist of either ECM replacement or EEPROM programming. If the diagnostic procedures require ECM replacement, check the ECM first to see if the correct part is being used.

Note. Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. The replacement control module must be programmed.

Removal Procedure

1. Using a scan tool, retrieve the percentage of remaining engine oil and the remaining automatic transmission fluid life. Record the remaining engine oil and the remaining automatic transmission fluid life.
2. Remove the right front wheelhouse filler panel. Refer to «Wheelhouse Filler Replacement»(/cadillac/xlr/i-2003-2009/remont/exterior-body-panels/#body-front-end) in Body Front End.
3. Disconnect the ECM electrical harness connectors (2).
4. Remove the fasteners (2) from the ECM (3).

Installation Procedure

1. Install the ECM (3) to the ECM bracket (4).
2. Install the ECM retaining fasteners (2). Tighten: Tighten the ECM retaining fasteners to 3.0 N.m (27 lb in).
3. Connect the electrical connectors (2) to the ECM (3).
4. Install the right front wheelhouse filler panel. Refer to «Wheelhouse Filler Replacement»(/cadillac/xlr/i-2003-2009/remont/exterior-body-panels/#body-front-end) in Body Front End.
5. If a new ECM is being installed, program the ECM. Refer to «Control Module References»(/cadillac/xlr/i-2003-2009/remont/communication-devices/#computerintegrating-systems__control-module-references) in Computer/Integrating Systems.

Crankshaft Position System Variation Learn

1. Install a scan tool.
2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/cadillac/xlr/i-2003-2009/remont/oem-general-information/#vehicle-dtc-information__diagnostic-trouble-code-dtc-list) for the applicable DTC that set.
3. With a scan tool, select the CKP system variation learn procedure within the Module Setup menu and perform the following: Observe the fuel cut-off for the applicable engine. Block the drive wheels. Set the parking brake. Place the vehicle's transmission in Park or Neutral. Turn the air conditioning (A/C) OFF. Cycle the ignition from OFF to ON. Apply and hold the brake pedal for the duration of the procedure. Start and idle the engine. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. Release the throttle when fuel cut-off occurs.
4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, or if any other DTCs set, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/cadillac/xlr/i-2003-2009/remont/oem-general-information/#vehicle-dtc-information__diagnostic-trouble-code-dtc-list) for the applicable DTC that set.
5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully.

Note. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

1. Turn OFF the ignition
2. Drain the coolant to below the level of the engine coolant temperature (ECT) sensor. 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 supercharger assembly. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
4. Disconnect the ECT sensor harness connector (2).
5. Remove the ECT sensor (1) from the right-hand cylinder head.

Note. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

Note. Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.

1. Coat the sensor threads with sealer. Refer to «Sealers, Adhesives, and Lubricants»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__sealers-adhesives-and-lubricants) .
2. Install the ECT sensor (1). Tighten: Tighten the ECT sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor harness connector (2).
4. Install supercharger assembly. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
5. Refill the coolant 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. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (3).
2. Remove the MAF/IAT sensor screws (2).
3. Carefully remove the MAF/IAT sensor (1) from the air cleaner housing duct.
4. Discard the MAF/IAT sensor gasket.

1. Install a NEW MAF/IAT sensor gasket.
2. Carefully install the MAF/IAT sensor (1) into the air cleaner housing duct.
3. Install the MAF/IAT sensor screws (2). Tighten: Tighten the screws to 4 N.m (35 lb in).
4. Reconnect the MAF/IAT sensor electrical connector (3).

1. Remove the intake manifold sight shield. Refer to «Intake Manifold Sight Shield Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
2. Disconnect the intake air temperature (IAT) sensor 2 electrical connector.
3. Remove the IAT sensor 2 (1).

Note. Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.

1. Coat the sensor threads with sealer. Refer to «Sealers, Adhesives, and Lubricants»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__sealers-adhesives-and-lubricants) .
2. Install the IAT sensor 2 (1). Tighten: Tighten the IAT sensor 2 to 20 N.m (15 lb ft).
3. Connect the IAT sensor 2 electrical connector.
4. Install the intake manifold sight shield. Refer to «Intake Manifold Sight Shield Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .

1. Turn the ignition OFF.
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. Disconnect the manifold absolute pressure (MAP) sensor (3) electrical connector.
4. Remove the MAP sensor from the bracket.
5. Disconnect the vacuum line fitting (1) from the bottom of the MAP sensor.
6. Inspect the MAP sensor vacuum line and fittings (1,2) for leaks.

1. Connect the vacuum line fitting (1) to the port on the bottom of the MAP sensor.
2. Install the MAP sensor to the bracket.
3. Connect the MAP sensor (3) electrical connector.
4. 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. Turn the ignition OFF.
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. Disconnect the barometric pressure (BARO) sensor (2) electrical connector.
4. Remove the BARO sensor (2) from the bracket.

1. Install the BARO sensor (2) to the bracket.
2. Connect the BARO sensor electrical connector.
3. 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. Turn the ignition OFF.
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. Disconnect the supercharger inlet absolute pressure (SCIAP) sensor (1) electrical connector.
4. Remove the SCIAP sensor from the bracket.
5. Disconnect the vacuum line fitting (2) from the bottom of the SCIAP sensor.
6. Inspect the SCIAP sensor vacuum line and fittings (1, 2) for leaks.

1. Connect the vacuum line fitting (2) to the port on the bottom of the SCIAP sensor.
2. Install the SCIAP sensor to the bracket.
3. Connect the SCIAP sensor (1) electrical connector.
4. 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. 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) .
2. Disconnect the electrical connector (3) from the supercharger bypass regulator solenoid valve (2).
3. Disconnect the vacuum line fittings (4, 5) from the supercharger bypass regulator solenoid valve.
4. Remove the supercharger bypass regulator solenoid valve from the bracket.
5. Remove the bolt (1) and bracket if necessary.
6. Inspect the bypass regulator solenoid valve vacuum supply line and fittings (1, 2). Replace the vacuum line if necessary.
7. Inspect the bypass regulator solenoid valve to bypass valve actuator vacuum line and fittings (1, 2). Replace the vacuum line if necessary.

1. Install the bracket and bolt (1) if previously removed. Tighten: Tighten the supercharger bypass regulator solenoid valve bracket bolt to 9 N.m (80 lb in).
2. Install the bypass regulator solenoid valve (2) to the bracket.
3. Connect the vacuum line fittings (4, 5) to the bypass regulator solenoid valve.
4. Connect the electrical connector (3) to the bypass regulator solenoid valve.
5. 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) .

Tools Required

EN-47814 Supercharger Bypass Valve Actuator Setting Tool

1. 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) .
2. Remove the front section of the supercharger inlet duct. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
3. Remove the supercharger bypass regulator solenoid valve (3). Refer to «Supercharger Bypass Regulator Solenoid Valve Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
4. Drain the charge air cooling system. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system) or «Charge Air Cooling System Draining and Filling (GE 47716)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system) .
5. Remove the front portion of the supercharger front manifold (2) and discard the O-rings. It is not necessary to remove the hoses from the manifold. Position the hoses with manifold aside. Refer to «Charge Air Cooler Front Manifold Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
6. Disconnect the vacuum lines (3, 4) from the supercharger bypass actuator valve.
7. Remove the actuator mounting bolts (1, 2).
8. The bypass valve actuator rod is keyed with the bypass valve actuator cable.
9. Remove the fuel line from the clip on the front of the supercharger. Position the fuel line aside using mechanics wire.
10. Push the bypass valve actuator downward in order to remove the bypass valve actuator rod from the bypass valve actuator cable. The downward pressure will rotate the end of the cable into the proper position so that the actuator rod can be removed from the cable end. Use a flat blade screwdriver if necessary, to disengage the rod from the cable end.
11. Remove the supercharger bypass valve actuator from the vehicle.

1. Grasp the end of the actuator valve cable (1) with the EN-47814 (2).
2. Pull the cable end towards the front of vehicle and down as shown.
3. Install the actuator valve rod to the cable end as shown.
4. Remove the EN-47814 .
5. Install the actuator valve bolts (1, 2) loosely so that the actuator can be moved up and down by hand.
6. Gently pull up on the actuator until all slack from the cable is gone.
7. Tighten the bolts (1, 2) enough to hold the actuator in place.
8. Install the guide pin (1) from the EN-47814 to the front of the supercharger. Use a screw driver to ensure that the pin is installed tightly.
9. Install the adjustment block (3) from the EN-47814 to the guide pin (2).
10. With the adjustment block sitting on the actuator (4), tighten the thumb screw (1).
11. Loosen the actuator mounting bolts and allow the actuator to drop down.
12. Insert the flat handle from the EN-47814 between the actuator and the actuator adjustment block (2).
13. With the handle from the EN-47814 in place acting as a spacer, pull the actuator up removing all slack.
14. With the slack removed, tighten the actuator mounting bolts. Tighten: Tighten the supercharger bypass valve actuator bolts to 10 N.m (89 lb in).
15. Remove the EN-47814 .
16. Install the fuel line to the clip on the front of the supercharger.
17. Connect the vacuum lines (3, 4) to the supercharger bypass actuator valve.
18. Using NEW O-rings, install the front portion of the supercharger front manifold (2). Refer to «Charge Air Cooler Front Manifold Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
19. Install the supercharger bypass regulator solenoid valve (2). Refer to «Supercharger Bypass Regulator Solenoid Valve Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
20. Install the front section of the supercharger inlet duct. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
21. 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) .
22. Fill the charge air cooling system with coolant and check for leaks. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system) or «Charge Air Cooling System Draining and Filling (GE 47716)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system) .

1. EN-47814 Supercharger Bypass Valve Actuator Setting Tool
2. EN-47748 Supercharger Lift Bracket
3. EN-47833 Supercharger Service Holding Fixture

1. Remove the supercharger using the EN-47748 . Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
2. Install the EN-47833 supercharger service holding fixture to the supercharger while the supercharger is suspended by the engine hoist.
3. Place the supercharger on a workbench and remove the engine hoist.
4. Remove the rear section of the supercharger inlet duct assembly. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
5. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
6. Disconnect the bypass valve actuator vacuum hose at the supercharger bypass valve actuator (1).
7. Disconnect the bypass valve actuator pressure hose at the supercharger bypass valve actuator (1).
8. Remove the bypass valve actuator bolts.
9. Pivot the bypass valve actuator clockwise in order to remove the bypass valve actuator from the bypass valve actuator cable.
10. Align the tab on the bypass valve actuator rod with the slot in the bypass valve actuator cable end.
11. Slide the bypass valve actuator rod out of the bypass valve actuator cable.
12. Remove the bypass valve actuator.
13. Remove the bypass valve actuator cable bracket bolts from the supercharger.
14. Slide the bypass valve actuator cable clip off of the pin on the supercharger bypass valve.
15. Remove the bypass valve actuator cable.
16. Do NOT remove the supercharger bypass valve (1) from the supercharger.

1. Install the bypass valve actuator cable.
2. Install the bypass valve actuator cable bracket bolts to the supercharger. Tighten: Tighten the bypass valve actuator cable bracket bolts to 10 N.m (89 lb in).
3. Slide the bypass valve actuator cable clip onto the pin on the supercharger bypass valve.
4. A new cable will have a plastic spacer installed that is used to set the slack in the bypass system. Use this spacer OR the EN-47814 following the instructions below.
5. Pull the retainer up on the wire above the bypass valve actuator cable clip in order to install the plastic spacer OR the EN-47814 . The plastic spacer OR the EN-47814 must be used to set the necessary slack in the bypass valve actuator cable.
6. Place the EN-47814 on the cable as shown.
7. Eliminate the slack in the bypass valve actuator cable by pressing down on the wire retainer.
8. Install the bypass valve actuator.
9. Align the bypass valve actuator rod to the bypass valve actuator cable.
10. Align the tab on the bypass valve actuator rod with the slot in the bypass valve actuator cable end.
11. Slide the bypass valve actuator rod into the bypass valve actuator cable.
12. Pivot the bypass valve actuator counter-clockwise in order to install bypass valve actuator.
13. Loosely install the bypass valve actuator bolts.
14. Pull up on the bypass valve actuator in order to eliminate any slack in the bypass valve actuator cable.
15. Tighten the bypass valve actuator bolts while maintaining proper alignment between the bypass valve actuator and the bypass valve actuator cable. Tighten: Tighten the bypass valve actuator bolts to 10 N.m (89 lb in).
16. Depending on the tool used, remove the plastic spacer or the EN-47814 .
17. Connect the bypass valve actuator pressure hose to the supercharger bypass valve actuator (1).
18. Connect the bypass valve actuator vacuum hose to the supercharger bypass valve actuator (1).
19. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
20. Install the rear section of the supercharger inlet duct assembly. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
21. Lift the supercharger off of the workbench using EN-47748 and engine hoist.
22. Remove the EN-47833 supercharger service holding tool fixture from the supercharger.
23. Install the supercharger. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .

Note. Refer to Oxygen Sensor Notice .

1. 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) .
2. Remove the ball studs (1), loosen the duct clamps (2) and remove the front section of the supercharger inlet duct assembly. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
3. Release the lock tab, and disconnect the PCV foul air tube (1) from the PCV orifice fitting on the right camshaft cover. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
4. Separate the bank 1, sensor 1 electrical connector assembly (1) from the fuel rail bracket.
5. Disconnect the oxygen sensor electrical connector from the engine wiring harness connector.
6. Using a small screw driver, remove the electrical connector retainer (1) from the electrical connector.
7. Attach a suitable length of mechanics wire to the oxygen sensor electrical connector.
8. Separate the bank 1, sensor 2 electrical connector assembly (1) from the fuel rail bracket.
9. Disconnect the oxygen sensor electrical connector from the engine wiring harness connector.
10. Remove both oxygen sensor electrical connectors and wires from under the two engine wire harnesses.
11. Remove both oxygen sensor electrical connectors and wires from under the rear section of the supercharger inlet duct. Reposition the duct as necessary.
12. 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) .
13. Remove the oxygen sensor wire harnesses from the retainer (1) at the rear of the engine.
14. Note the wire routing for reassembly.
15. Gently pull the bank 1 sensor 1 oxygen sensor (2) wire harness and connector down from the engine compartment.
16. Remove the mechanics wire from the electrical connector.
17. Remove the bank 1 sensor 1 oxygen sensor (2) from the exhaust manifold.

1. Install the bank 1 sensor 1 oxygen sensor (2) to the exhaust manifold. Tighten: Tighten the heated oxygen sensor (HO2S) to 42 N.m (31 lb ft).
2. Attach the mechanics wire to the oxygen sensor electrical connector.
3. Lower the vehicle.
4. Using the mechanics wire, pull the exhaust sensor electrical connector and wire harness upward to the engine compartment.
5. Route both oxygen sensor electrical connectors and wires under the rear section of the supercharger inlet duct. Reposition the duct as necessary.
6. Route both oxygen sensor electrical connectors and wires under the two engine wire harnesses.
7. Install the electrical connector retainer to the electrical connector.
8. Connect both oxygen sensor electrical connectors to the engine wiring harness connectors.
9. Install both oxygen sensor electrical connector assemblies (1,2) to the fuel rail brackets.
10. Connect the PCV foul air tube (1) to the PCV orifice fitting on the right camshaft cover. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
11. 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) .
12. Install the oxygen sensor wire harnesses to the retainer (1) at the rear of the engine. Ensure that the wire harnesses are secure and away from hot exhaust components.
13. Lower the vehicle.
14. Install the front section of the supercharger inlet duct assembly. Tighten the duct clamps (2) and secure the duct assembly with the ball studs (1). Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
15. 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) .

Note. Refer to Oxygen Sensor Notice .

1. 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) .
2. Remove the ball studs (1), loosen the duct clamps (2) and remove the front section of the supercharger inlet duct assembly. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
3. Release the lock tab, and disconnect the PCV foul air tube (1) from the PCV orifice fitting on the right camshaft cover. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
4. Separate the bank 1, sensor 1 electrical connector assembly (1) from the fuel rail bracket.
5. Disconnect the oxygen sensor electrical connector from the engine wiring harness connector.
6. Separate the bank 1, sensor 2 electrical connector assembly (1) from the fuel rail bracket.
7. Disconnect the oxygen sensor electrical connector from the engine wiring harness connector.
8. Remove both oxygen sensor electrical connectors and wires from under the two engine wire harnesses.
9. Remove both oxygen sensor electrical connectors and wires from under the rear section of the supercharger inlet duct. Reposition the duct as necessary.
10. Attach a suitable length of mechanics wire to the bank 1, sensor 2 electrical connector.
11. 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) .
12. Remove the oxygen sensor wire harnesses from the retainer (1) at the rear of the engine.
13. Note the wire routing for reassembly.
14. Gently pull the bank 1 sensor 2 oxygen sensor (1) wire harness down from the engine compartment.
15. Remove the mechanics wire from the electrical connector.
16. Remove the bank 1 sensor 2 oxygen sensor (1) from the exhaust manifold.

1. Install the bank 1 sensor 2 oxygen sensor (1) to the exhaust manifold. Tighten: Tighten the heated oxygen sensor (HO2S) to 42 N.m (31 lb ft).
2. Attach the mechanics wire to the oxygen sensor electrical connector.
3. Lower the vehicle.
4. Using the mechanics wire, pull the exhaust sensor electrical connector and wire harness upward to the engine compartment.
5. Route both oxygen sensor electrical connectors and wires under the rear section of the supercharger inlet duct. Reposition the duct as necessary.
6. Route both oxygen sensor electrical connectors and wires under the two engine wire harnesses.
7. Connect both oxygen sensor electrical connectors to the engine wiring harness connectors.
8. Install both oxygen sensor electrical connector assemblies (1,2) to the fuel rail brackets.
9. Connect the PCV foul air tube to the PCV orifice fitting (1) on the right camshaft cover. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
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. Install the oxygen sensor wire harnesses to the retainer (1) at the rear of the engine. Ensure that the wire harnesses are secure and away from hot exhaust components.
12. Lower the vehicle.
13. Install the front section of the supercharger inlet duct assembly. Tighten the duct clamps (2) and secure the duct assembly with the ball studs (1). Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
14. 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) .

Note. Refer to Oxygen Sensor Notice .

1. 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) .
2. Remove the ball studs (1), loosen the duct clamps (2) and remove the front section of the supercharger inlet duct assembly. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
3. Separate the bank 2, sensor 1 electrical connector assembly (1) from the fuel rail bracket.
4. Disconnect the oxygen sensor electrical connector from the engine wiring harness connector.
5. Using a small screw driver, remove the electrical connector retainer (1) from the electrical connector.
6. Attach a suitable length of mechanics wire to the oxygen sensor electrical connector.
7. Separate the bank 2, sensor 2 electrical connector assembly (1) from the fuel rail bracket.
8. Disconnect the oxygen sensor electrical connector from the engine wiring harness connector.
9. Disconnect the evaporative emission (EVAP) hose (3) from the chassis bundle at the front of dash. Position the hose aside.
10. Disconnect the brake booster hose and check valve from the brake booster. Position the hose aside.
11. Reposition the rear inlet duct upward. Place the inlet duct bracket (1) on top of the mounting stud (2).
12. Remove both oxygen sensor electrical connectors and wires from under the rear section of the supercharger inlet duct.
13. 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) .
14. Remove the oxygen sensor wire harnesses from the retainer (1) at the rear of the engine.
15. Note the wire routing for reassembly.
16. Gently pull the bank 2 sensor 1 oxygen sensor (1) wire harness and connector down from the engine compartment.
17. Remove the mechanics wire from the electrical connector.
18. Remove the bank 2 sensor 1 oxygen sensor (1) from the exhaust manifold.

1. Install the bank 2 sensor 1 oxygen sensor (1) to the exhaust manifold. Tighten: Tighten the heated oxygen sensor (HO2S) to 42 N.m (31 lb ft).
2. Attach the mechanics wire to the oxygen sensor electrical connector.
3. Lower the vehicle.
4. Using the mechanics wire, pull the exhaust sensor electrical connector and wire harness upward to the engine compartment.
5. Route both oxygen sensor electrical connectors and wires under the rear section of the supercharger inlet duct.
6. Install the electrical connector retainer to the electrical connector.
7. Connect both oxygen sensor electrical connectors to the engine wiring harness connectors.
8. Install both oxygen sensor electrical connector assemblies (1, 2) to the fuel rail brackets.
9. Place the rear inlet duct to the installed position.
10. Connect the brake booster hose and check valve to the brake booster.
11. Connect the evaporative emission (EVAP) hose (3) to the chassis bundle at the front of dash.
12. 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) .
13. Install the oxygen sensor wire harnesses to the retainer (1) at the rear of the engine. Ensure that the wire harnesses are secure and away from hot exhaust components.
14. Lower the vehicle.
15. Install the front section of the supercharger inlet duct assembly. Tighten the duct clamps (2) and secure the duct assembly with the ball studs (1). Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
16. 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) .

Note. Refer to OXYGEN SENSOR NOTICE .

1. 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) .
2. Remove the ball studs (1), loosen the duct clamps (2) and remove the front section of the supercharger inlet duct assembly. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
3. Separate the bank 2, sensor 1 electrical connector assembly (1) from the fuel rail bracket.
4. Disconnect the oxygen sensor electrical connector from the engine wiring harness connector.
5. Separate the bank 2, sensor 2 electrical connector assembly (1) from the fuel rail bracket.
6. Disconnect the oxygen sensor electrical connector from the engine wiring harness connector.
7. Attach a suitable length of mechanics wire to the bank 2, sensor 2 oxygen sensor electrical connector.
8. Disconnect the evaporative emission (EVAP) hose (3) from the chassis bundle at the front of dash. Position the hose aside.
9. Disconnect the brake booster hose and check valve from the brake booster. Position the hose aside.
10. Reposition the rear inlet duct upward. Place the inlet duct bracket (1) on top of the mounting stud (2).
11. Remove both oxygen sensor electrical connectors and wires from under the rear section of the supercharger inlet duct.
12. 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) .
13. Remove the oxygen sensor wire harnesses from the retainer (1) at the rear of the engine.
14. Note the wire routing for reassembly.
15. Gently pull the bank 2 sensor 2 oxygen sensor (2) wire harness and connector down from the engine compartment.
16. Remove the mechanics wire from the electrical connector.
17. Remove the bank 2 sensor 2 oxygen sensor (2) from the exhaust manifold.

1. Install the bank 2 sensor 2 oxygen sensor (2) to the exhaust manifold. Tighten: Tighten the heated oxygen sensor (HO2S) to 42 N.m (31 lb ft).
2. Attach the mechanics wire to the oxygen sensor electrical connector.
3. Lower the vehicle.
4. Using the mechanics wire, pull the exhaust sensor electrical connector and wire harness upward to the engine compartment.
5. Route both oxygen sensor electrical connectors and wires under the rear section of the supercharger inlet duct.
6. Install the electrical connector retainer to the electrical connector.
7. Connect both oxygen sensor electrical connectors to the engine wiring harness connectors.
8. Install both oxygen sensor electrical connector assemblies (1,2) to the fuel rail brackets.
9. Place the rear inlet duct to the installed position.
10. Connect the brake booster hose and check valve to the brake booster.
11. Connect the evaporative emission (EVAP) hose (3) to the chassis bundle at the front of dash.
12. 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) .
13. Install the oxygen sensor wire harnesses to the retainer (1) at the rear of the engine. Ensure that the wire harnesses are secure and away from hot exhaust components.
14. Lower the vehicle.
15. Install the front section of the supercharger inlet duct assembly. Tighten the duct clamps (2) and secure the duct assembly with the ball studs (1). Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
16. 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) .

Note. Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type.

1. Remove the left instrument panel (I/P) on the lower closeout 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. Disconnect the electrical connector (1) from the accelerator pedal sensor module.
3. Remove the accelerator pedal mounting bolts (1).
4. Remove the accelerator pedal (2).

1. Install the accelerator pedal to the steering column support bracket.
2. Install the accelerator pedal mounting bolts (1). Tighten: Tighten the accelerator pedal mounting bolts to 10 N.m (89 lb in).
3. Connect the accelerator pedal sensor module electrical connector (1).
4. Check for correct carpet fit under the accelerator pedal.
5. Install the left I/P on the lower closeout 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.

Scheme 128

Throttle Body Assembly Replacement

Throttle Body Inspection and Cleaning

1. Remove the supercharger. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
2. Remove the rear supercharger inlet duct and seal. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
3. Using a mirror, inspect the throttle body bore and the throttle body plate for deposits. You will need to open the throttle plate in order to inspect all surfaces.
4. Clean the throttle body bore and the throttle plate using a clean shop towel with GM top engine cleaner, P/N 1052626 or AC Delco Carburetor Tune-up Conditioner, P/N X66P, or equivalent product.
5. Install the rear supercharger inlet duct and seal. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
6. Install the supercharger. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .

Fuel Pressure Relief

Tools Required

1. J 34730-1A Fuel Pressure Gage. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
2. J 42242 Fuel Pressure Gage Adapter. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .

1. Turn the ignition OFF.
2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Refer to «Battery Negative Cable Disconnection and Connection»(/cadillac/xlr/i-2003-2009/remont/charging-system/#battery-charging-system-and-starting-system) .
3. 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) .
4. Remove the cap from the fuel pressure test port valve on the fuel rail.
5. Connect the J 42242 (1) to the fuel pressure test port valve. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) . Wrap a shop towel around the fitting while connecting the adapter in order to avoid spillage.
6. Connect the J 34730-1A (2) to the J 42242 (1). See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) . Wrap a shop towel around the fittings while connecting the gage to the adapter in order to avoid spillage.
7. Install the bleed hose into an approved container.
8. Open the valve in order to bleed the system pressure. Fuel connections are now safe for servicing.
9. Drain any fuel remaining in the gage into an approved container.
10. Remove the J 34730-1A and the J 42242 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
11. Install the cap to the fuel pressure test port valve.
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) .
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) .

Fuel Pressure Gage Installation and Removal

Tools Required

1. J 34730-1A Fuel Pressure Gage. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
2. J 42242 Fuel Pressure Gage Adapter. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .

Note. Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections The hose connections The areas surrounding the connections

1. 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) .
2. Remove the cap from the fuel pressure test port valve.
3. Connect the J 42242 (1) to the fuel pressure test port valve. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) . Wrap a shop towel around the fitting while connecting the adapter in order to avoid spillage.
4. Connect the J 34730-1A (2) to the J 42242 (1). See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) . Wrap a shop towel around the fittings while connecting the gage to the adapter in order to avoid spillage.
5. Turn ON the ignition, with the engine OFF.
6. Place the bleed hose of the fuel pressure gage into an approved gasoline container.
7. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage.
8. Command the fuel pump ON with a scan tool.
9. Close the bleed valve on the fuel pressure gage.
10. Command the fuel pump ON with a scan tool.
11. Inspect for fuel leaks.

1. Drain any fuel remaining in the gage into an approved container.
2. Place a shop towel under the J 34730-1A (2) and the J 42242 (1) to catch any remaining fuel spillage. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
3. Remove the J 34730-1A (2) and the J 42242 (1). See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) .
4. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
5. Install the cap to the fuel pressure test port valve.
6. 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) .

J 37088-A Tool Set, Fuel Line Quick-Connect Separator. See Special Tools .

1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-46l-lh2-introduction-2-of-2) .
2. Slide the dust cover from the quick-connect fitting, if equipped.
3. Blow any dirt out of the fitting, using compressed air.
4. Choose the correct tool from the J 37088-A Tool Set for the size of the fitting. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) . Insert the tool into the female connector, then push inward in order to release the locking tabs.
5. Pull the connection apart.
6. Using a clean shop towel, wipe off the male pipe end.
7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.

1. Apply a few drops of clean engine oil to the male pipe end.
2. Push both sides of the fitting together in order to cause the retaining tabs to snap into place.
3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure.
4. Reposition the dust cover over the quick-connect fitting.

J 37088-A Fuel Line Disconnect Tool Set

1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-46l-lh2-introduction-2-of-2) .
2. Using compressed air, blow any dirt out of the quick-connect fitting.
3. Squeeze the plastic retainer release tabs.
4. Choose the correct tool from the J 37088-A Tool Set for the size of the fitting. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__special-tools) . Insert the tool into the female connector, then push inward in order to release the locking tabs. The plastic retainer will remain on the female connector.
5. Pull the connection apart.

1. Apply a few drops of clean engine oil to the male fuel pipe end.
2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs/fingers to snap into place.
3. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure.

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) .

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.

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) .

Fuel System Cleaning

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 tanks. Refer to «Fuel Tank Draining»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
4. Remove the fuel tanks. Refer to «Fuel Tank Replacement - Left Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) and «Fuel Tank Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
5. Remove the fuel tank modules. 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) and «Fuel Tank Fuel Pump Module Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
6. Inspect the left fuel tank module. Replace a contaminated strainer for the left fuel tank module.
7. Inspect the left fuel tank module fuel pump and fuel pump inlet for debris. Replace the left fuel tank module assembly if you find debris in the fuel pump inlet.
8. Inspect the right fuel tank module strainer. Replace the right fuel tank module assembly if you find a contaminated strainer. The right fuel tank module strainer is not serviced separately.
9. Flush the fuel tanks with hot water.
10. Pour the water out of the fuel tank module assembly openings. Rock the tanks to be sure that removal of the water from the tanks is complete.
11. Install the fuel tank module assemblies to the fuel tanks. 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) and «Fuel Tank Fuel Pump Module Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
12. Disconnect the fuel feed hose/pipe from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
13. Use compressed air in order to apply air pressure to the fuel lines in the opposite direction from the normal fuel flow.
14. Remove the fuel injectors and fuel rail. Refer to «Fuel Injector and Fuel Rail Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
15. Clean and inspect the fuel injectors and fuel rail.
16. Install the fuel injectors and fuel rail. Refer to «Fuel Injector and Fuel Rail Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
17. Connect the fuel feed hose/pipe to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
18. Install the fuel tanks. Refer to «Fuel Tank Replacement - Left Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) and «Fuel Tank Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
19. Refill the fuel system.
20. Install the fuel filler cap.
21. Connect the negative battery cable.
22. 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.
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. 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) .
2. Remove the front section of the supercharger inlet duct assembly. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
3. Clean the fuel rail and injector ports on the supercharger with compressed air.
4. Disconnect the electrical connectors from the following sensors: The supercharger inlet absolute pressure (SCIAP) sensor (1) The barometric pressure (BARO) sensor (2) The manifold absolute pressure (MAP) sensor (3)
5. Disconnect the vacuum lines from the MAP and SCIAP sensors.
6. Remove the SCIAP, BARO and MAP sensors with the bracket.
7. Partially drain the charge air cooling system. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system) or «Charge Air Cooling System Draining and Filling (GE 47716)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system) .
8. Remove the front section of the charge air cooler front manifold assembly (2), and discard the O-ring seals. It is not necessary to remove the hoses from the manifold pipes. Position the manifold with hoses aside to allow for removal of the fuel rail assembly. Refer to «Charge Air Cooler Front Manifold Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
9. Disconnect the electrical connector from the air inlet temperature 2 sensor and position aside.
10. Disconnect the supercharger bypass solenoid valve electrical connector (3) and position the harness aside.
11. Disconnect the vacuum line from the supercharger actuator valve and position the line aside.
12. Disconnect the engine compartment fuel line fitting (1) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
13. Disconnect the fuel injector electrical connectors (1, 4, 6, 8) from the left and right side of the engine.
14. Remove the ground wire (1) from the right rear injector rail bolt.
15. Remove the oxygen sensor electrical connector assemblies (1,2) from the right side fuel rail brackets.
16. Remove the oxygen sensor electrical connector assemblies (1,2) from the left side fuel rail brackets.
17. Open the clip that secures the fuel rail to the front of the supercharger.
18. Remove the fuel rail attaching studs (2).
19. Reposition the rear inlet duct (3) as necessary, and remove the fuel rail assembly (1) from the supercharger.
20. Remove the injector lower O-ring seal from the spray tip end of each injector.
21. Discard the O-ring seals.
22. Remove the retainers from the fuel injectors if fuel injector removal is necessary.
23. Remove the fuel injectors from the fuel rail.
24. Remove the O-ring seals from the fuel injectors. Discard the O-ring seals.

1. If the injectors were removed from the fuel rail, lubricate the new fuel injector O-ring seals with clean engine oil.
2. Install the new fuel injector O-ring seals on to the fuel injectors.
3. Install the fuel injectors to the fuel rail using new retainer clips.
4. Ensure that the injectors are aligned by orientating the electrical connectors perpendicular to the crankshaft centerline.
5. Lubricate and install the new O-ring seals on the spray tip end of each injector.
6. Align the fuel injectors and fuel rail to the supercharger assembly.
7. Reposition the rear inlet duct (3) as necessary, and carefully press the fuel rail assembly (1) downward until fully seated.
8. Install the fuel rail attaching studs (2). Tighten: Tighten the studs to 10 N.m (89 lb in).
9. Install the fuel rail to the clip on the front of the supercharger.
10. Install the oxygen sensor electrical connector assemblies (1,2) to the left side fuel rail brackets.
11. Install the oxygen sensor electrical connector assemblies (1,2) to the right side fuel rail brackets.
12. Install the ground wire (1) to the right rear injector rail bolt.
13. Connect the fuel injector electrical connectors (1,4,6,8) to the left and right side of the engine.
14. Connect the engine compartment fuel line fitting (1) to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
15. Connect the vacuum line to the supercharger actuator valve.
16. Connect the supercharger bypass solenoid valve electrical connector (3).
17. Connect the electrical connector to the air inlet temperature 2 sensor.
18. Using NEW O-ring seals, install the front section of the charge air cooler front manifold assembly (2). Refer to «Charge Air Cooler Front Manifold Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
19. Install the SCIAP (1), BARO (2) and MAP (3) sensors with the bracket.
20. Connect the vacuum lines to the MAP (3) and SCIAP (1) sensors.
21. Connect the electrical connectors to the following sensors: The SCIAP sensor The BARO sensor The MAP sensor
22. Install the front section of the supercharger inlet duct assembly. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
23. Install the fuel fill pipe cap.
24. Fill the charge air cooling system with coolant. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system) or «Charge Air Cooling System Draining and Filling (GE 47716)»(/cadillac/xlr/i-2003-2009/remont/cooling-system-mechanical/#engine-cooling-system) .
25. Check the fuel system for leaks.
26. 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) .

Scheme 129

Evaporative Emission Canister Purge Solenoid Valve Replacement

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/xlr/i-2003-2009/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Lower the right muffler. Refer to «Exhaust Muffler Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/exhaust/#engine-exhaust-system) .
3. Disconnect the EVAP canister valve harness connector.
4. Disconnect the vent hose (2) from the EVAP canister vent valve (1).
5. Remove the EVAP canister vent valve (2) from the vent bracket (1).

1. Install the EVAP canister vent valve (2) to the vent bracket (1).
2. Connect the vent hose (2) to the EVAP canister vent valve (1).
3. Connect the EVAP vent valve electrical connector.
4. Install the right muffler. Refer to «Exhaust Muffler Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/exhaust/#engine-exhaust-system) .
5. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/xlr/i-2003-2009/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Remove the right muffler assembly. Refer to «Exhaust Muffler Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/exhaust/#engine-exhaust-system) .
3. Disconnect the vent hose (2) from the evaporative emission (EVAP) vent valve (1).
4. Remove the clamp from the vent hose.
5. 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) .
6. Remove the EVAP canister access cover.
7. Working through the right wheel house, disconnect the vent hose (3) from the EVAP canister.
8. Remove the vent hose.
9. Cap the EVAP vent valve and the EVAP canister in order to prevent possible EVAP system contamination.

1. Remove the caps from the EVAP vent valve and the EVAP canister.
2. Route the vent hose over the floor panel tunnel panel rear brace.
3. Install the clamps on the vent hose.
4. Connect the vent hose (3) to the EVAP canister.
5. Connect the vent hose (2) to the EVAP vent valve.
6. Install the right muffler assembly. Refer to «Exhaust Muffler Replacement - Right Side»(/cadillac/xlr/i-2003-2009/remont/exhaust/#engine-exhaust-system) .
7. Install the EVAP canister access cover.
8. 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) .
9. Lower the vehicle.

1. 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) .
2. Disconnect the engine purge pipe (3) from the chassis purge pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
3. Cap the engine purge pipe in order to prevent possible contamination.
4. Disconnect the chassis fuel and evaporative emission (EVAP) pipe retainer (1) from the upper front of dash mounting stud (3).
5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/xlr/i-2003-2009/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
6. Remove the exhaust intermediate pipe. Refer to «Intermediate Pipe Replacement»(/cadillac/xlr/i-2003-2009/remont/exhaust/#engine-exhaust-system) .
7. Remove the driveline tunnel closeout panel. Refer to «Driveline Tunnel Closeout Panel Replacement»(/cadillac/xlr/i-2003-2009/remont/driveshaft-universal-joints/#propeller-shaft) .
8. Remove the EVAP canister vent valve (2) from the bracket (1).
9. Disconnect the rear purge pipe (1) from the chassis purge pipe (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
10. Cap the rear purge pipe.
11. Remove the chassis purge pipe (4) underbody retainer nuts (3).
12. Remove the chassis purge pipe (4) from the rear underbody retainers (2).
13. Disconnect the chassis purge pipe (4) from the side underbody retainers (6).
14. Remove the chassis purge pipe.

1. Install the chassis purge pipe (4) into the side underbody retainers (6).
2. Install the chassis purge pipe (4) into the rear underbody retainers (2).
3. Install the underbody retainers on the mounting studs.
4. Install the chassis purge pipe underbody retainer nuts. Tighten: Tighten the EVAP pipe retainer bracket nuts to 6 N.m (53 lb in).
5. Uncap the rear EVAP pipe.
6. Connect the rear EVAP pipe (1) to the chassis purge pipe (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
7. Install the EVAP canister vent valve (2) to the bracket (1).
8. Install the driveline tunnel closeout panel. Refer to «Driveline Tunnel Closeout Panel Replacement»(/cadillac/xlr/i-2003-2009/remont/driveshaft-universal-joints/#propeller-shaft) .
9. Install the exhaust intermediate pipe. Refer to «Intermediate Pipe Replacement»(/cadillac/xlr/i-2003-2009/remont/exhaust/#engine-exhaust-system) .
10. Lower the vehicle.
11. Uncap the engine purge pipe.
12. Connect the chassis fuel and EVAP pipe retainer at the upper front of dash mounting stud. Tighten: Tighten the fuel and EVAP pipe bracket retainer nut to 6 N.m (53 lb in).
13. Connect the engine purge pipe (3) to the chassis purge pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
14. 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. 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) .
2. Disconnect the engine purge pipe (3) quick-connect fitting from the evaporative emission (EVAP) canister purge valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
3. Disconnect the engine purge pipe (3) quick-connect fitting from the chassis pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
4. Remove the EVAP pipe.
5. Cap the chassis pipe and the EVAP canister purge valve in order to prevent possible contamination.

1. Remove the caps from the chassis pipe and the EVAP canister purge valve.
2. Install the EVAP pipe (3) to the chassis pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
3. Install the EVAP pipe (3) to the EVAP canister purge valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
4. 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. 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. Remove the fuel tank crossover tube. Refer to «Fuel Tank Crossover Tube/Hose Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
4. Disconnect the evaporative emission (EVAP) pipe (2) at the right tank EVAP pipe (3) and the left tank EVAP pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
5. Remove the rear EVAP pipe (2).
6. Cap the open pipes in order to prevent possible contamination.

1. Remove the caps from the pipes.
2. Connect the EVAP pipe (2) at the right tank EVAP pipe (3) and the left tank EVAP pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
3. Install the fuel tank crossover tube. Refer to «Fuel Tank Crossover Tube/Hose Replacement»(/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. 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 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) .
2. Disconnect the vent hose from the EVAP canister.
3. Disconnect the purge pipe at the EVAP canister.
4. Remove the EVAP canister bracket bolt (3).
5. Remove the EVAP canister (1) from the EVAP canister bracket (2).

1. Install the new EVAP canister (1) to the EVAP canister bracket (2).
2. Install the EVAP canister bracket bolt (3). Tighten: Tighten the EVAP canister bracket bolt to 7 N.m (62 lb in).
3. Connect the purge pipe at the EVAP canister.
4. Connect the vent hose to the EVAP canister.
5. 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) .

Scheme 130

Ignition Coil Replacement - Bank 1

Scheme 131

Ignition Coil Replacement - Bank 2

Spark Plug Inspection

Spark Plug Usage

1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to «Ignition System Specifications»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-46l-lh2-introduction-2-of-2__ignition-system-specifications) for the correct spark plug.
2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug Pre-ignition causing spark plug and/or engine damage-Hotter plug

Spark Plug Inspection

1. Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move.
2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground.
3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
4. Inspect (3) for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to «Ignition System Specifications»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-46l-lh2-introduction-2-of-2__ignition-system-specifications) . An excessively wide electrode gap can prevent correct spark plug operation. Inspect for the correct spark plug torque. Refer to «Ignition System Specifications»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-46l-lh2-introduction-2-of-2__ignition-system-specifications) . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). Inspect for a broken or worn side electrode (3). Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. A loose center electrode (4) reduces the spark intensity. Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. Inspect for excessive fouling.
5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation.

Spark Plug Visual Inspection

1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives.
2. Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors Excessive fuel pressure Restricted air filter element Incorrect combustion Reduced ignition system voltage output Weak coils Worn ignition wires Incorrect spark plug gap Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.
3. Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode.

1. Turn OFF the ignition switch.
2. Remove the ignition coil assemblies. Refer to «Ignition Coil Replacement - Bank 1»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) and «Ignition Coil Replacement - Bank 2»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
3. Remove the spark plugs from the engine.
4. Inspect the spark plugs. Refer to «Spark Plug Inspection»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__spark-plug-inspection) .

1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. Refer to «Ignition System Specifications»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-46l-lh2-introduction-2-of-2__ignition-system-specifications) , correct as necessary.
2. Install the spark plugs to the engine. Tighten: Tighten the spark plugs to 15 N.m (11 lb ft).
3. Install the ignition coil assemblies. Refer to «Ignition Coil Replacement - Bank 1»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) and «Ignition Coil Replacement - Bank 2»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .

1. Remove the supercharger. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
2. Disconnect the crankshaft position sensor electrical connector.
3. Remove the crankshaft sensor retaining bolt.
4. Remove the crankshaft sensor.

1. Lubricate the crankshaft sensor O-ring with clean engine oil.
2. Install the crankshaft sensor and the retaining bolt. Tighten: Tighten the retaining bolt between 10 N.m (89 lb in).
3. Connect the crankshaft position sensor electrical connector.
4. Install the supercharger. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
5. Perform the crankshaft position sensor system variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2__crankshaft-position-system-variation-learn) .

1. 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) .
2. Disconnect the electrical connector from the left bank exhaust camshaft position sensor (4).
3. Remove the camshaft position sensor retaining bolt.
4. Remove the left bank exhaust camshaft position sensor (4).

1. Lubricate the camshaft position sensor O-ring with engine oil.
2. Install the left bank exhaust camshaft position sensor (4) and retaining bolt. Tighten: Tighten the camshaft position sensor retaining bolt to 10 N.m (89 lb in).
3. Connect the camshaft position sensor electrical connector.
4. Operate the engine and inspect the camshaft position sensor for engine oil leaks.
5. 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. 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) .
2. Disconnect the electrical connector from the left bank intake camshaft position sensor (3).
3. Remove the camshaft position sensor retaining bolt.
4. Remove the left bank intake camshaft position sensor (3).

1. Lubricate the camshaft position sensor O-ring with engine oil.
2. Install the left bank intake camshaft position sensor (3) and retaining bolt. Tighten: Tighten the camshaft position sensor retaining bolt to 10 N.m (89 lb in).
3. Connect the camshaft position sensor electrical connector.
4. Operate the engine and inspect the camshaft position sensor for engine oil leaks.
5. 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. 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) .
2. Disconnect the electrical connector from the right bank exhaust camshaft position sensor (1).
3. Remove the camshaft position sensor retaining bolt.
4. Remove the right bank exhaust camshaft position sensor (1).

1. Lubricate the camshaft position sensor O-ring with engine oil.
2. Install the right bank exhaust camshaft position sensor (1) and retaining bolt. Tighten: Tighten the camshaft position sensor retaining bolt to 10 N.m (89 lb in).
3. Connect the camshaft position sensor electrical connector.
4. Operate the engine and inspect the camshaft position sensor for engine oil leaks.
5. 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. 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) .
2. Disconnect the electrical connector from the right bank intake camshaft position sensor (2).
3. Remove the camshaft position sensor retaining bolt.
4. Remove the right bank intake camshaft position sensor (2).

1. Lubricate the camshaft position sensor O-ring with engine oil.
2. Install the right bank intake camshaft position sensor (2) and retaining bolt. Tighten: Tighten the camshaft position sensor retaining bolt to 10 N.m (89 lb in).
3. Connect the camshaft position sensor electrical connector.
4. Operate the engine and inspect the camshaft position sensor for engine oil leaks.
5. 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. 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) .
2. Disconnect the actuator solenoid electrical connector.
3. Remove the right intake camshaft position (CMP) actuator solenoid bolts.
4. Remove the right intake CMP actuator solenoid.

Note. DO NOT remove the camshaft position actuator magnet unless it needs to be replaced. The camshaft position actuator magnet is precisely aligned to the camshaft position actuator oil control valve on the end of the camshaft during engine assembly. If the camshaft position actuator magnet is removed and/or needs to be replaced, it will be necessary to realign the camshaft position actuator magnet to the camshaft position actuator oil control valve after the camshaft position actuator housing is installed to the cylinder head. Failure to realign the camshaft position actuator magnet to the camshaft position actuator oil control valve can lead to poor engine performance and engine component damage.

To allow for CMP actuator solenoid to CMP actuator oil control valve alignment, DO NOT install the NEW CMP actuator solenoid alignment plugs at this time.

Camshaft Position Actuator Solenoid Alignment Procedure

1. Make an alignment pin from drill rod 15/64 inch diameter and at least 50 mm (1.97 in) long.
2. Verify that the alignment pin will pass through the CMP actuator solenoid alignment hole.
3. Verify that the alignment pin will fit into the alignment hole in the CMP actuator oil control valve.
4. Apply a 2 mm (0.079 in) bead of RTV GM P/N 12378521 (Canadian P/N 88901148) around the flange of the CMP actuator solenoid.
5. Install the CMP actuator solenoid over the oil control valve.
6. Install the alignment pin through the solenoid alignment hole and into the oil control valve alignment hole.
7. With the alignment pin in place, install the CMP actuator solenoid bolts. Tighten: Tighten the CMP actuator solenoid bolts to 8 N.m (71 lb in).
8. Remove the alignment pin.
9. Install a NEW CMP actuator solenoid plug.
10. Connect the electrical connector to the actuator solenoid.
11. 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. 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) .
2. Remove the power steering fluid reservoir. Refer to «Remote Power Steering Fluid Reservoir Replacement»(/cadillac/xlr/i-2003-2009/remont/manual-power-steering/#power-steering-system) .
3. Disconnect the actuator solenoid electrical connector.
4. Remove the right exhaust camshaft position (CMP) actuator solenoid bolts.
5. Remove the right exhaust CMP actuator solenoid.

Note. DO NOT remove the camshaft position actuator magnet unless it needs to be replaced. The camshaft position actuator magnet is precisely aligned to the camshaft position actuator oil control valve on the end of the camshaft during engine assembly. If the camshaft position actuator magnet is removed and/or needs to be replaced, it will be necessary to realign the camshaft position actuator magnet to the camshaft position actuator oil control valve after the camshaft position actuator housing is installed to the cylinder head. Failure to realign the camshaft position actuator magnet to the camshaft position actuator oil control valve can lead to poor engine performance and engine component damage.

To allow for CMP actuator solenoid to CMP actuator oil control valve alignment, DO NOT install the NEW CMP actuator solenoid alignment plugs at this time.

1. Make an alignment pin from drill rod 15/64 inch diameter and at least 50 mm (1.97 in) long.
2. Verify that the alignment pin will pass through the CMP actuator solenoid alignment hole.
3. Verify that the alignment pin will fit into the alignment hole in the CMP actuator oil control valve.
4. Apply a 2 mm (0.079 in) bead of RTV GM P/N 12378521 (Canadian P/N 88901148) around the flange of the CMP actuator solenoid.
5. Install the CMP actuator solenoid over the oil control valve.
6. Install the alignment pin through the solenoid alignment hole and into the oil control valve alignment hole.
7. With the alignment pin in place, install the CMP actuator solenoid bolts. Tighten: Tighten the CMP actuator solenoid bolts to 8 N.m (71 lb in).
8. Remove the alignment pin.
9. Install a NEW CMP actuator solenoid plug.
10. Connect the electrical connector to the actuator solenoid.
11. Install the power steering fluid reservoir. Refer to «Remote Power Steering Fluid Reservoir Replacement»(/cadillac/xlr/i-2003-2009/remont/manual-power-steering/#power-steering-system) .
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. 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) .
2. Disconnect the actuator solenoid electrical connector.
3. Remove the left intake camshaft position (CMP) actuator solenoid bolts.
4. Remove the left intake CMP actuator solenoid.

Note. DO NOT remove the camshaft position actuator magnet unless it needs to be replaced. The camshaft position actuator magnet is precisely aligned to the camshaft position actuator oil control valve on the end of the camshaft during engine assembly. If the camshaft position actuator magnet is removed and/or needs to be replaced, it will be necessary to realign the camshaft position actuator magnet to the camshaft position actuator oil control valve after the camshaft position actuator housing is installed to the cylinder head. Failure to realign the camshaft position actuator magnet to the camshaft position actuator oil control valve can lead to poor engine performance and engine component damage.

To allow for CMP actuator solenoid to CMP actuator oil control valve alignment, DO NOT install the NEW camshaft position actuator solenoid alignment plugs at this time.

1. Make an alignment pin from drill rod 15/64 inch diameter and at least 50 mm (1.97 in) long.
2. Verify that the alignment pin will pass through the CMP actuator solenoid alignment hole.
3. Verify that the alignment pin will fit into the alignment hole in the CMP actuator oil control valve.
4. Apply a 2 mm (0.079 in) bead of RTV GM P/N 12378521 (Canadian P/N 88901148) around the flange of the CMP actuator solenoid.
5. Install the CMP actuator solenoid over the oil control valve.
6. Install the alignment pin through the solenoid alignment hole and into the oil control valve alignment hole.
7. With the alignment pin in place, install the CMP actuator solenoid bolts. Tighten: Tighten the CMP actuator solenoid bolts to 8 N.m (71 lb in).
8. Remove the alignment pin.
9. Install a NEW CMP actuator solenoid plug.
10. Connect the electrical connector to the actuator solenoid.
11. 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. 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) .
2. Remove the water pump and generator drive belt tensioner. Refer to «Water Pump and Generator Belt Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
3. Disconnect the actuator solenoid electrical connector.
4. Remove the left exhaust camshaft position (CMP) actuator solenoid bolts.
5. Remove the left exhaust CMP actuator solenoid.

Note. DO NOT remove the camshaft position actuator magnet unless it needs to be replaced. The camshaft position actuator magnet is precisely aligned to the camshaft position actuator oil control valve on the end of the camshaft during engine assembly. If the camshaft position actuator magnet is removed and/or needs to be replaced, it will be necessary to realign the camshaft position actuator magnet to the camshaft position actuator oil control valve after the camshaft position actuator housing is installed to the cylinder head. Failure to realign the camshaft position actuator magnet to the camshaft position actuator oil control valve can lead to poor engine performance and engine component damage.

To allow for CMP actuator solenoid to CMP actuator oil control valve alignment, DO NOT install the NEW CMP actuator solenoid alignment plugs at this time.

1. Make an alignment pin from drill rod 15/64 inch diameter and at least 50 mm (1.97 in) long.
2. Verify that the alignment pin will pass through the CMP actuator solenoid alignment hole.
3. Verify that the alignment pin will fit into the alignment hole in the CMP actuator oil control valve.
4. Apply a 2 mm (0.079 in) bead of RTV GM P/N 12378521 (Canadian P/N 88901148) around the flange of the CMP actuator solenoid.
5. Install the CMP actuator solenoid over the oil control valve.
6. Install the alignment pin through the solenoid alignment hole and into the oil control valve alignment hole.
7. With the alignment pin in place, install the CMP actuator solenoid bolts. Tighten: Tighten the CMP actuator solenoid bolts to 8 N.m (71 lb in).
8. Remove the alignment pin.
9. Install a NEW CMP actuator solenoid plug.
10. Connect the electrical connector to the actuator solenoid.
11. Install the water pump and generator drive belt tensioner. Refer to «Water Pump and Generator Belt Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
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. Remove the supercharger assembly. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
2. Disconnect the electrical connector (3) from the knock sensor (KS) (4).
3. Remove the bolt in the center of the KS.
4. Remove the KS (4) from the engine block.

1. Thoroughly clean the mating surfaces of the KS and the engine block. The entire contact surface of the KS must lie directly on the engine block.
2. Install the KS (1) and the bolt to the engine block. Tighten: Tighten the KS bolt to 20 N.m (15 lb ft).
3. Ensure that the wiring harness is installed correctly.
4. Connect the electrical connector (3) to the KS (4).
5. Install the supercharger assembly. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .

1. Remove the supercharger assembly. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
2. Disconnect the electrical connector (2) from the knock sensor (KS) (1).
3. Remove the bolt in the center of the KS.
4. Remove the KS (1) from the engine block.

1. Thoroughly clean the mating surfaces of the KS and the engine block. The entire contact surface of the KS must lie directly on the engine block.
2. Install the KS (1) and the bolt to the engine block. Tighten: Tighten the KS bolt to 20 N.m (15 lb ft).
3. Ensure that the wiring harness is installed correctly.
4. Connect the electrical connector (2) to the KS (1).
5. Install the supercharger assembly. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .

1. The supercharger must be removed to remove the rear section of the supercharger inlet duct assembly.
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. Remove the air cleaner outlet duct (1). Refer to «Air Cleaner Outlet Duct Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
4. Disconnect the (PCV) hose fitting (1) from the underside of the inlet duct assembly.
5. Loosen the rear screw clamps (2) located between the front and rear section of the inlet duct assembly.
6. Remove all the ball studs (1) that retain the inlet duct to the supercharger. There are a total of 6 ball studs.
7. Remove the front section of the supercharger inlet duct.
8. Remove the hood assembly. Refer to «Hood Replacement»(/cadillac/xlr/i-2003-2009/remont/exterior-body-panels/#body-front-end) .
9. Remove supercharger assembly. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
10. Loosen the rear screw clamps on the inlet duct seal.
11. Remove the rear section of the supercharger inlet duct from the supercharger.

1. Install the rear section of the supercharger inlet duct assembly to the supercharger.
2. Tighten the rear screw clamps on the inlet duct seal. Tighten: Tighten the supercharger inlet seal screw clamps to 2.5 N.m (20 lb in).
3. Install the supercharger. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
4. Install the hood assembly. Refer to «Hood Replacement»(/cadillac/xlr/i-2003-2009/remont/exterior-body-panels/#body-front-end) .
5. Install the front section of the supercharger inlet duct to the vehicle.
6. Tighten the inlet duct screw clamps (2). Tighten: Tighten the supercharger inlet seal screw clamps to 2.5 N.m (20 lb in).
7. Install the ball studs (1) that retain the inlet duct to the supercharger. There are a total of 6 ball studs. Tighten: Tighten the supercharger inlet duct ball studs to 10 N.m (89 lb in).
8. Connect the (PCV) hose fitting (1) to the underside of the inlet duct assembly.
9. Install the air cleaner outlet duct (1). Refer to «Air Cleaner Outlet Duct Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
10. 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. Remove front section of the supercharger inlet duct. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
2. Loosen the screw clamps on the supercharger inlet duct seals.
3. Remove the supercharger inlet duct seals (2).
4. Remove the supercharger assembly. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
5. Remove the rear section of the supercharger inlet duct assembly. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
6. Loosen the screw clamp on the supercharger inlet duct seal.
7. Remove the supercharger inlet duct seal.

1. Install the supercharger inlet duct seal and clamp to the throttle body. Tighten the supercharger inlet duct seal screw clamp. Tighten: Tighten the supercharger inlet duct seal screw clamp to 2.5N.m (20 lb in).
2. Install the rear section of the supercharger inlet duct assembly to the supercharger. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) . Tighten: Tighten the supercharger inlet duct seal screw clamp to 2.5N.m (20 lb in).
3. Install the supercharger assembly. Refer to «Supercharger Replacement»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-1-of-5) .
4. Install the supercharger inlet duct seals and clamps (2) to the front section of the supercharger inlet duct.
5. Tighten the screw clamps on the supercharger inlet duct seals. Tighten: Tighten the supercharger inlet duct seal screw clamps to 2.5N.m (20 lb in).
6. Install the front section of the supercharger inlet duct. Refer to «Supercharger Inlet Duct Assembly Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .

1. Remove the air cleaner housing assembly splash shields, if necessary.
2. Release the air cleaner housing latches (1).
3. Open the air cleaner housing covers and remove the air cleaner filter elements (1).
4. Inspect the air cleaner housing for debris and clean if necessary.

1. Install the air cleaner filter elements (1) and housing covers to the air cleaner housing assembly.
2. Secure the air cleaner housing cover latches (1).
3. If previously removed, install the air cleaner housing assembly splash shields.

1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector.
2. Remove the MAF/IAT sensor if necessary. Refer to «Mass Airflow Sensor/Intake Air Temperature Sensor Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
3. Loosen the air cleaner outlet duct clamp at the supercharger inlet duct.
4. Remove the air cleaner housing from the vehicle.
5. Remove the air cleaner housing splash shields, if necessary.

1. Install the air cleaner housing splash shields to the air cleaner assembly if previously removed.
2. Install the air cleaner assembly to the vehicle.
3. Tighten the air cleaner outlet duct clamp at the supercharger inlet duct. Tighten: Tighten the air cleaner clamp to 3 N.m (27 lb in).
4. Install the MAF/IAT sensor if previously removed. Refer to «Mass Airflow Sensor/Intake Air Temperature Sensor Replacement»(/cadillac/xlr/i-2003-2009/remont/testing-diagnostics/#engine-controls-44l-introduction-2-of-2) .
5. Connect the MAF/IAT sensor electrical connector.

1. Loosen the air duct clamp at the supercharger inlet duct assembly.
2. Loosen the air duct clamp at the air cleaner housing assembly.
3. Remove the air cleaner duct from the vehicle.

1. Install the air cleaner duct to the vehicle.
2. Tighten the air cleaner duct clamps at the supercharger inlet duct and air cleaner housing assembly. Tighten: Tighten the air cleaner outlet duct clamps to 3 N.m (27 lb in).

Engine Control Module Description

The engine control module (ECM) interacts with many emission related components and systems, and monitors the emission related components and systems for deterioration. OBD II diagnostics monitor the system performance and a diagnostic trouble code (DTC) sets if the system performance degrades.

The malfunction indicator lamp (MIL) operation and the DTC storage are dictated by the DTC type. A DTC is ranked as a Type A or Type B if the DTC is emissions related. Type C is a non-emissions related DTC.

The ECM is in the engine compartment. The ECM is the control center of the engine controls system. The ECM controls the following components

1. The fuel injection system
2. The ignition system
3. The emission control systems
4. The on-board diagnostics
5. The A/C and fan systems
6. The throttle actuation control (TAC) system

The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect the vehicle performance and the emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the MIL. When the ECM detects a malfunction, the ECM stores a DTC. The condition area is identified by the particular DTC that is set. This aids the technician in making repairs.

ECM Function

The engine control module (ECM) can supply 5 volts or 12 volts to the various sensors or switches. This is done through pull-up resistors to the regulated power supplies within the ECM. In some cases, even an ordinary shop voltmeter will not give an accurate reading because the resistance is too low. Therefore, a DMM with at least 10 megohms input impedance is required in order to ensure accurate voltage readings.

The ECM controls the output circuits by controlling the ground or the power feed circuit through the transistors or a device called an output driver module.

EEPROM

The electronically erasable programmable read only memory (EEPROM) is a permanent memory that is physically part of the engine control module (ECM). The EEPROM contains program and calibration information that the ECM needs in order to control the powertrain operation.

Special equipment, as well as the correct program and calibration for the vehicle, are required in order to reprogram the ECM.

Data Link Connector (DLC)

The data link connector (DLC) is a 16-pin connector that provides the technician a means of accessing serial data for aid in the diagnosis. This connector allows the technician to use a scan tool in order to monitor the various serial data parameters, and display the DTC information. The DLC is located inside of the drivers compartment, underneath the dash.

Malfunction Indicator Lamp (MIL) Operation

The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON

Scheme 132

Scheme 133

The MIL indicates that an emissions related fault has occurred and vehicle service is required.

The following is a list of the modes of operation for the MIL

1. The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate.
2. The MIL turns OFF after the engine is started if a diagnostic fault is not present.
3. The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate.
4. The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter.
5. When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON.
6. When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON.

ECM Service Precautions

The engine control module (ECM), by design, can withstand the normal current draws that are associated with the vehicle operations. However, care must be used in order to avoid overloading any of these circuits. When testing for opens or shorts, do not ground or apply voltage to any of the ECM circuits unless the diagnostic procedure instructs you to do so. These circuits should only be tested with a DMM.

Emissions Diagnosis For State I/M Programs

This OBD II equipped vehicle is designed to diagnose any conditions that could lead to excessive levels of the following emissions

1. Hydrocarbons (HC)
2. Carbon monoxide (CO)
3. Oxides of nitrogen (NOx)
4. Evaporative emission (EVAP) system losses

Should this vehicles on-board diagnostic system (ECM) detect a condition that could result in excessive emissions, the ECM turns ON the malfunction indicator lamp (MIL) and stores a DTC that is associated with the condition.

Aftermarket (Add-On) Electrical And Vacuum Equipment

Note. Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or systems.

Note. Connect any add-on electrically operated equipment to the vehicle's electrical system at the battery (power and ground) in order to prevent damage to the vehicle.

Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a vehicle after leaving the factory that connects to the vehicles electrical or vacuum systems. No allowances have been made in the vehicle design for this type of equipment.

Add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include equipment not connected to the vehicle electrical system, such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain condition is to eliminate all of the aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, the problem may be diagnosed in the normal manner.

Electrostatic Discharge (ESD) Damage

The electronic components that are used in the control systems are often designed to carry very low voltage. The electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components.

There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat.

Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore, it is important to use care when handling and testing electronic components.

Emissions Control Information Label

The underhood Vehicle Emissions Control Information Label contains important emission specifications and setting procedures. In the upper left corner is the exhaust emission information. This identifies the year, the manufacturing division of the engine, the displacement of the engine in liters, the class of the vehicle, and type of fuel metering system. There is also an illustrated emission components and vacuum hose schematic.

This label is located in the engine compartment of every General Motors vehicle. If the label has been removed, it can be ordered from GM service parts operations (GMSPO).

Underhood Inspection

Perform a careful underhood inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a condition without further steps. Use the following guidelines when performing an inspection

1. Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects.
2. Inspect any hoses that are difficult to see.
3. Inspect all of the wires in the engine compartment for the following conditions: Burned or chafed spots Pinched wires Contact with sharp edges Contact with hot exhaust manifolds

Description

The LC3 supercharger is a positive displacement pump that consists of 2 counter-rotating rotors, an inlet port and an outlet port, and an air bypass valve that is built into a housing. The rotors are designed with 3 lobes and a helical twist. An air bypass valve is built into the housing. The rotors in the supercharger are designed to run at a minimal clearance, not in contact with each other or the housing and are timed to each other by a pair of precision spur gears which are pressed onto the rotor shafts. The front ends of the rotors are held in position by deep-groove ball bearings, while the rear ends of the rotors are supported by sealed roller bearings.

The gears and ball bearings are lubricated by a synthetic oil. The oil reservoir is self-contained in the supercharger, isolated from the engine oil, sealed for the life of the unit and is not serviceable.

The cover on the supercharger contains the input shaft which is supported by 2 deep-groove ball bearings, and is coupled to the rotor drive gears. The pulley is pressed onto the input shaft and is not serviceable. The bearings are lubricated by the synthetic oil contained in the same reservoir.

Operation

The supercharger is designed to increase the air pressure and density in the intake manifold. When this air is mixed with the correct amount of fuel the result is more power from the engine. This excess air creates a boost pressure in the intake manifold with a maximum engine boost of 83 kPa (12 psi). Because the supercharger is a positive displacement pump and is directly driven from the engine drive belt system, boost pressure is available at all driving conditions.

When boost is not required, such as during idle or light throttle cruising, the excess air is routed through the bypass passage between the intake manifold and the supercharger inlet. This bypass circuit is regulated by a bypass valve which is similar to a throttle plate. The bypass valve is controlled by a vacuum actuator which is connected to the vacuum signal between the throttle and the supercharger inlet. Spring force from the actuator holds the valve in a normally closed position to create boost, and vacuum pulls the valve open when the throttle closes to decrease boost.

A solenoid valve is attached to the supercharger housing. This three-way valve, controlled by the engine control module (ECM), determines whether pressure from the manifold is routed to the bypass actuator or closed off. This valve allows pressure from the manifold to open the bypass valve and lower boost pressure during specific driving conditions. The open bypass valve reduces the pumping effort of the supercharger, thereby increasing the fuel efficiency in light load operations.

Intercooler XLR V

The supercharger has an integrated intercooler. Cooling the air enhances the effectiveness of the supercharger. The intercooler uses conventional coolant in a separate sealed system from the engine cooling system. The intercooler system has a radiator, a back fill port at the rear of the supercharger, attaching hoses, and a pump capable of a flow rate of 22 liters (6 gallons) per minute. The pump is commanded ON, by the control module, whenever the engine is running, intake air temperature (IAT) sensor 2 is more than 0°C (32°F), intake air temperature (IAT) sensor is more than -25°C (-13°F), and engine run time is more than 10 seconds.

Scheme 134

Scheme 135

Supercharger boost pressure is regulated to prevent engine and drive train damage. When the engine is operating under high boost conditions, the engine control module (ECM) limits boost pressure to 83 kPa (12 psi). The ECM disables boost under the following conditions

1. When reverse gear is selected, boost is disabled.
2. When drivetrain abuse is detected, boost is disabled.
3. If an electronic throttle control (ETC) fault is detected, boost is disabled.
4. If the coolant temperature is more than 125°C (257°F), boost is disabled.
5. If an intercooler pump failure is detected, boost is disabled.
6. If the intake air temperature (IAT) sensor 2 becomes excessively high, equal to or more than 120.5°C (248°F), boost pressure is limited to 145 kPa (7 psi). The ECM commands the boost control solenoid to 62 percent DC.
7. If vehicle speeds exceed 159 mph in third, second, and fourth gears only, after 150 seconds boost is trimmed actively.
8. If the intake cam phasers are inoperable, boost pressure is limited to 145 kPa (7 psi). The ECM commands the boost control solenoid to 62 percent DC.

The ECM controls boost pressure by using the boost control solenoid. The boost control solenoid is normally an open valve. Under most conditions, the ECM commands the boost control solenoid to operate at a 99-100 percent duty cycle. This keeps the solenoid valve closed and allows only inlet vacuum to control the position of the bypass valve. At idle, engine vacuum is applied to the upper side of the bypass valve actuator, counteracting spring tension to hold the bypass valve open. As engine load is increased, engine vacuum is decreased, causing the spring in the bypass valve actuator to overcome the applied vacuum, closing the bypass valve and allowing the boost pressure to increase. The bypass valve starts to close when the vacuum measures 250 mm Hg (10 in Hg) and is fully closed at 90 mm Hg (3.5 in Hg). When reduced boost pressure is desired, the ECM commands the boost control solenoid to operate at a 0 percent duty cycle, but may command a partial duty cycle, approximately 62 percent, depending on the operating condition. This opens the solenoid valve and allows boost pressure to enter the bypass valve actuator at the lower side to counteract the spring tension, opening the bypass valve and re-circulating excess boost pressure back into the supercharger inlet.

Results of Incorrect Operation

An open boost control solenoid control circuit, an open ignition 1 circuit, or boost control solenoid valve stuck open will cause reduced engine power, especially during wide open throttle operation.

If the boost control solenoid control circuit is shorted to ground, the boost control solenoid valve is stuck closed or a restriction in the boost source or signal hoses will cause full boost to be commanded at all times and a possible overboost condition during high engine load situations.

A restriction in the exhaust system may cause an overboost condition and reduced fuel economy.

A restriction in the vacuum signal hose to the bypass valve actuator or a stuck closed bypass valve will cause a noisy idle and reduced fuel economy.

TAC System

The throttle actuator control (TAC) system delivers improved throttle response and greater reliability and eliminates the need for a mechanical cable. The TAC system performs the following functions

1. Accelerator pedal position sensing
2. Throttle positioning to meet driver and engine demands
3. Throttle position sensing
4. Internal diagnostics
5. Cruise control functions
6. Manage TAC electrical power consumption

The TAC system includes the following components

1. The accelerator pedal position (APP) sensors
2. The throttle body assembly
3. The engine control module (ECM)

Accelerator Pedal Position (APP) Sensor

The accelerator pedal contains 2 individual sensors within the assembly. The accelerator pedal position (APP) sensors 1 and 2 are potentiometer type sensors, each with the following 3 circuits

1. A 5-volt reference circuit
2. A low reference circuit
3. A signal circuit

The APP sensors are used to determine the pedal angle. The engine controls module (ECM) provides each APP sensor with a 5-volt reference circuit and a low reference circuit. The APP sensors provide the ECM with signal voltage proportional to the pedal movement. The APP sensor 1 signal voltage at rest position is near low reference and increases as the pedal is actuated. The APP sensor 2 signal voltage at rest position is near low reference and increases as the pedal is actuated.

Throttle Body Assembly

The throttle body assembly contains the following components

1. The throttle blade
2. The throttle actuator motor
3. The throttle position (TP) sensor 1 and 2

The throttle body functions are similar to a conventional throttle body with the following exceptions

1. An electric motor opens and closes the throttle valve.
2. The throttle blade is spring loaded in both directions and the default position is slightly open.
3. There are 2 individual TP sensors within the throttle body assembly.

TP sensors are sensors 1 and 2 are potentiometer type sensors, they are used to determine the throttle plate angle. The TP sensors provide the engine control module (ECM) with a signal voltage proportional to throttle plate movement. The TP sensor 1 signal voltage at closed throttle is near the 5-volt reference voltage and decreases as the throttle plate is opened. The TP sensor 2 signal voltage at closed throttle is near the low reference voltage and increases as the throttle plate is opened. Each TP sensor has a signal circuit and they both share a 5-volt reference and a low reference circuits.

Engine Control Module

The engine control module (ECM) is the control center for the throttle actuator control (TAC) system. The ECM determines the drivers intent, then calculates the appropriate throttle response. The ECM achieves throttle positioning by providing a pulse width modulated voltage to the TAC motor.

Normal Mode

During the operation of the TAC system, several modes or functions are considered normal. The following modes may be entered during normal operation

1. Minimum pedal value-At key-up, the ECM updates the learned minimum pedal value.
2. Minimum TP values-At key-up, the ECM updates the learned minimum TP value. In order to learn the minimum TP value, the throttle blade is moved to the closed position.
3. Ice break mode-If the throttle is not able to reach a predetermined minimum throttle position, the ice break mode is entered. During the ice break mode, the ECM commands the maximum pulse width several times to the throttle actuator motor in the closing direction.
4. Battery saver mode-After a predetermined time without engine RPM, the ECM commands the battery saver mode. During the battery saver mode, the TAC module removes the voltage from the motor control circuits, which removes the current draw used to maintain the idle position and allows the throttle to return to the spring loaded default position.

Reduced Engine Power Mode

When the ECM detects a condition with the TAC system, the ECM may enter a reduced engine power mode. Reduced engine power may cause one or more of the following conditions

1. Acceleration limiting-The ECM will continue to use the accelerator pedal for throttle control however, the vehicle acceleration is limited.
2. Limited throttle mode-The ECM will continue to use the accelerator pedal for throttle control however, the maximum throttle opening is limited.
3. Throttle default mode-The ECM will turn OFF the throttle actuator motor and the throttle will return to the spring loaded default position.
4. Forced idle mode-The ECM will perform the following actions: Limit engine speed to idle by positioning the throttle position, or by controlling the fuel and spark if the throttle is turned OFF Ignore the accelerator pedal input
5. Engine shutdown mode-The ECM will disable the fuel and de-energize the throttle actuator

Camshaft Actuator System Description

The camshaft position (CMP) actuator system is used for a variety of engine performance enhancements. The CMP actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. These enhancements include the following

1. Lower emission output through exhaust gas recirculation (EGR) control
2. A wider engine torque range
3. Improved gas mileage
4. Improved engine idle stability

The CMP actuator system is comprised of the following components

1. Four CMP actuator solenoids
2. Four oil control valves
3. Four vane style CMP actuators
4. Four CMP sensors

The CMP actuator system requires a very complex electrical signal from the engine control module (ECM) in order to control the position of the CMP actuators. The electrical signal requires use of an un-fixed pulse width modulation (PWM) signal as well as 2 different operating frequencies of 150 and 500 Hz. Changes in the PWM can happen every 100 milliseconds and thus makes it difficult to measure the correct PWM or frequency with a DMM during CMP actuator control. At idle, the ECM commands a consistent 7 percent duty cycle at 150 Hz. The ECM uses this signal in order to sense certain circuit failures.

Scheme 136

The CMP actuator solenoids, or electromagnets, are located on the front of the engine and are mounted to their corresponding bank CMP actuator housing.

The oil control valves are threaded, and attach the CMP actuators to the front of the camshafts. The oil control valve meters the oil flow to the CMP actuator through the advancing and retarding oil ports. With no command fro the ECM, all of the oil is ported to the advancing chambers of the exhaust CMP actuators and to the retarding chambers of the intake CMP actuators. With full command from the ECM, all of the oil is ported to the retarding chambers of the exhaust CMP actuators and to the advancing chambers of the intake CMP actuators. When the intake or exhaust camshafts reach a desired position, above 0 degrees on the scan tool, the ECM will apply an electrical signal to the solenoids in order to hold the CMP actuators in the desired position. The oil control valves will port engine oil evenly to the advancing and retarding chambers of the CMP actuators in order to hold the camshafts in the desired position. The oil control valves will allow enough engine oil to flow to compensate for any leakage past the CMP actuators in order to hold the camshafts in a steady position.

The CMP actuators interface the timing chain to the camshafts, and are able to change the camshaft timing in relation to the crankshaft. The intake CMP actuators have the ability to move the intake camshafts a total of 40 degrees from the parked position. The exhaust CMP actuators have the ability to move the exhaust camshafts a total of 50 degrees from the parked position. With the engine OFF or with the CMP actuators not commanded, the exhaust CMP actuators are parked at the full advance position of 133 degrees ATDC and the intake CMP actuators are parked at the full retard position of 117 degrees before top dead center (BTDC). The CMP Angle parameters on the scan tool will indicate 0 degrees with the engine running and the CMP actuators in the parked position for both exhaust and intake camshafts.

A locking pin keeps the CMP actuators in the parked position in order to avoid valve train noise upon engine start-up. The locking pin will release the actuator after the engine oil pressure is sufficient to overcome the locking pin spring pressure. The exhaust CMP actuators have return springs. The return springs are necessary to assist the CMP actuators to return to the parked position due to the rotational inertia of the valve train components upon engine shutdown.

An oil outlet tube is used to transfer oil from a dedicated oil galley in the engine block, from the replaceable oil filter, up to each head and is located in the timing chain area. The oil outlet tube incorporates a non-replaceable 40 micron oil filter. If the filter becomes clogged with contamination and can not be cleaned, the tube and filter must be replaced as an assembly. Engine oil pressure, level, viscosity, and temperature can have an adverse affect on the CMP actuator performance.

The CMP sensors are used by the ECM to monitor the position of the camshafts. The intake cam sensor wheels have 4X targets. The exhaust cam sensor wheels have a 4X target. The ECM can detect a camshaft position variance as small as 4 degrees. The variance is the difference between the actual camshaft position and the desired camshaft position. A CMP actuator performance DTC will set if the ECM detects the camshaft position has a 4 degree to 11 degree variance. A 4 degree variance takes more time for the ECM to detect than an 11 degree variance. A crankshaft to camshaft correlation DTC will set if the ECM detects a 12 degree variance or more.

If a CMP actuator system DTC is present, the ECM will disable the CMP actuator system control for that ignition cycle.

CMP Actuator System Operation

The engine control module (ECM) sends an electrical signal to the camshaft position (CMP) actuator solenoids through the control circuits when a camshaft timing change is desired. The ground circuit of the CMP actuator solenoid is used as a return. The CMP actuator solenoid uses electromagnetic force to pull on the plunger of the oil control valve. The oil control valve will port the pressurized engine oil to either the advancing or retarding chambers of the CMP actuator. The CMP actuator, in turn, changes the camshaft position relative to crankshaft position. The ECM uses the CMP sensors to determine the position of the camshafts.

The ECM calculates the optimum CMP through the following inputs

1. Engine speed
2. Throttle position indicated angle
3. Crankshaft position (CKP)
4. CMP
5. Engine load
6. Barometric pressure (BARO)
7. Intake air temperature (IAT)

The ECM monitors the following inputs before assuming control of the CMP actuator system

1. Engine coolant temperature (ECT)
2. Loop status
3. Calculated engine oil temperature (EOT)
4. Engine oil pressure (EOP)
5. Engine oil level
6. Crankshaft/camshaft correlation
7. Ignition 1 signal voltage
8. Barometric pressure (BARO)

System Overview

The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions.

Two fuel tanks store the fuel supply. An electric turbine style fuel pump (13) attaches to the fuel sender assembly inside the left fuel tank. The fuel pump supplies high pressure fuel through the fuel filter (17) and the fuel feed pipe (3) to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to the venturi pump (14) located on the bottom of the left fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir (12). The primary fuel pressure regulator (15), a part of the left fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve (16). The check valve, the primary fuel pressure regulator, and the secondary fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times.

The fuel pump also supplies a small amount of pressurized fuel through the auxiliary fuel feed pipe (4) to the siphon jet pump (9) inside the right fuel tank. The pressurized fuel creates a venturi action inside the siphon jet pump. The venturi action causes the fuel to be drawn out of the right fuel tank. The fuel transfers from the right fuel tank to the left fuel tank through the auxiliary fuel return pipe (5). The auxiliary fuel return pipe inside the left fuel tank contains an anti-siphon hole (11) in order to prevent fuel from siphoning from the left fuel tank into the right fuel tank. Both the auxiliary fuel feed pipe and the auxiliary fuel return pipe are located inside the convoluted stainless steel crossover hose (10).

The right fuel sender assembly contains a secondary fuel pressure regulator (8). The secondary fuel pressure regulator has a lower set point than the primary regulator in order to allow fuel to flow to the siphon jet pump on the right fuel sender. When the engine is shut off, the pressure in the feed pipes immediately drops to the secondary regulator set point. This prevents the siphon jet pump from operating and in turn prevents the equalization of the left and right fuel tanks. The secondary fuel pressure regulator maintains fuel pressure in the auxiliary fuel feed pipe which reduces the time to prime the siphon jet pump. The pressurization also reduces fuel vaporization and boiling in the auxiliary fuel feed pipe.

Scheme 137

The fuel tanks (6, 8) store the fuel for the vehicle. The fuel tanks are located on the left and right side of the vehicle in front of the rear wheels. The fuel tanks are molded from high density polyethylene.

Fuel Tank Fill Pipe and Hose

The fuel tank fill pipe is positioned at the rear of the vehicle on the left side. A built in restrictor in the fuel tank fill pipe prevents refueling with leaded fuel. The fuel tank fill pipe connects to the left fuel tank with a rubber hose. Fuel transfers to the right fuel tank during fueling by a stainless steel convoluted crossover tube/hose which connects the left fuel tank to the right fuel tank.

Scheme 138

Note. If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a serious malfunction of the fuel and EVAP system.

The fuel tank filler pipe has a tethered fuel tank filler cap. The fuel tank filler cap requires a quarter of a turn in order to be removed. A torque limiting device prevents the cap from being over tightened.

Scheme 139

A fuel sender assembly is located inside each fuel tank. The fuel sender assembly attaches to the top of each fuel tank. The left fuel sender assembly consists of the following major components

1. The fuel level sensor
2. The fuel pump and reservoir assembly
3. The fuel pump strainer
4. The fuel filter (4)
5. The primary fuel pressure regulator (9)

Scheme 140

The right fuel sender assembly consists of the following major components

1. The fuel level sensor (7)
2. The siphon jet pump (5)
3. The secondary fuel pressure regulator (2)
4. The fill limiter vent valve (FLVV)

Fuel Level Sensor

The fuel level sensor consists of a float, a wire float arm, and a variable resistor. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes the resistance corresponding to the amount of fuel in the fuel tanks. The ECM uses inputs from both fuel level sensors in order to calculate the total fuel remaining in both fuel tanks. This information is sent via a Class 2 message to the instrument panel cluster (IPC) to be displayed on the fuel gage.

Fuel Pump

An electric turbine style fuel pump attaches to the fuel sender assembly inside the left fuel tank. The fuel pump supplies fuel to the fuel rail assembly at a specified flow and pressure. The fuel pump delivers a constant flow of fuel to the engine even during low fuel conditions and aggressive vehicle maneuvers. The ECM controls the electric fuel pump operation through a fuel pump relay.

The fuel pump also supplies a small amount of pressurized fuel to the right fuel tank siphon jet pump through the auxiliary fuel feed pipe. The pressurized fuel creates a venturi action inside the siphon jet pump. The venturi action causes the fuel to be drawn out of the right fuel tank. Fuel is then transferred from the right fuel tank to the left fuel tank through the auxiliary fuel return pipe. The fuel pump also supplies fuel to a venturi pump located on the bottom of the left fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir.

Fuel Strainer

The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter the contaminants and to wick the fuel. The fuel strainer attaches to the bottom of the fuel pump inside of the fuel sender reservoir. The fuel strainer normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tanks contain an abnormal amount of sediment. If the fuel strainer is plugged, refer to Fuel System Cleaning .

Fuel Filter

The fuel filter is contained in the fuel sender assembly inside the left fuel tank. The paper filter element of the fuel filter traps particles in the fuel that may damage the fuel injection system. The fuel filter housing is made to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There is no service interval for fuel filter replacement.

Primary Fuel Pressure Regulator

The primary fuel pressure regulator is contained in the left fuel sender assembly. The fuel pressure regulator is a diaphragm relief valve. The diaphragm has fuel pressure on one side and regulator spring pressure on the other side. A software bias compensates the injector on-time because the fuel pressure regulator is not referenced to the manifold vacuum. The primary fuel pressure regulator keeps fuel available to the injectors at a regulated pressure.

Secondary Fuel Pressure Regulator

The right fuel sender assembly contains a secondary fuel pressure regulator. The secondary fuel pressure regulator has a lower set point than the primary regulator in order to allow fuel to flow to the siphon jet pump on the right fuel sender. When the engine is shut off, the pressure in the feed pipes immediately drops to the secondary regulator set point. This prevents the siphon jet pump from operating and in turn prevents the equalization of the left and right fuel tanks. The secondary fuel pressure regulator maintains fuel pressure in the auxiliary fuel feed pipe which reduces the time to prime the siphon jet pump. The pressurization also reduces fuel vaporization and boiling in the auxiliary fuel feed pipe.

Fuel Feed and Return Pipes

The engine compartment connecting fuel pipe connects the chassis fuel pipe to the fuel rail assembly. The engine compartment fuel pipe is constructed of Teflon® with a braided stainless steel covering.

The chassis fuel pipe is located under the vehicle on the left side of the tunnel. The chassis fuel pipe connects the rear fuel feed pipe from the left fuel sender assembly to the engine compartment connecting fuel pipe. The chassis fuel pipe is constructed of aluminum with a plastic coating.

The rear fuel feed pipe connects the left fuel sender fuel pipe to the chassis fuel pipe. The rear fuel feed pipe is constructed of nylon with a covering of heat resistant rubber hose.

The auxiliary fuel feed pipes and the auxiliary fuel return pipes are located inside of the fuel crossover hose and inside of each fuel tank. The fuel pump supplies fuel through the auxiliary fuel feed pipe to the siphon jet pump inside the right fuel tank. The siphon jet pump transfers fuel from the right fuel tank to the left fuel tank through the auxiliary fuel return pipe. The return pipe feeds returning fuel from the right fuel tank directly into the left fuel sender reservoir. The auxiliary fuel feed and return pipes are constructed of nylon.

Scheme 141

The fuel tank crossover tube/hose is comprised of a convoluted stainless steel outer tubing. The crossover tube/hose internally houses the auxiliary fuel feed pipe and the auxiliary fuel return pipe. The crossover tube/hose has the following functions

1. Fuel liquid and vapor transfer during refueling
2. High pressure siphon jet pump feed
3. Low pressure siphon jet pump return
4. Electrostatic discharge ground to body

Nylon Fuel Pipes

Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There are 2 sizes of nylon fuel pipes used. A 9.53 mm (3/8 in) ID pipe is used for the fuel feed pipe and the auxiliary fuel return pipe. A 7.94 mm (5/16 in) ID pipe is used for the auxiliary fuel feed pipe. Heat resistant rubber hose protects the section of the rear fuel feed pipe that is exposed to chafing, high temperature or vibration.

Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes will kink and restrict the fuel flow. Also, once exposed to the fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes.

Quick-Connect Fittings

Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings located inside the female connector provide the fuel seal. Integral locking tabs located inside the female connector hold the fittings together.

Scheme 142

The on-board refueling vapor recovery system (ORVR) is an on board vehicle system designed to recover fuel vapors during the vehicle refueling operation. The flow of liquid fuel down the fuel filler pipe provides a liquid seal which prevents vapor from leaving the fuel filler pipe. An EVAP pipe transports the fuel vapor to the EVAP canister for use by the engine. Listed below are the ORVR system components with a brief description of their operation

1. The EVAP canister (1)-the EVAP canister receives refueling vapor from the fuel system, stores the vapor and releases the vapor to the engine upon demand.
2. The EVAP pipes (2)-transports fuel vapor from the fuel tank to the EVAP canister.
3. The fuel filler pipe (3)-the pipe which carries fuel from the fuel nozzle to the fuel tank.
4. The check valve (4)-the check valve limits fuel "spit back" from the fuel tank during the refueling operation by allowing fuel flow only into the fuel tank. This check valve is located at the bottom of the fuel filler pipe.
5. The modular fuel sender assembly (5)-this assembly pumps fuel to the engine from the fuel tank.
6. The fill limiter vent valve (FLVV) (6)-this valve acts as a shut off valve. The FLVV is located on the right fuel sender. This valve is not serviced separately. The FLVV has the following functions: Controls the fuel tank fill level by closing the primary vent from the fuel tank. Prevents the fuel from exiting the fuel tank via the EVAP pipe to the canister. Provides fuel-spillage protection in the event of a vehicle rollover by closing the vapor path from the fuel tank to the EVAP canister.

Scheme 143

The fuel rail assembly attaches to the engine intake manifold. The fuel rail assembly performs the following functions

1. Positions the injectors in the intake manifold
2. Distributes the fuel evenly to the injectors
3. Integrates the fuel pulse dampener into the fuel metering system

Fuel Injectors

The fuel injector assembly is a solenoid device, controlled by the ECM, that meters pressurized fuel to a single engine cylinder. The ECM energizes the injector solenoid to open a normally closed ball valve. This allows the fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has machined holes that control the fuel flow, generating a spray of finely-atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions.

Fuel Metering Modes of Operation

The ECM monitors voltages from several sensors in order to determine how much fuel to give the engine. The ECM controls the amount of fuel delivered to the engine by changing the fuel injector pulse width. The fuel is delivered under one of several modes.

Starting Mode

When the ignition is first turned ON, the ECM energizes the fuel pump relay for 2 seconds. This allows the fuel pump to build pressure in the fuel system. The ECM calculates the air/fuel ratio based on inputs from the engine coolant temperature (ECT), mass air flow (MAF), manifold absolute pressure (MAP), and throttle position (TP) sensors. The system stays in starting mode until the engine speed reaches a predetermined RPM.

Clear Flood Mode

If the engine floods, clear the engine by pressing the accelerator pedal down to the floor and then crank the engine. When the TP sensor is at wide open throttle (WOT), the ECM reduces the fuel injector pulse width in order to increase the air to fuel ratio. The ECM holds this injector rate as long as the throttle stays wide open and the engine speed is below a predetermined RPM. If the throttle is not held wide open, the ECM returns to the starting mode.

Run Mode

The run mode has 2 conditions called Open Loop and Closed Loop. When the engine is first started and the engine speed is above a predetermined RPM, the system begins Open Loop operation. The ECM ignores the signal from the heated oxygen sensors (HO2S). The ECM calculates the air/fuel ratio based on inputs from the ECT, MAF, MAP, and TP sensors. The system stays in Open Loop until meeting the following conditions

1. Both front HO2S have varying voltage output, showing that both HO2S are hot enough to operate properly.
2. The ECT sensor is above a specified temperature.
3. A specific amount of time has elapsed after starting the engine.

Specific values for the above conditions exist for each different engine, and are stored in the electrically erasable programmable read-only memory (EEPROM). The system begins Closed Loop operation after reaching these values. In Closed Loop, the ECM calculates the air/fuel ratio, injector ON time, based upon the signal from various sensors, but mainly from the HO2S. This allows the air/fuel ratio to stay very close to 14.7:1.

Acceleration Mode

When the driver pushes on the accelerator pedal, air flow into the cylinders increases rapidly. To prevent possible hesitation, the ECM increases the pulse width to the injectors to provide extra fuel during acceleration. This is also known as power enrichment. The ECM determines the amount of fuel required based upon the TP, the ECT, the MAP, the MAF, and the engine speed.

Deceleration Mode

When the driver releases the accelerator pedal, air flow into the engine is reduced. The ECM monitors the corresponding changes in the TP, the MAP, and the MAF. The ECM shuts OFF fuel completely if the deceleration is very rapid, or for long periods, such as long, closed-throttle coast-down. The fuel shuts OFF in order to prevent damage to the catalytic converters.

Battery Voltage Correction Mode

When the battery voltage is low, the ECM compensates for the weak spark delivered by the ignition system in the following ways

1. Increasing the amount of fuel delivered
2. Increasing the idle RPM
3. Increasing the ignition dwell time

Fuel Cutoff Mode

The ECM cuts OFF fuel from the fuel injectors when the following conditions are met in order to protect the powertrain from damage and improve driveability

1. The ignition is OFF. This prevents engine run-on.
2. The ignition is ON but there is no ignition reference signal. This prevents flooding or backfiring.
3. The engine speed is too high, above red line.
4. The vehicle speed is too high, above rated tire speed.
5. During an extended, high speed, closed throttle coast down-This reduces emissions and increases engine braking.
6. During extended deceleration, in order to prevent damage to the catalytic converters

Fuel Trim

The ECM controls the air/fuel metering system in order to provide the best possible combination of driveability, fuel economy, and emission control. The ECM monitors the HO2S signal voltage while in Closed Loop and regulates the fuel delivery by adjusting the pulse width of the injectors based on this signal. The ideal fuel trim values are around 0 percent for both short and long term fuel trim. A positive fuel trim value indicates the ECM is adding fuel in order to compensate for a lean condition by increasing the pulse width. A negative fuel trim value indicates that the ECM is reducing the amount of fuel in order to compensate for a rich condition by decreasing the pulse width. A change made to the fuel delivery changes the long and short term fuel trim values. The short term fuel trim values change rapidly in response to the HO2S signal voltage. These changes fine tune the engine fueling. The long term fuel trim makes coarse adjustments to fueling in order to re-center and restore control to short term fuel trim. A scan tool can be used to monitor the short and long term fuel trim values. The long term fuel trim diagnostic is based on an average of several of the long term speed load learn cells. The ECM selects the cells based on the engine speed and engine load. If the ECM detects an excessively lean or rich condition, the ECM will set a fuel trim diagnostic trouble code (DTC).

EVAP System Operation

The evaporative emission (EVAP) control system limits fuel vapors from escaping into the atmosphere. Fuel tank vapors move from the fuel tank, due to pressure in the tank, through the vapor pipe, into the EVAP canister. Carbon in the canister absorbs and stores the fuel vapors. Excess pressure is vented through the vent line and EVAP vent solenoid to the atmosphere. The EVAP canister stores the fuel vapors until the engine is able to use them. At an appropriate time, the control module will command the EVAP purge solenoid ON, allowing engine vacuum to be applied to the EVAP canister. With the EVAP vent solenoid OFF, fresh air is drawn through the vent solenoid and the vent line to the EVAP canister. Fresh air is drawn through the canister, pulling fuel vapors from the carbon. The air/fuel vapor mixture continues through the EVAP purge pipe and EVAP purge solenoid into the intake manifold to be consumed during normal combustion. The control module uses several tests to determine if the EVAP system is leaking.

Large Leak Test

This tests for large leaks and blockages in the EVAP system. The control module commands the EVAP vent solenoid ON and commands the EVAP purge solenoid ON, with the engine running, allowing engine vacuum into the EVAP system. The control module monitors the fuel tank pressure (FTP) sensor voltage to verify that the system is able to reach a predetermined level of vacuum within a set amount of time. The control module then commands the EVAP purge solenoid OFF, sealing the system, and monitors the vacuum level for decay. If the control module does not detect that the predetermined vacuum level was achieved, or the vacuum decay rate is more than a calibrated level on 2 consecutive tests, DTC P0455 will set.

Small Leak Test

The engine off natural vacuum (EONV) diagnostic is the small-leak detection diagnostic for the EVAP system. The EONV diagnostic monitors the EVAP system pressure or vacuum with the key OFF. Because of this, it may be normal for the control module to remain active for up to 40 minutes after the engine is turned OFF. This is important to remember when performing a parasitic draw test on vehicles equipped with EONV.

The EONV utilizes the temperature changes and the resulting naturally occurring vacuum or pressure in the fuel tank immediately following a drive cycle. When the vehicle is driven, the temperature rises in the tank. After the vehicle is parked, the temperature in the tank continues to rise for a period of time, then begins to decrease. The EONV diagnostic relies on this temperature change and it's corresponding pressure change to determine if an EVAP system leak is present.

The EONV diagnostic is designed to detect leaks as small as 0.51 mm (0.020 inches). The diagnostic can determine if a small leak is present based on vacuum or pressure readings in the EVAP system. When the system is sealed, a finite amount of pressure or vacuum will be observed. When a 0.51 mm (0.020 inches) leak is present, little or no pressure or vacuum is observed. If the test reports a failing value, DTC P0442 will set.

Canister Vent Restriction Test

If the EVAP vent system is restricted, fuel vapors will not be properly purged from the EVAP canister. The control module tests this by commanding the EVAP purge solenoid ON, commanding the EVAP vent solenoid OFF, and monitoring the FTP sensor for an increase in vacuum. If the vacuum increases more than a calibrated value, DTC P0446 will set.

Purge Solenoid Leak Test

If the EVAP purge solenoid does not seal properly fuel vapors could enter the engine at an undesired time, causing driveability concerns. The control module tests for this by commanding the EVAP purge solenoid OFF and the vent solenoid ON, sealing the system, and monitors the FTP for an increase in vacuum. If the control module detects that the EVAP system vacuum increases above a calibrated value, DTC P0496 will set.

Check Gas Cap Message

The PCM sends a class 2 message to the driver information center (DIC) illuminating the Check Gas Cap message when any of the following occur

1. A malfunction in the EVAP system and a large leak test fails
2. A malfunction in the EVAP system and a small leak test fails

EVAP System Components

The EVAP system consists of the following components

EVAP Canister

The canister is filled with carbon pellets used to absorb and store fuel vapors. Fuel vapor is stored in the canister until the control module determines that the vapor can be consumed in the normal combustion process.

EVAP Purge Solenoid

The EVAP purge solenoid controls the flow of vapors from the EVAP system to the intake manifold. The purge solenoid opens when commanded ON by the control module. This normally closed solenoid is pulse width modulated (PWM) by the control module to precisely control the flow of fuel vapor to the engine. The solenoid will also be opened during some portions of the EVAP testing, allowing engine vacuum to enter the EVAP system.

EVAP Vent Solenoid

The EVAP vent solenoid controls fresh airflow into the EVAP canister. The solenoid is normally open. The control module commands the solenoid ON, closing the solenoid during some EVAP tests, allowing the system to be tested for leaks.

Fuel Tank Pressure Sensor

The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure.

EVAP Service Port

The EVAP service port is located in the EVAP purge pipe between the EVAP purge solenoid and the EVAP canister. The service port is identified by a green colored cap.

Electronic Ignition (EI) System Operation

The electronic ignition (EI) system produces and controls the high energy secondary spark. This spark ignites the compressed air/fuel mixture at precisely the correct time, providing optimal performance, fuel economy, and control of exhaust emissions. The engine control module (ECM) primarily collects information from the crankshaft position (CKP) and camshaft position (CMP) sensors to control the sequence, dwell, and timing of the spark.

The crankshaft position (CKP) sensor circuits consist of an engine control module (ECM) supplied 5-volt reference circuit, a low reference circuit, and an output signal circuit. The CKP sensor is an internally magnetic biased digital output integrated circuit sensing device. The sensor detects magnetic flux changes of the teeth and slots of a 58-tooth reluctor wheel on the crankshaft. Each tooth on the reluctor wheel is spaced at 60-tooth spacing, with 2 missing teeth for the reference gap. The CKP sensor produces an ON/OFF DC voltage of varying frequency, with 58 output pulses per crankshaft revolution. The frequency of the CKP sensor output depends on the velocity of the crankshaft. The CKP sensor sends a digital signal, which represents an image of the crankshaft reluctor wheel, to the ECM as each tooth on the wheel rotates past the CKP sensor. The ECM uses each CKP signal pulse to determine crankshaft speed and decodes the crankshaft reluctor wheel reference gap to identify crankshaft position. This information is then used to determine the optimum ignition and injection points of the engine. The ECM also uses CKP sensor output information to determine the camshaft relative position to the crankshaft, to control camshaft phasing, and to detect cylinder misfire.

Crankshaft Reluctor Wheel

The crankshaft reluctor wheel is part of the crankshaft. The reluctor wheel consists of 58 teeth and a reference gap. Each tooth on the reluctor wheel is spaced 6 degrees apart with a 12-degree space for the reference gap. The pulse from the reference gap is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position, while the other teeth provide cylinder location during a revolution.

Camshaft Position (CMP) Sensor

The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built onto the exhaust camshaft sprocket. The CMP sensor provides four signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size which is used to identify the compression stroke of each cylinder and to enable sequential fuel injection. The CMP sensor is connected to the engine control module (ECM) by the following circuits

1. A 5-volt reference circuit
2. A low reference circuit
3. A signal circuit

Ignition Coil/Module

Each ignition coil/module has the following circuits

1. An ignition voltage circuit
2. A ground
3. An ignition control (IC) circuit
4. A low reference circuit

The engine control module (ECM) controls the individual coils by transmitting timing pulses on the IC circuit of each ignition coil/module to enable a spark event.

The spark plugs are connected to each coil by a short boot. The boot contains a spring that conducts the spark energy from the coil to the spark plug. The spark plug electrode is tipped with platinum for long wear and higher efficiency.

Engine Control Module (ECM)

The engine control module (ECM) controls all ignition system functions, and constantly corrects the spark timing. The ECM monitors information from various sensor inputs that include the following

1. The throttle position (TP) sensor
2. The engine coolant temperature (ECT) sensor
3. The mass air flow (MAF) sensor
4. The intake air temperature (IAT) sensor
5. The vehicle speed sensor (VSS)
6. The engine knock sensor (KS)
7. The manifold absolute pressure (MAP) sensor

Modes of Operation

During normal operation the engine control module (ECM) controls all ignition functions. If either the crankshaft position (CKP) or camshaft position (CMP) sensor signal is lost, the engine will continue to run because the ECM will default to a limp home mode using the remaining sensor input. Each coil is internally protected against damage from excessive voltage. If one or more coils were to fail in this manner, a misfiring condition would result. Diagnostic trouble codes are available to accurately diagnose the ignition system with a scan tool.

Special Tools

Special Tools Illustration Tool Number/ Description GE 41415-50 Fuel Fill Cap Adapter J 26792 Spark Tester J 34730-1A Fuel Pressure Gage J 34730-405 Injector Test Light J 35555 Metal Mityvac Pump J 35616-A/BT-8637 Connector Test Adapter Kit J 36012-A Ignition System Diagnostic Harness J 36169-HD Heavy Duty Fused Jumper J 36850 Transjel Lubricant J 37088-A Fuel Line Disconnect Tool Set J 37287 Fuel Line Shut-Off Adapters J 38522 Variable Signal Generator J 39021 Fuel Injector Coil/Balance Tester J 39765-A Fuel Sender Lock Ring Tool J 41413-200 Evaporative Emissions System Tester (EEST) J 41413-SPT High Intensity White Light J 41413-VLV EVAP Service Port Vent Fitting J 41416 Ultrasonic Leak Detector J 42242 Fuel Pressure Gage Adapter J 42598 Vehicle Data Recorder J 42960-2 Fuel Flapper Door Holder J 42964-1 3/8 Fuel Pipe Shut-Off Valve J 42964-2 5/16 Fuel Pipe Shut-Off Valve J 43244 Relay Puller Pliers J 44175 Fuel Composition Tester J 44602 Injector Test Adapter J 45004 Fuel Tank Drain Hose J 45747 Fuel Sender Lock Nut Wrench EN 47748 Supercharger Lifting Fixture EN 47814 Supercharger Bypass valve Actuator Setting Tool EN 47833 Supercharger Service Holding Fixture

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See also:
• DTC P0010, P0013, P0020, or P0023
• DTC P0196
• DTC P0506 or P0507
• Wheelhouse Filler Replacement
• Fastener Notice
• Control Module References
• Diagnostic Trouble Code (DTC) List - Vehicle
• Cooling System Draining and Filling (Static Fill)
• Cooling System Draining and Filling (GE 47716)
• Supercharger Replacement
• Sealers, Adhesives, and Lubricants
• Charge Air Cooling System Draining and Filling (Static Fill)
• Oxygen Sensor Notice
• Lifting and Jacking the Vehicle
• Instrument Panel Insulator Panel Replacement - Left Side
• Battery Negative Cable Disconnection and Connection
• GASOLINE/GASOLINE VAPORS CAUTION
• Fuel Pressure Relief
• Driveline Support Assembly Replacement
• Tire and Wheel Removal and Installation
• Rear Wheelhouse Liner Panel Replacement
• Exhaust Muffler Replacement - Left Side
• Transmitter Programming (Domestic and Japan)
• Transmitter Programming (Export - Including Canada)
• Delphi Connectors (Weather Pack)
• Battery Disconnect Caution
• FUEL AND EVAPORATIVE EMISSION PIPE CAUTION
• Control Valve Lower Body and Upper Body Replacement
• Ignition System Specifications
• Remote Power Steering Fluid Reservoir Replacement
• Fuel System Cleaning
• Supercharger Inlet Duct Assembly Replacement
• Fastener Tightening Specifications
• Special Tools
• Fuel Pressure Relief
• Spark Plug Inspection
• Crankshaft Position System Variation Learn