1995 JEEP XJ drain bolt

A/C RECIRCULATING DOOR VACUUM MOTOR
REPLACEMENT
(1) Remove the vacuum motor cover (Fig. 14).
(2) Disconnect the vacuum hose (Fig. 15).
(3) Remove the actuating rod clip and disengage
the rod from the door lever.
(4) Remove the vacuum motor retaining nuts and
then remove the vacuum motor.
To install the motor, reverse the removal proce-
dures.
CONDENSER FILTER DRIERÐ2.5L ENGINES
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THIS
OPERATION.
REMOVAL
(1) Drain the radiator.
(2) Disconnect the fan shroud and the radiator
hoses.
(3) Disconnect the transmission cooler lines (if
equipped with automatic transmission).
(4) Recover refrigerant from the system and dis-
connect A/C lines from the condenser.
(5) Unplug the harness from the pressure cut-off
switch (Fig. 16).
(6) Remove the radiator and condenser as an as-
sembly.
(7) Remove the retaining bolts and separate the
condenser from the radiator.
(8) Remove the filter drier from the condenser.
Keep filter/drier openings plugged at all times
to prevent moisture from entering the filter
drier.
INSTALLATION
Add 30 ml (1 fluid oz.) of refrigerant oil to the A/C
system if the condenser or filter drier is replaced.
(1) Remove the plugs from the filter drier open-
ings. Install filter drier into the condenser.
(2) Install the condenser to the radiator. Tighten
the retaining bolts.
(3) Install the radiator and condenser as an assem-
bly (refer to Group 7, Cooling System for the proper
procedure).
Fig. 14 Vacuum Door Motor Cover
Fig. 15 Vacuum Door Motor
Fig. 16 Condenser Filter DrierÐLHD 2.5L Engine
JHEATING AND AIR CONDITIONING 24 - 27

(1) Install the filter drier.
(2) Install and tighten the nut attaching the filter
drier to the side sill weld stud.
(3) Plug the harness to the low pressure switch.
(4) Remove the plugs the openings. Connect the
A/C hoses to the receiver dryer.
(5) Evacuate and charge the A/C system.
EVAPORATOR/BLOWER HOUSING
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THIS
OPERATION.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Recover refrigerant from A/C system and dis-
connect A/C lines from the expansion valve.
(3) Disconnect the blower motor wires and the vent
tube.
(4) Remove center console. Refer to Group 23 body
for procedure.
(5) Remove the lower instrument panel.
(6) Disconnect the electrical connections at the
blower motor resistors and cycling clutch switch. Dis-
connect the vacuum hose at the vacuum motor (Fig.
19).
(7) Cut the plastic retaining strap that retains the
evaporator/blower housing to the heater core housing
(Fig. 20).
(8) Disconnect and remove the heater control cable.
(9) Remove the clip at the rear of the blower hous-
ing flange and remove the retaining screws.(10) Remove the housing attaching nuts from en-
gine compartment side of the dash panel (Fig. 21).
Remove evaporator drain tube.
(11) Remove right kick panel and remove the in-
strument panel support bolt.
(12) To disengage housing studs from the dash panel,
gently pull out on the right side of the dash. Then ro-
tate housing downward and toward the rear of the ve-
hicle . Remove the evaporator/blower housing.
INSTALLATION
(1) Position evaporator/blower housing into place,
being sure to line up the housings using the provided
alignment tabs (Figs. 22 and 23).
Fig. 19 Evaporator Housing Components
Fig. 20 Evaporator Housing
Fig. 21 Evaporator Housing Mounting
JHEATING AND AIR CONDITIONING 24 - 29

(11) Connect the heater hoses.
(12) Fill cooling system.
FRESH AIR DOOR VACUUM MOTOR
REMOVAL
(1) Remove glove box and assist handle.
(2) Disconnect vacuum hose from the motor.
(3) Remove motor lever retaining clip.
(4) Remove motor attaching nuts and remove the
motor from the fresh air duct.
INSTALLATION
(1) Position motor on fresh air duct and install the
motor attaching nuts.
(2) Align motor lever with the air door lever and
install the lever retaining clip.
(3) Connect vacuum hose to the motor.
(4) Install glove box and assist handle.
FRESH AIR INTAKE DUCT
REVIEW 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 dash panel from inside the engine com-
partment.
(4) Disconnect speedometer cable.
(5) Remove glove box and assist handle.
(6) Tilt heater housing back and pull it rearward
and out from under the instrument panel.
(7) Disconnect vent cables.
(8) Remove windshield bracket bolts and lower
windshield.
(9) Remove fresh air intake grille from the cowl.
(10) Remove fresh air intake duct.
INSTALLATION
(1) Install fresh air intake duct.
(2) Install defroster nozzle and duct.
(3) Raise and secure the windshield.
(4) Install fresh air 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 nuts on the heater housing studs.
CAUTION: DO NOT over tighten the attaching nuts.
The housing could become distorted causing air
leaks and improper heater door operation. Tightenthe nuts alternately and evenly until 2 stud threads
are visible beyond each nut.
(9) Install glove box and assist handle.
(10) Connect speedometer cable.
(11) Connect heater hoses.
(12) Fill cooling system.
TEMPERATURE CONTROL THERMOSTAT
REMOVAL
(1) Remove mounting bolts and lower the evapora-
tor housing.
(2) Remove the attaching screws holding the top
and bottom housings together.
(3) Separate the housings.
(4) Remove the thermostat.
INSTALLATION
(1) Install temperature control thermostat. Insert
thermostat capillary tube into the evaporator coil a
minimum of 50 mm (2 inch).
CAUTION: Handle the tube with care to avoid bends
or kinks that could cause the thermostat to mal-
function.
(2) Assemble the housing and install the attaching
screws. DO NOT over tighten the attaching screws.
(3) Install the evaporator housing.
A/C CONDENSER
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THIS
OPERATION.
REMOVAL
(1) Recover refrigerant from A/C system.
(2) Drain the radiator.
(3) Remove fan shroud and radiator.
(4) Disconnect A/C line from the condenser.
(5) Remove condenser attaching screws and tilt the
bottom of the condenser toward the engine.Plug all
the condenser openings to prevent entry of dirt
or moisture.
(6) Working from under the vehicle, disconnect the
receiver-drier to-evaporator hose fitting from the re-
ceiver-drier.
(7) Remove condenser and receiver-drier as an as-
sembly.
(8) Remove receiver-drier from the condenser, if
necessary.
INSTALLATION
Add 30 ml (1 fluid oz.) of refrigerant oil to the A/C
system if the condenser is replaced.
(1) Attach receiver-drier to the condenser.
(2) Install condenser and connect A/C line to the
receiver-drier.
24 - 34 HEATING AND AIR CONDITIONINGJ