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

Removal Procedure
  1. Remove the hood. Refer to Hood Replacement.
  2. Remove the engine sight shield. Refer to Intake Manifold Sight Shield Replacement.
  3. Remove the front supercharger inlet duct assembly. Refer to Supercharger Inlet Duct Assembly Replacement.
  4. Drain the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling.

    5. Note: Do not allow coolant to contact the supercharger drive belt.

    Place a shop rag under the front portion of the supercharger to catch any remaining coolant.


    Object Number: 1614613 Size: SH
  5. Remove the charge air cooler hoses from the front section of the charge air cooler front manifold.
  6. Remove the bolts (1) and remove the front portion of the supercharger front manifold (2). Discard the manifold O-ring seals.

    7. Object Number: 1644303 Size: SH
  7. Remove the supercharger bypass regulator solenoid valve and bracket. Refer to Charge Air Bypass Regulator Solenoid Valve Replacement.

    8. Note: The remaining section of the front manifold and the rear manifold must be serviced together. If only one manifold is serviced, there is a possibility of unseating the O-ring seals on the opposite manifold.


    Object Number: 1644344 Size: SH
  8. Remove the charge air cooler front manifold bolts.

    9. Object Number: 1644346 Size: SH
  9. Remove the charge air cooler front manifold.

    10. Object Number: 1644347 Size: SH
  10. Remove and discard the charge air cooler front manifold gasket.

    11. Object Number: 1644351 Size: SH
  11. Remove and discard the charge air cooler cooling tube front O-rings.

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

    13. Object Number: 1644357 Size: SH
  13. Remove the charge air cooler rear manifold bolts.

    14. Object Number: 1644359 Size: SH
  14. Remove the charge air cooler rear manifold.

    15. Object Number: 1644361 Size: SH
  15. Remove and discard the charge air cooler rear manifold gaskets.

    16. Object Number: 1644367 Size: SH
  16. Remove and discard the charge air cooler cooling tube rear O-rings.

    17. Object Number: 1644368 Size: SH
  17. Remove the charge air cooler cooling tube rear spacers, if required.
  18. Remove the inboard and outboard charge air cooling tubes, if required. Refer to Charge Air Cooler Cooling Tube Replacement.
  19. Clean and inspect the charge air cooler manifolds and cooling tubes. Refer to Supercharger Cleaning and Inspection.

Installation Procedure

    Note: The charge air cooler cooling tubes must be installed with the restrictor plates and notch facing the proper directions.

  1. Install the charge air cooling tubes, if previously removed. Refer to Charge Air Cooler Cooling Tube Replacement.

    2. Object Number: 1644368 Size: SH
  2. Install the charge air cooler cooling tube rear spacers, if previously removed.

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

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

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

    6. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1644357 Size: SH
  6. Install the charge air cooler rear manifold bolts and tighten to 10 N·m (89 lb in).

    7. Object Number: 1644352 Size: SH
  7. Install the charge air cooler cooling tube front spacers, if previously removed.

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

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

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

    11. Object Number: 1644344 Size: SH
  11. Install the charge air cooler front manifold bolts and tighten to 10 N·m (89 lb in).

    12. Object Number: 1644303 Size: SH
  12. Install the supercharger bypass regulator solenoid valve and bracket. Refer to Charge Air Bypass Regulator Solenoid Valve Replacement.

    13. Object Number: 1614613 Size: SH
  13. Using NEW O-ring seals, install the front portion of the charge air cooler front manifold (2).
  14. Install the manifold bolts (1) and tighten to 10 N·m (89 lb in).
  15. Install the charge air cooler hoses to the front section of the charge air cooler front manifold.
  16. Fill the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling.
  17. Install the front supercharger inlet duct assembly. Refer to Supercharger Inlet Duct Assembly Replacement.
  18. Install the engine sight shield. Refer to Intake Manifold Sight Shield Replacement.
  19. Install the hood. Refer to Hood Replacement.