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

Disassemble Procedure

    Object Number: 1685825 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
  2. Remove the fuel rail. Refer to Fuel Injector and Fuel Rail Replacement.

    3. Object Number: 1644346 Size: SH
  3. Drain the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling.

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

  4. Place a shop rag under the front portion of the supercharger to catch any remaining coolant.
  5. Remove the charge air cooler front manifold. Refer to Charge Air Cooler Front Manifold Replacement.

    6. Object Number: 1644359 Size: SH
  6. Remove the charge air cooler rear manifold. Refer to Charge Air Cooler Coolant Rear Manifold Replacement.
  7. Remove the charge air cooler cooling tubes, if necessary. Refer to Charge Air Cooler Cooling Tube Replacement.

    8. Object Number: 1644382 Size: SH
  8. Remove the long charge air cooler bolts.

    9. Object Number: 1644383 Size: SH
  9. Remove the short charge air cooler perimeter bolts.

    10. Object Number: 1644384 Size: SH
  10. Remove the charge air cooler housing.

    11. Object Number: 1644399 Size: SH
  11. Remove and discard the charge air cooler housing perimeter gasket.
  12. Remove and discard the charge air cooler housing interior O-ring gaskets.

Installation Procedure

    Object Number: 1644399 Size: SH
  1. Install the NEW charge air cooler housing interior O-ring gaskets.
  2. Install the NEW charge air cooler housing perimeter gasket.

    3. Object Number: 1644384 Size: SH
  3. Install the charge air cooler housing.

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


    Object Number: 1644382 Size: SH
  4. Install the long charge air cooler bolts.

    5. Tighten
    Tighten the long charge air cooler bolt to 10 N·m (89 lb in).


    Object Number: 1644383 Size: SH
  5. Install the short charge air cooler perimeter bolts.

    6. Tighten
    Tighten the short charge air cooler bolt to 10 N·m (89 lb in).


    Object Number: 1644359 Size: SH
  6. Install the charge air cooler cooling tubes, if necessary. Refer to Charge Air Cooler Cooling Tube Replacement.
  7. Install the charge air cooler rear manifold. Refer to Charge Air Cooler Coolant Rear Manifold Replacement.

    8. Object Number: 1644346 Size: SH
  8. Install the charge air cooler front manifold. Refer to Charge Air Cooler Front Manifold Replacement.
  9. Fill the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling.

    10. Object Number: 1685825 Size: SH
  10. Install the fuel rail. Refer to Fuel Injector and Fuel Rail Replacement.
  11. Install the fuel fill cap.
  12. Check the charge air cooling system for leaks.
  13. Check the fuel system for leaks.