GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Cadillac 🢒 2004 🢒 XLR 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Powertrain Removal and Installation

Removal Procedure
  1. Open the trunk.
  2. Disconnect the electronic suspension control module connectors from the module. Refer to Electronic Suspension Control Module Replacement.
  3. Close the trunk.
  4. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  5. Recover the air conditioning (A/C) refrigerant. Refer to Refrigerant Recovery and Recharging.
  6. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
  7. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.

    8. Object Number: 932115 Size: SH
  8. Disconnect the EVAP emission canister purge pipe (1) from the chassis purge pipe (2).
  9. Cap the open pipes in order to prevent possible contamination.
  10. Disconnect the fuel inlet quick-connect fitting at the fuel line and secure. Refer to Metal Collar Quick Connect Fitting Service.

    11. Important: Cap the hoses and inlets when separating the cooling system components. This prevents dirt and other contaminants from entering the cooling system.

  11. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
  12. Remove the radiator. Refer to Radiator Replacement.
  13. Remove the surge tank. Refer to Radiator Surge Tank Replacement.
  14. Remove the air conditioning condenser. Refer to Air Conditioning Condenser Replacement.

    15. Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

    Important: The brake hydraulic system does not need to be opened.


    Object Number: 63936 Size: SH
  15. Disconnect the vacuum brake booster hose from the brake booster.

    16. Object Number: 675866 Size: SH
  16. Disconnect the electrical connector (1) from the brake fluid level sensor.

    17. Object Number: 63941 Size: SH
  17. Remove the brake master cylinder nuts from the brake booster studs.
  18. Pull master cylinder forward out of contact with the brake booster studs.
  19. Secure master cylinder to engine.

    20. Object Number: 908202 Size: SH
  20. Remove bolts from intermediate steering shaft.
  21. Disconnect steering shaft from steering gear.
  22. Tie-wrap steering shaft to engine.
  23. Remove battery. Refer to Battery Replacement.
  24. Remove battery tray. Refer to Battery Tray Replacement.

    25. Object Number: 1237963 Size: SH
  25. Remove the ground strap nut and terminal from the stud on the frame.

    26. Object Number: 907852 Size: SH
  26. Disconnect the A/C electrical connector from pressure sensor.
  27. Remove UHJB from wheelhouse.
  28. Disconnect wiring harness connector from UHJB.
  29. Secure wiring harness to engine.
  30. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  31. Remove the front wheels and tires. Refer to Tire and Wheel Removal and Installation.
  32. Remove right front wheelhouse panel (access to ECM/TCM electrical connectors). Refer to Wheelhouse Filler Replacement.
  33. Disconnect and secure the following wiring harness electrical connectors to the top of engine:
    34. • The ECM. Refer to Engine Control Module Replacement.
    • The engine electrical harness. Refer to Underhood Electrical Center or Junction Block Replacement.
  34. Disconnect A/C lines from front of dash connections. Refer to Air Conditioning Compressor Hose Replacement.
  35. Disconnect heater hoses from heater pipes. Refer to Heater Pipes Replacement.
  36. Disconnect the front wheel speed sensor electrical connectors.

    37. Object Number: 925350 Size: SH
  37. Disconnect the road sensing suspension position sensor links from the front lower control arms.
  38. Support the lower control arm with a straight jack.

    39. Object Number: 906229 Size: SH
  39. Remove the shock absorber lower mounting bolts.
  40. Disconnect the upper ball joint from the suspension knuckle. Refer to Steering Knuckle Replacement.
  41. Remove the straight jack from the control arm.
  42. Repeat steps-through-for the other side of the vehicle.
  43. Remove the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
  44. Disconnect the rear park brake cables from the actuator. Refer to Parking Brake Rear Cable Replacement.

    45. Object Number: 919156 Size: SH
  45. Disconnect the rear wheel speed sensor electrical connectors.

    46. Object Number: 925365 Size: SH
  46. Disconnect the road sensing suspension position sensor links from the rear lower control arms.
  47. Support the lower control arm with a straight jack.

    48. Object Number: 906234 Size: SH
  48. Remove the rear shock absorber lower mounting bolt.
  49. Disconnect the upper ball joint from the suspension knuckle. Refer to Knuckle Replacement.
  50. Remove the straight jack from the control arm.
  51. Repeat steps-through-for the other side of the vehicle.
  52. Remove the RH muffler assembly. Refer to Exhaust Muffler Replacement - Right Side.
  53. Remove the LH muffler assembly. Refer to Exhaust Muffler Replacement - Left Side.
  54. Remove the exhaust intermediate pipe. Refer to Intermediate Pipe Replacement.

    55. Object Number: 67894 Size: SH
  55. Remove bolts from driveline tunnel closeout panel.
  56. Remove the driveline tunnel closeout panel.

    57. Object Number: 932167 Size: SH
  57. Remove the nuts retaining the transmission shift cable bracket to the transmission.

    58. Object Number: 932165 Size: SH
  58. Disconnect the transmission shift control cable from the transmission shift lever. Unsnap to release the cable.
  59. Reposition the transmission shift cable and bracket.
  60. Disconnect the wiring harness and ground from the rear crossmember.
  61. Remove the rear brake intermediate pipes from the clips and place the pipes near the driveline support assembly.

    62. Object Number: 927856 Size: SH
  62. Disconnect the wiring harness connector from the bank 1 sensor 1 oxygen sensor.
  63. Disconnect the wiring harness connector from the bank 2 sensor 1 oxygen sensor.

    64. Object Number: 205288 Size: SH
  64. Disconnect the park/neutral position switch electrical connectors.
  65. Remove the bolt retaining the transmission wiring harness to the transmission case.
  66. Release the wiring harness from the harness retainer along the top of the transmission.
  67. Position powertrain table under front cradle.
  68. Position powertrain table under rear cradle.
  69. With the aid of an assistant, slowly lower the vehicle on to the powertrain tables.

    70. Object Number: 581372 Size: SH
  70. Using HAND TOOLS ONLY, remove the front and rear crossmember nuts. Refer to Front Suspension Crossmember Replacement.
  71. Carefully raise the vehicle to clear the supported powertrain assembly.

Installation Procedure
  1. Position the powertrain under the vehicle.
  2. With the aid of an assistant, slowly lower the vehicle onto the powertrain.
  3. Guide the front and rear cradle into the cradle bolts.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Using HAND TOOLS ONLY, install the front and rear cradle nuts.

    5. Tighten
    Tighten the nuts to 110 N·m (81 lb ft).

  5. Attach the transmission shift cable bracket to the transmission.

    6. Object Number: 932167 Size: SH
  6. Install the nuts retaining the transmission shift cable bracket to the transmission.

    7. Tighten
    Tighten the nuts to 20 N·m (15 lb ft).


    Object Number: 932165 Size: SH
  7. Connect the transmission shift cable to the transmission shift lever.

    8. Object Number: 205288 Size: SH
  8. Install the transmission wiring harness to the left side of the transmission case retaining bolt.

    9. Tighten
    Tighten the transmission wiring harness to the left side of the transmission case retaining bolts to 2.5 N·m (22 lb in).

  9. Connect the park/neutral position switch electrical connectors.

    10. Object Number: 927856 Size: SH
  10. Connect the wiring harness connector to the bank 2 sensor 1 oxygen sensor.
  11. Connect the wiring harness connector to the bank 1 sensor 1 oxygen sensor.
  12. Install the rear intermediate brake pipes into the clips.

    13. Object Number: 67894 Size: SH
  13. Install the driveline tunnel closeout panel.
  14. Install the bolts to the driveline closeout panel.

    15. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  15. Install the RH muffler assembly. Refer to Exhaust Muffler Replacement - Right Side.
  16. Install the LH muffler assembly. Refer to Exhaust Muffler Replacement - Left Side.
  17. Install the exhaust intermediate pipe. Refer to Intermediate Pipe Replacement.
  18. Connect the upper ball joint to the right knuckle. Refer to Knuckle Replacement.

    19. Object Number: 906234 Size: SH
  19. Install the rear shock absorber lower mounting bolts.

    20. Tighten
    Tighten the bolts to 28 N·m (21 lb ft).


    Object Number: 925365 Size: SH
  20. Connect the road sensing suspension position link to lower control arm.
  21. Repeat steps-through-for the other side of the vehicle.

    22. Object Number: 919156 Size: SH
  22. Connect the rear wheel speed sensor electrical connectors.
  23. Connect the rear park brake cables to the actuators. Refer to Parking Brake Rear Cable Replacement.
  24. Install the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
  25. Connect the upper ball joint to the right front suspension knuckle. Refer to Steering Knuckle Replacement.

    26. Object Number: 906229 Size: SH
  26. Install the shock absorber lower mounting bolts.

    27. Object Number: 925350 Size: SH
  27. Connect the road sensing suspension position sensor link to the front lower connect arm.

    28. Object Number: 919156 Size: SH
  28. Connect the front wheel speed sensor electrical connector.
  29. Repeat steps-through-for other side of vehicle.
  30. Install the master cylinder to the brake booster. Refer to Master Cylinder Replacement.
  31. Install the intermediate steering shaft to the steering column. Refer to Intermediate Steering Shaft Replacement.

    32. Object Number: 63936 Size: SH
  32. Connect the vacuum brake booster hose to the brake booster.
  33. Connect the heater hoses to the heater pipes. Refer to Heater Pipes Replacement.
  34. Connect the A/C lines to the front of dash connections. Refer to Air Conditioning Compressor Hose Replacement.

    35. Object Number: 1237963 Size: SH
  35. Attach the engine ground cable to the right side body frame rail.

    36. Tighten
    Tighten to 8 N·m (71 lb in).

  36. Connect the following wiring harness electrical connectors:
    37. • The ECM--Refer to Engine Control Module Replacement.
    • C101-engine electrical harness--Refer to Underhood Electrical Center or Junction Block Replacement.
  37. Install the right front wheelhouse panel. Refer to Wheelhouse Filler Replacement.
  38. Install the front wheels and tires. Refer to Tire and Wheel Removal and Installation.
  39. Connect the UHJB to the wheelhouse.

    40. Object Number: 907852 Size: SH
  40. Connect the A/C electrical connector to the pressure sensor.
  41. Install the battery tray. Refer to Battery Tray Replacement.
  42. Install the battery. Refer to Battery Replacement.
  43. Install the air conditioning condenser. Refer to Air Conditioning Condenser Replacement.
  44. Install the radiator. Refer to Radiator Replacement.
  45. Install the surge tank. Refer to Radiator Surge Tank Replacement.
  46. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
  47. Connect the fuel inlet quick-connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.

    48. Object Number: 932115 Size: SH
  48. Connect the EVAP emission canister purge pipe (1) to the chassis purge pipe (2).
  49. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
  50. Charge the air conditioning (A/C) refrigerant. Refer to Refrigerant Recovery and Recharging.
  51. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  52. Program the transmitters. Refer to Transmitter Programming.
  53. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations.
  54. Reset the oil life monitoring system. Refer to GM Oil Life System Resetting.
  55. Perform the engine pre-lubrication procedures. Refer to Engine Prelubing.
  56. Start the engine.
  57. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
  58. Inspect for fuel, oil, and/or coolant leaks while the engine is running.
  59. Perform a final inspection for the proper engine oil and coolant levels.