L81

1. Disconnect negative battery cable.

IMPORTANT:
Verifying the purity of the refrigerant with a purity identifier before recovery is recommended.

2. Recover refrigerant using an approved refrigerant recovery system. Measure the amount of oil removed during recovery and record.

CAUTION:
DO NOT REMOVE HOSES OR LINES BEFORE SYSTEM IS FULLY DISCHARGED.

3. Remove battery heat shield.

4. Disconnect front upper oxygen sensor connector and remove wire harness from retaining clips.

CAUTION:
MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.

5. Raise vehicle.





6. Remove exhaust manifold pipe to exhaust manifold nuts.





7. Remove front exhaust manifold pipe to rear exhaust manifold pipe attachment bolts.

8. Remove front exhaust pipe with oxygen sensor attached.





9. Remove right front lower splash shield.





10. Remove suction (inlet) pipe-to-compressor bolt and remove suction pipe.

NOTICE:
Do not lubricate seal washers.

11. Install new seal washer and new fastener to suction (inlet) pipe.

12. Install suction (inlet) pipe-to-compressor and hand start bolt.

Torque:

Suction Pipe-to-Compressor

Bolt: 19 Nm (14 ft-lbs)

13. Remove discharge (outlet) line from compressor.

NOTICE:
Do not lubricate seal washers.

14. Install new seal washer and new fastener to discharge (outlet) line.

15. Install discharge (outlet) line-to-compressor and hand start bolt.

Torque:

Discharge Line-to-Compressor

Bolt: 19 Nm (14 ft-lbs)

16. Position gasket on exhaust manifold pipe.

17. Position front exhaust manifold pipe to vehicle.

NOTICE:
Do not tighten fasteners.





18. Install exhaust manifold pipe to exhaust manifold nuts.

19. Position gasket between front and rear exhaust manifold pipes.





20. Install front exhaust manifold pipe to rear exhaust manifold pipe bolts and tighten.

Torque:

Exhaust Manifold Pipe Bolts: 20 Nm (15 ft-lbs)

21. Tighten exhaust manifold pipe to exhaust manifold nuts.

Torque:

Exhaust Manifold Pipe-to-Exhaust Manifold

Nuts: 30 Nm (25 ft-lbs)

22. Route oxygen sensor wiring to top of engine.





23. Install right front lower splash shield bolts.

Torque:

Right Splash Shield-to-Body

Bolts: 5 Nm (44 in-lbs)

24. Lower vehicle.

25. Connect oxygen sensor connector and route wiring into clips.

26. Install battery heat shield.

27. Connect negative battery cable.

Torque:

Battery Terminal Bolt: 17 Nm (13 ft-lbs)

28. Evacuate, recharge, and leak check the A/C system.

IMPORTANT:
Do not cover any existing underhood labels when affixing Campaign Completion Label.

29. Affix Campaign Completion Label on a clean and dry surface of radiator core support, in an area clearly visible when hood is raised. (For more information, refer to "Campaign Completion Label" in this bulletin.)