GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Cadillac 🢒 2008 🢒 XLR 🢒 Engine 🢒 Engine Mechanical - 4.4L 🢒 Charge Air Cooler Cooling Tube Replacement

Removal Procedure

    Important: The charge air cooling tubes are replaced as a set. If any one of the charge air cooler cooling tubes needs to be replaced, all the charge air cooler cooling tubes must be replaced in order to maintain consistent cooling of the charge air.


    Object Number: 1644346 Size: SH
  1. Drain the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling .
  2. Remove the front section of the supercharger inlet duct assembly. Refer to Supercharger Inlet Duct Assembly Replacement .

    3. Important: Do not allow any draining coolant to contact the supercharger drive belt.

  3. Place a shop rag under the front portion of the supercharger to collect any remaining coolant that may drain from the charge air cooling system.
  4. Remove the charge air cooler front manifold, gasket, O-rings, and spacers. Refer to Charge Air Cooler Front Manifold Replacement .

    5. Object Number: 1644359 Size: SH
  5. Remove the charge air cooler rear manifold, gaskets, O-rings, and spacers. Refer to Charge Air Cooler Coolant Rear Manifold Replacement .

    6. Object Number: 1687870 Size: SH
  6. Carefully remove the outboard charge air cooler cooling tubes.
  7. The charge air cooler cooling tubes are fragile and must be placed in a protected area.

    8. Object Number: 1687874 Size: SH
  8. Carefully remove the inboard charge air cooler cooling tubes.
  9. The charge air cooler cooling tubes are fragile and must be placed in a protected area.

    10. Object Number: 1644408 Size: SH
  10. Inspect the charge air cooler cooling tubes for the following:
    11. • Damaged, clogged, bent or missing fins (1)
    • Damage, corrosion or restrictions to the cooling passages (2)
    • Damage, corrosion, restrictions or missing diversion end plate (3)

    Object Number: 1644411 Size: SH
  11. Inspect the charge air cooler cooling tubes for the following:
    12. • Damaged, clogged, bent or missing fins (1)
    • Damage, corrosion or restrictions to the cooling passages (2)
    • Damage, corrosion or restrictions to the intake end (3)

    Important: The charge air cooling tubes are replaced as a set. If any one of the charge air cooler cooling tubes needs to be replaced, all the charge air cooler cooling tubes must be replaced in order to maintain consistent cooling of the charge air.

  12. Replace any damaged, corroded or restricted charge air cooler cooling tubes as a set.

Installation Procedure

    Object Number: 1687874 Size: SH
  1. Carefully install the inboard charge air cooler cooling tubes.

    2. Object Number: 1646471 Size: SH
  2. The charge air cooler cooling inboard tubes are installed with the restrictor plates (1) to the front of the supercharger, towards the drive belt pulley.

    3. Object Number: 1687879 Size: SH
  3. Align the wide notch at a 45 degree angle up from horizontal and outboard as shown.

    4. Object Number: 1687870 Size: SH
  4. Carefully install the outboard charge air cooler cooling tubes.

    5. Object Number: 1646471 Size: SH
  5. The charge air cooler cooling outboard tubes are installed with the restrictor plates (1) to the rear of the supercharger. The open end of the cooling tube will be to the front of the supercharger, towards the drive belt pulley.

    6. Object Number: 1687877 Size: SH
  6. Align the wide notch at a 45 degree angle up from horizontal and outboard as shown.

    7. Object Number: 1644368 Size: SH
  7. Install the charge air cooler cooling tube rear spacers.

    8. Object Number: 1644367 Size: SH
  8. Install the NEW charge air cooler cooling tube rear O-rings.

    9. Object Number: 1644361 Size: SH
  9. Install the NEW charge air cooler rear manifold gaskets.

    10. Object Number: 1644359 Size: SH
  10. Install the charge air cooler rear manifold.

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


    Object Number: 1644357 Size: SH
  11. Install the charge air cooler rear manifold bolts.

    12. Tighten
    Tighten the charge air cooler rear manifold bolt to 10 N·m (89 lb in).


    Object Number: 1644352 Size: SH
  12. Install the charge air cooler cooling tube front spacers.

    13. Object Number: 1644351 Size: SH
  13. Install the NEW charge air cooler cooling tube front O-rings.

    14. Object Number: 1644347 Size: SH
  14. Install the NEW charge air cooler front manifold gasket.

    15. Object Number: 1644346 Size: SH
  15. Install the charge air cooler front manifold.

    16. Object Number: 1644344 Size: SH
  16. Install the charge air cooler front manifold bolts.

    17. Tighten
    Tighten the charge air cooler front manifold bolt to 10 N·m (89 lb in).

  17. Install the remaining portion of the charge air cooler front manifold. Refer to Charge Air Cooler Front Manifold Replacement .
  18. Install the front section of the supercharger inlet duct assembly. Refer to Supercharger Inlet Duct Assembly Replacement .
  19. Fill the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling .