1995 JEEP CHEROKEE Back

(8) Return the tape stripe/decal back to its original
position. If a wetting solution is used, position the
adhesive side of the tape stripe/decal on the panel.
Apply wetting solution to the outside of the tape
stripe/decal. Use firm strokes with a squeegee to ad-
here the tape stripe/decal to the body.
(9) Hold tape stripe/decal firmly against the panel
surface while separating the carrier from the tape
stripe/decal (Fig. 9).
(10) Where applicable, extend the tape stripe/decal
12 mm (1/2 in) beyond the door edge. Next, wrap it
around on the flange and adhere it to the door flange
(Fig. 10).Use care to avoid trapping air under
the tape stripe/decal.Where necessary, trim excess
tape stripe/decal.
(11) If applicable, remove the cover from the face of
the tape stripe/decal.
(12) Inspect tape stripe/decal with reflected light to
check for defects that could have developed during
the installation process. Remove all air and/or mois-
ture bubbles.COMPLETE REPLACEMENT
The following procedure will simplify installation of
a complete or large section(s) of tape stripe/decal on a
vehicle (Fig. 11 and 12).
(1) Place the tape stripe/decal on a clean, flat sur-
face with the carrier side facing upward.
(2) Bend a corner of the carrier inward, and sepa-
rate the corner of the carrier from the tape stripe/de-
cal.
CAUTION: Hold tape stripe/decal at extreme outer
edges of the corners while separating the carrier.
(3) Hold tape stripe/decal firmly against the flat
surface and separate the carrier from the tape stripe/
decal.
If hot and humid, a slight jerking motion will
aid separating the carrier from the tape stripe/
decal.
(4) Use a clean sponge and apply ample wetting
solution to the tape stripe/decal adhesive and to the
Fig. 7 Tape Stripe/Decal and Carrier Reversed On
Body Panel
Fig. 8 Tape Stripe/Decal and Carrier Separated
Fig. 9 Tape Stripe/Decal Installation
Fig. 10 Tape Stripe/Decal Installation On Door
Flange
JEXTERIOR COMPONENTSÐYJ 23 - 119

painted panel surface. The solution will permit ease
of tape stripe/decal movement when positioning it on
the panel.
(5) Position adhesive-coated side of tape stripe/de-
cal on the panel with the bottom aligned with char-
acter line. Where applicable:
²align the end of the replacement tape stripe/decal
with the end of the existing tape stripe/decal, and
correctly align the index darts and index notches.
(6) If a complete replacement tape stripe/decal is
not being installed:
²Position the replacement tape stripe/decal section
at the center of the repair area.
²Align it with the existing tape stripe/decal and al-
low at least 12 mm (1/2 in) of the tape stripe/decal
section to overlap the existing tape stripe/decal
edges.(7) Apply wetting solution to the outer side of the
tape stripe/decal to allow the squeegee to freely slide
while adhering the stripe/decal to the panel.
CAUTION: Avoid unnecessary pulling and stretch-
ing at the ends of the tape stripe/decal because this
could cause it to tear.
(8) Position and slide a squeegee from the center to
the ends of the tape stripe/decal. This will ensure
complete bonding of the tape stripe/decal to the
painted panel surface.
(9) If a wrinkle is trapped in the tape stripe/decal
during the squeegee operation, stop. Lift wrinkled
area and re-align stripe/decal with panel character
line.Do not lift the tape stripe/decal if only a
few air bubbles exist.
(10) Where applicable, allow 12 mm (1/2 in) extra
tape stripe/decal to extend beyond the edges to be
folded over.
(11) Fold the excess tape stripe/decal back onto in-
side flange area.Use care to avoid trapping air
under the tape stripe/decal.Where necessary, trim
excess tape stripe/decal.
(12) Inspect tape installation with reflected light to
detect any defects that could have developed during
the installation.
(13) Remove all air and moisture bubbles from the
tape stripe/decal with a needle or pin.
(14) Install any removed components and clean the
vehicle as necessary.
EXTERIOR NAMEPLATES (ADHESIVE-BACKED)ÐYJ
All of the YJ exterior nameplates (Fig. 13) are at-
tached to the vehicle panels with adhesive.
REMOVAL/INSTALLATION
(1) With the use of a putty knife, carefully pry the
nameplate from the body outer panel.
(2) Clean the panel surface.
Fig. 11 Islander Decals
Fig. 12 Sahara Decals
Fig. 13 YJ Nameplate Decals
23 - 120 EXTERIOR COMPONENTSÐYJJ

HEATING AND AIR CONDITIONING
CONTENTS
page page
COMPONENT SERVICEÐXJ VEHICLES...... 23
COMPONENT SERVICEÐYJ VEHICLES...... 32
COMPRESSOR SERVICE.................. 19
GENERAL INFORMATION.................. 1
HEATING AND AIR CONDITIONING TEST
PROCEDURES......................... 15REFRIGERANT SERVICE AND PERFORMANCE
TEST................................ 11
TORQUE SPECIFICATIONS................ 37
WARNINGS, CAUTIONS AND SERVICE
PRECAUTIONS......................... 9
GENERAL INFORMATION
INDEX
page page
A/C Components.......................... 4
Heater and A/C Operation.................... 1
Manifold Gauge Set........................ 7Refrigerant............................... 7
Refrigerant Equipment...................... 7
HEATER AND A/C OPERATION
HEATERÐXJ
A blend-air heating system is used in XJ vehicles.
The temperature of heated air is controlled by regu-
lating the quantity of air flow through the heater
core. This is accomplished by blending outside air
with heated air from the heater core to obtain the de-
sired discharge temperature. A temperature control
lever on the heater control determines air flow
through the heater core. The lever uses a cable to op-erate the blend-air door. This door controls air flow
through the core. Vacuum motors are used to actuate
and position the remaining door in the system.
On left hand drive (LHD) XJ vehicles a water valve
controls coolant flow to the heater core. The valve is
vacuum operated. When vacuum is applied, the valve
opens and coolant is directed through the heater core
and back to the engine. When the water valve is
closed (no vacuum applied) coolant flow bypasses the
heater core back to the engine.
JHEATING AND AIR CONDITIONING 24 - 1

motor is controlled by a vacuum switch in the heater
control panel. The vent air doors are opened and
closed by a cable and linkage operated by the air con-
trol lever. Fresh air intake occurs only when the le-
ver is in the VENT position.
AIR CONDITIONING
The compressor increases the pressure and temper-
ature of the refrigerant. The heated refrigerant vapor
is pumped into the condenser where it is cooled by
air passing over the condenser fins. As the refriger-
ant cools in the condenser, it condenses into a liquid.
Still under high pressure, the liquid refrigerant
passes into the receiver. The receiver acts as a reser-
voir to furnish refrigerant to the expansion valve at
all times. From the receiver, the high pressure liquid
refrigerant passes to the expansion valve. The expan-
sion valve meters refrigerant into the evaporator.
The low pressure is maintained by the suction side of
the compressor. As it enters the evaporator, the re-
frigerant begins to absorb heat from the air passing
over the evaporator core. Having given up its heat to
boil the refrigerant, the air is cooled and passes into
the passenger compartment. From the evaporator the
vaporized refrigerant is drawn back to the compres-
sor to repeat the cycle.
A/C COMPONENTS
COMPRESSOR:The SD7H15 Compressor is used
on all models. The purpose of the compressor is to
compress the low-pressure refrigerant vapor into a
high pressure, high temperature vapor. The compres-
sor is serviced as a assembly only.
CLUTCH PULLEY AND COIL:They are
mounted on the compressor and providing a way to
drive the compressor. The compressor clutch and coil
are the only serviced parts on the SD7H15 compres-
sor. When the compressor is not in operation, the
pulley free wheels on the clutch hub bearing. When
the coil is energized the clutch plate is magnetically
engaged with the pulley and turns the compressor
shaft.
CONDENSER:The condenser is located in front of
the engine radiator. Its function is to cool the hot
high pressure refrigerant gas. This causes it to con-
dense into high pressure liquid refrigerant.
EXPANSION VALVE:The expansion valve is lo-
cated in the engine compartment on XJ vehicles. On
YJ vehicles it is located behind the A/C housing. Its
function is to meter refrigerant into the evaporator in
accordance with cooling requirements.
Fig. 3 Fresh Air Intake System Components
24 - 4 HEATING AND AIR CONDITIONINGJ

EVAPORATOR COIL:The coil is located in the
A/C housing. Its function is to remove heat and de-
humidify the air before it enters the vehicle.
FIN SENSING CYCLING CLUTCH SWITCH:
The switch is attached to the evaporator coil with the
temperature sensing probe inserted into the coil fins.
This switch controls evaporator temperature and pre-
vents condensate water on the evaporator coil from
freezing. It does this by sending signals to the Pow-
ertrain Control Module (PCM) to cycling the com-
pressor clutch on and off. This switch is used onXJ
only.
FILTER-DRIER:The drier is used to remove any
traces of moisture from the refrigerant system. A
sight glass is located on top of the filter drier. It is
used as a diagnostic tool to observe refrigerant flow.
HIGH PRESSURE RELIEF VALVE:The valve is
located on the filter drier. The valve is used to pre-
vent excessive high pressure build of 3445 to 4135
kPa (500 to 600 psi) and above. This prevents dam-
age to the compressor and other system components.
LOW-PRESSURE HIGH-PRESSURE CUT-OFF
SWITCH:The switch is located on the filter drier
and is wired in series with compressor clutch. When
the pressure drops down to 193 kPa (28 psi) the
switch interrupts the power to the compressor clutch.
When the pressure increases above 3100 to 3375 kPa
(450 to 490 psi) the switch interrupts the power to
the compressor clutch.
THERMOSTAT:The thermostat is located in the
evaporator housing. The thermostat temperature
sensing probe is inserted into the evaporator coil. Its
function is to cycles the compressor clutch on and off.
This switch controls temperature and prevents con-
densate water on the evaporator coil from freezing.
The thermostat is used on theYJonly.
REFRIGERANT LINES:The lines are used to
carry the refrigerant between the various system
components.
SERVICE PORTS:The high pressure service port
is located on the discharge line near the compressor.
The low pressure service port is located on the suc-
tion line near the compressor. These ports are used
to attach A/C gauges. After servicing the refrigerant
system, always install service port caps.
REFRIGERANT
XJ and YJ vehicles use a new type of refrigerant
called R-134a. It is a non-toxic, non-flammable, clear
color-less liquified gas.
R-134a refrigerant is not compatible with R-12 re-
frigerant. A small amount of R-12 in a R-134a system
will cause compressor failure, oil sludge or poor air
conditioning performance.R-134a refrigerant requires a special type of com-
pressor oil (SP20 PAG). When adding oil, make sure
that it is designed to be used in a R-134a system and
the SD7H15 compressor.
Service ports have been designed to ensure that
the system is not accidentally filled with R-12 refrig-
erant.
REFRIGERANT EQUIPMENT
WARNING: EYE PROTECTION MUST BE USED
WHEN SERVICING AN AIR CONDITIONING REFRIG-
ERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE)
ALL VALVES ON THE EQUIPMENT BEING USED
BEFORE PROCEEDING WITH THIS OPERATION.
PERSONNEL INJURY CAN RESULT.
Chrysler Corporation recommends a (R-134a) recy-
cling device that meets SAE standard J2210 be used
when servicing the refrigerant system. Contact an
automotive service equipment supplier for refrigerant
recycling equipment that is available in your area.
Refer to the operating instructions provided with the
recycling equipment for proper operation.
MANIFOLD GAUGE SET
CAUTION: DO NOT use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
A manifold gauge set (Fig. 1) may be needed in
conjunction with the charging and or recovery/recy-
cling device. The service hoses on the gauge set being
used should have manual (turn wheel) or automatic
back flow valves at the service port connector ends.
This will prevent refrigerant from being release into
the atmosphere.
LOW PRESSURE GAUGE HOSE
The low pressure hose (BLUE with BLACK STRIP)
should be attached to the charging/service port. This
port is located at the right front of the engine com-
partment in the condenser-to-evaporator line.
HIGH PRESSURE GAUGE HOSE
The high pressure hose (RED with BLACK STRIP)
should be attached to the discharge/service port. This
port is located on the compressor plumbing or mani-
fold.
RECOVERY/RECYCLING/EVACUATION/
CHARGING HOSE
The center manifold hose (YELLOW or WHITE
with BLACK STRIP) is used to recover, evacuate and
charge the refrigerant system. When the low or high
pressure valves on the manifold gauge set are
opened, the refrigerant in the system will escape
through this hose.
JHEATING AND AIR CONDITIONING 24 - 7

REFRIGERANT OIL
It is important to have the correct amount of oil in
the A/C system. This will ensure proper lubrication of
the compressor. Too little oil will result in damage to
the compressor. Too much oil will reduce the cooling
capacity of the system.
The oil used in the SD7H15 compressor is a poly-
alkylene glycol synthetic oil SP-20 PAG, wax-free re-
frigerant oil. Only refrigerant oil of the same type
should be used to service the system. Do not use any
other oil. The oil container should be kept tightly
capped until it is ready for use and then capped after
use to prevent contamination. Refrigerant oil will
quickly absorb any moisture it comes in contact with.
OIL LEVEL CHECK
It will not be necessary to check oil level in the
compressor or to add oil unless there has been an oil
loss. This may be due to a rupture or leak from a
line, shaft seal, evaporator or condenser. Oil loss at a
leak point will be evident by the presence of a wet,
shiny surface around the leak.
When an A/C system is assembled at the factory,
all components (except the compressor) are refriger-
ant oil free. After the system has been charged and
operated, the oil in the compressor is dispersed
through the system. The receiver-drier, evaporator,
condenser and compressor will retain a significant
amount of oil.
Refrigerant oil must be added when a receiver-
drier, evaporator, condenser or compressor are re-
placed. When the compressor is replaced, the oil
must be drained from the replaced compressor and
measured. Drain all the oil from the new compressor.
Add back into the new compressor the amount of oil
that was drained out of the old compressor.
Add an additional 30 ml (1 fluid oz.) of com-
pressor oil to the system when a receiver-drier,
condenser or evaporator is replaced.
AIR CONDITIONING PERFORMANCE TESTS
Humidity has an important bearing on the temper-
ature of the air delivered to the vehicle's interior. It
is important to understand the effect humidity has
on the performance of the system. When humidity is
high, the evaporator has to perform a double duty. It
must lower the air temperature and the temperature
of the moisture carried in the air. Condensing the
moisture in the air transfers a great deal of heat en-
ergy into the evaporator fins and tubing. This re-
duces the amount of heat the evaporator can absorb
from the air. High humidity greatly reduces the evap-
orator's ability to lower the temperature of the air.Evaporator capacity used to reduce the amount of
moisture in the air is not wasted. Wringing some of
the moisture out of the air entering the vehicle adds
to the comfort of the passengers. However, an owner
may expect too much from their air conditioning sys-
tem on humid days. A performance test is the best
way to determine whether or not the system is per-
forming up to standard. This test also provides valu-
able clues to the possible cause of trouble.
Air temperature in test room must be 21ÉC (70ÉF)
minimum for this test.
(1) Connect a Tachometer and manifold gauge set.
(2) Set A/C controls to Max A/C, temperature lever
on full cool and blower on high.
(3) Start engine and adjust idle to 1,000 RPM with
A/C clutch engaged.
(4) Engine should be warmed up with doors, win-
dows and hood closed.
(5) Insert a thermometer in the left center A/C out-
let. Operate the A/C and engine for 5 minutes. The
A/C clutch may cycle depending on ambient temper-
atures.
(6) After 5 minutes note the discharge air temper-
ature. If the clutch cycles, take the reading before
the clutch disengages.
(7) On LHD XJ vehicles open the hood and discon-
nect vacuum line going to the heater water control
valve. Observe the valve arm for movement as the
line is disconnected. Plug the vacuum line to prevent
leakage. If it does not move repair vacuum circuit.
(8) Operate the A/C for 2 more minutes and take
the discharge air temperature reading again. On XJ
vehicles if the temperature increased by more than
2ÉC (5ÉF) check the blend air door cable for correct
operation.
(9) Compare the discharge air temperature to the
A/C Performance (Temperature and Pressure) Chart.
If the discharge air temperature is high, refer to Re-
frigerant Leak Testing and Refrigerant System Diag-
nosis Chart.
(10) Compare the compressor discharge and suc-
tion pressures to the A/C Performance (Temperature
and Pressure) Chart. If the compressor discharge or
suction pressure is not normal, check the operation of
the refrigerant system. Refer to Refrigerant System
Diagnosis Chart.
If pressures are abnormal, refer to the Pressure
and Performance Diagnosis Charts.
The following chart have been developed for quick
reference.
24 - 12 HEATING AND AIR CONDITIONINGJ

(6) Test A/C blower switch HIGH terminal with
blower switch in HIGH, should be battery voltage. If
not, replace switch.
BLOWER MOTOR
The A/C blower motor is attached to the evaporator
housing mounted under the instrument panel. The
motor has a ground wire and 3 wires connect to the
motor brushes. When voltage is applied to the sepa-
rate brushes it provides the 3 blower speeds LO,
MED, and HIGH.
BLOWER MOTOR TEST
Turn ignition switch to RUN for voltage tests and
turn ignition switch to OFF for resistance test.
(1) Test A/C blower motor ground terminal should
be 0 ohms. If not, repair ground circuit.
(2) Test A/C blower motor connector LO terminal
with blower switch in LO, should be battery voltage.
If not repair open from blower switch. If the blower
motor is still inoperative replace motor.
(3) Test A/C blower motor connector MED terminal
with blower switch in MED, should be battery volt-
age. If not repair open from blower switch. If the
blower motor is still inoperative replace motor.
(4) Test A/C blower motor connector HIGH termi-
nal with blower switch in HIGH, should be battery
voltage. If not, repair open from blower switch. If the
blower motor is still inoperative, replace motor.
HEATER DIAGNOSIS
On LHD XJ vehicles a water valve controls coolant
flow to the heater core. The valve is vacuum oper-
ated. When vacuum is applied, the valve opens and
coolant is directed through the heater core and back
to the engine. When the water valve is closed (no
vacuum applied) coolant flow bypasses the heater
core back to the engine.
The heating system receives its battery feed from
the fuse box. On YJ vehicles the feed circuit runs to
the HEATER/OFF switch and then to the BLOWER
switch. On XJ vehicles the feed circuit runs to the
HEAT/MODE switch and then to the BLOWER
switch.
The blower speed is controlled by the blower switch
and blower resistors. With the switch in LO, battery
voltage is supplied to the motor through all of the re-
sistors. The motor runs slowly. When the blower
switch is moved to a higher speed, battery voltage in-
creases to the blower motor which increase its speed.
This is accomplished by bypassing some of the blower
resistors. When the switch is in HI, blower resistors
are bypassed and battery voltage is applied directly
to the blower motor.
The following chart has been developed for quick
reference.
Refer to the Group 8W Wiring Diagrams for com-
plete wiring schematic.
JHEATING AND AIR CONDITIONING 24 - 17

INSTALLATION
(1) Install the cables to the heater control panel.
(2) Connect right vent door cable. DO NOT connect
the left door cable at this time.
(3) Open and close the right vent door (one time)
using the air control lever on the heater control
panel.
(4) Connect left vent door cable.
(5) Open and close both vent doors with the air
control lever. Verify that both vent doors open at the
same time.
HEATER CORE AND HOUSING
REVIEW ALL WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THIS
OPERATION.
REMOVAL
(1) Drain coolant from the radiator.
(2) Disconnect heater hoses.
(3) Disconnect vent door cables.
(4) Disconnect blower motor wire.
(5) Disconnect defroster duct.
(6) Remove nuts that attach the heater housing
studs to the engine compartment side of the dash
panel.
(7) Remove heater housing assembly by tilting it
downward, to disengage it from the defroster duct.
Pull it rearward and out from under the instrument
panel.
(8) Remove heater hosing cover from the housing.
(9) Remove heater core from the housing.
INSTALLATION
(1) Install the heater core into the housing and in-
stall the cover on the housing.
(2) Position heater housing on the dash panel. Be
sure the housing studs all extend through the dash
panel.
(3) Install the seals on the heater core outlet and
inlet tubes and over the blower motor housing.
(4) Install attaching nuts on the housing studs.
CAUTION: DO NOT over tighten the attaching nuts.
The housing could become distorted causing air
leaks and improper heater door operation. Tighten
the nuts alternately and evenly until 2 stud threads
are visible beyond each nut.
(5) Connect defroster duct to the housing.
(6) Connect blower motor wire.
(7) Connect vent door control cables.
(8) Connect heater hoses.
(9) Fill cooling system.
(10) Check system operation.
BLOWER MOTOR (HEATING)
REMOVAL
(1) Remove heater housing.
(2) Remove blower motor-to-heater housing attach-
ing screws/nuts.
(3) Remove blower motor from the housing.
INSTALLATION
(1) Position blower motor into housing.
(2) Install and tighten blower motor-to-heater
housing attaching screws/nuts.
(3) Install heater housing.
(4) Check blower motor and heater operation.
DEFROSTER NOZZLE AND DUCT
REVIEW ALL WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THIS
OPERATION.
REMOVAL
(1) Drain coolant from the radiator.
(2) Disconnect heater hoses.
(3) Remove nuts attaching the heater housing
studs to the engine compartment side of the dash
panel.
(4) Disconnect speedometer cable.
(5) Remove glove box.
(6) Tilt heater housing back and pull it rearward
and out from under the instrument panel.
(7) Disconnect vent control cables.
(8) Remove fresh air intake grille from the cowl.
(9) Remove fresh air intake duct.
(10) Lower windshield.
(11) Remove defroster nozzle attaching screws and
remove the nozzle and duct.
INSTALLATION
(1) Install defroster nozzle and duct.
(2) Raise and secure the windshield.
(3) Install fresh air intake duct.
(4) Install fresh air intake grille on the cowl.
(5) Install vent cables.
(6) Position heater housing on the dash panel. Be
sure all the housing studs extend through the dash
panel.
(7) Install seals on the blower motor and heater
core inlet and outlet tubes.
(8) Install on the housing studs.
CAUTION: DO NOT over tighten the attaching nuts.
The housing could become distorted causing air
leaks and improper heater door operation. Tighten
the nuts alternately and evenly until 2 stud threads
are visible beyond each nut.
(9) Install glove box.
(10) Connect speedometer cable.
JHEATING AND AIR CONDITIONING 24 - 33