GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Cadillac 🢒 2009 🢒 XLR 🢒 Preface 🢒 Dangers, Warnings, and Cautions 🢒 Powertrain Removal and Installation

Removal Procedure

    Object Number: 925391 Size: SH
  1. Open the trunk and disconnect the electronic suspension control module connectors from the module. Refer to Electronic Suspension Control Module Replacement.
  2. Close the trunk.
  3. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  4. Recover the air conditioning (A/C) refrigerant. Refer to Refrigerant Recovery and Recharging.
  5. Remove the engine sight shield. Refer to Intake Manifold Sight Shield Replacement.
  6. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.

    7. Object Number: 1685834 Size: SH
  7. Disconnect the engine compartment evaporative emission (EVAP) purge pipe (3) quick-connect fitting from the chassis pipe.
  8. Cap the open pipes in order to prevent possible contamination.
  9. Disconnect the fuel inlet quick-connect fitting (1) at the fuel rail and position the line aside. Refer to Metal Collar Quick Connect Fitting Service.

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

  10. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.

    11. Object Number: 1735512 Size: SH
  11. Remove the charge air cooler radiator. Refer to Charge Air Cooler Radiator Replacement.
  12. Remove the radiator. Refer to Radiator Replacement.
  13. Remove the surge tank. Refer to Radiator Surge Tank Replacement.
  14. Remove the A/C condenser. Refer to Air Conditioning Condenser Replacement.

    15. Object Number: 1614613 Size: SH
  15. Remove the front portion of the supercharger front manifold (2). 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.

    16. Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

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

  16. Disconnect the vacuum brake booster hose from the brake booster.

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

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

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

    26. Object Number: 1237963 Size: SH
  26. Remove the ground strap nut and terminals (1-3) from the stud on the frame.

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

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

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

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

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

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

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

    58. Object Number: 932167 Size: SH
  58. Remove the nuts (2) retaining the transmission shift cable bracket (3) to the transmission.

    59. Object Number: 932165 Size: SH
  59. Disconnect the transmission shift control cable (1) from the transmission shift lever (2). Unsnap to release the cable.
  60. Reposition the transmission shift cable and bracket.
  61. Disconnect the wiring harness and ground from the rear crossmember.

    62. Object Number: 71407 Size: SH
  62. Remove the rear brake intermediate pipes from the clips and place the pipes near the driveline support assembly.
  63. Disconnect the wiring harness connectors from bank 1 and bank 2 sensor 1 oxygen sensors. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 and Heated Oxygen Sensor Replacement - Bank 2 Sensor 1.

    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 the powertrain table under the front frame.
  68. Position the powertrain table under the rear frame.
  69. With the aid of an assistant, slowly lower the vehicle onto 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 and Rear Suspension Support 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 frame into the cradle bolts.

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

  4. Using HAND TOOLS ONLY, install the front and rear frame nuts and tighten 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 (2) retaining the transmission shift cable bracket (3) to the transmission and tighten to 20 N·m (15 lb ft).

    7. Object Number: 932165 Size: SH
  7. Connect the transmission shift cable (1) to the transmission shift lever (2).

    8. Object Number: 205288 Size: SH
  8. Install the transmission wiring harness to the left side of the transmission case retaining bolt and tighten to 2.5 N·m (22 lb in).
  9. Connect the park/neutral position switch electrical connectors.
  10. Connect the wiring harness connectors to the bank 1 and bank 2 sensor 1 oxygen sensors. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 and Heated Oxygen Sensor Replacement - Bank 2 Sensor 1.

    11. Object Number: 71407 Size: SH
  11. Install the rear intermediate brake pipes into the clips.

    12. Object Number: 67894 Size: SH
  12. Install the driveline tunnel closeout panel.
  13. Install the driveline closeout panel bolts and tighten to 10 N·m (89 lb in).
  14. Install the RH muffler assembly. Refer to Exhaust Muffler Replacement - Right Side.
  15. Install the LH muffler assembly. Refer to Exhaust Muffler Replacement - Left Side.
  16. Install the exhaust intermediate pipe. Refer to Intermediate Pipe Replacement.
  17. Connect the upper ball joint to the right knuckle. Refer to Knuckle Replacement.

    18. Object Number: 906234 Size: SH
  18. Install the rear shock absorber lower mounting bolts and tighten to 28 N·m (21 lb ft).

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

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

    25. Object Number: 906229 Size: SH
  25. Install the shock absorber lower mounting bolts. Refer to Shock Absorber Replacement.

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

    27. Object Number: 919156 Size: SH
  27. Connect the front wheel speed sensor electrical connector.
  28. Repeat for the other side of the vehicle.
  29. Install the master cylinder to the brake booster. Refer to Master Cylinder Replacement.
  30. Install the intermediate steering shaft to the steering column. Refer to Intermediate Steering Shaft Replacement.
  31. Connect the vacuum brake booster hose to the brake booster.
  32. Connect the heater hoses to the heater pipes. Refer to Heater Pipes Replacement.
  33. Connect the A/C lines to the front of dash connections. Refer to Air Conditioning Compressor Hose Replacement.

    34. Object Number: 1237963 Size: SH
  34. Attach the engine ground cables (1-3) to the right side body frame rail and tighten to 8 N·m (71 lb in).
  35. Connect the following wiring harness electrical connectors:
    36. • The ECM--Refer to Engine Control Module Replacement.
    • C101 engine electrical harness--Refer to Underhood Electrical Center or Junction Block Replacement.
  36. Install the right front wheelhouse panel. Refer to Rear Wheelhouse Panel Liner Replacement.
  37. Install the front wheels and tires. Refer to Tire and Wheel Removal and Installation.
  38. Connect the UHJB to the wheelhouse.

    39. Object Number: 907852 Size: SH
  39. Connect the A/C electrical connector to the pressure sensor.
  40. Install the battery tray. Refer to Battery Tray Replacement.
  41. Install the battery. Refer to Battery Replacement.
  42. Install the front portion of the supercharger front manifold. Refer to Charge Air Cooler Front Manifold Replacement.
  43. Install the air conditioning condenser. Refer to Air Conditioning Condenser Replacement.
  44. Install the radiator. Refer to Radiator Replacement.
  45. Install the charge air cooler radiator. Refer to Charge Air Cooler Radiator Replacement.
  46. Install the surge tank. Refer to Radiator Surge Tank Replacement.
  47. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
  48. Connect the fuel inlet quick-connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
  49. Connect the EVAP emission canister purge pipe to the chassis purge pipe.
  50. Install the engine sight shield. Refer to Intake Manifold Sight Shield Replacement.
  51. Charge the air conditioning (A/C) refrigerant. Refer to Refrigerant Recovery and Recharging.
  52. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  53. Program the transmitters. Refer to Transmitter Programming.
  54. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations.
  55. Fill the engine cooling system. Refer to Cooling System Draining and Filling.
  56. Fill the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling.
  57. Check the transmission fluid and add transmission fluid as necessary. Refer to Transmission Fluid Check.
  58. Reset the oil life monitoring system. Refer to GM Oil Life System Resetting.
  59. Perform the engine pre-lubrication procedures. Refer to Engine Prelubing.
  60. Start the engine.
  61. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
  62. Inspect for fuel, oil, and/or coolant leaks while the engine is running.
  63. Perform a final inspection for the proper engine oil and coolant levels.