1995 JEEP XJ heater

COMPONENT SERVICEÐXJ VEHICLES
INDEX
page page
A/C Recirculating Door Vacuum Motor
Replacement........................... 27
Blower Motor Resistors Replacement.......... 31
Blower Motor/Fan Replacement............... 24
Condenser Filter DrierÐ2.5L Engines.......... 27
CondenserÐ4.0L Engines................... 28
Description.............................. 23
Evaporator Coil........................... 30
Evaporator/Blower Housing.................. 29Expansion Valve.......................... 31
Filter DrierÐ4.0L Engines................... 28
Fin Sensing Cycling Clutch Switch............. 31
Heater and A/C Control Replacement.......... 23
Heater Core............................. 26
Heater Housing Replacement................ 26
Heater/Defroster/Instrument Panel Outlet Vacuum
Motor Replacement...................... 26
DESCRIPTION
The Climate Control System combines air condi-
tioning, heating and ventilating capabilities for vehi-
cles equipped with air conditioning. Vehicles without
air conditioning perform heating and ventilating
functions without the air conditioning evaporator.
Both systems consist basically of 2 parts:
²Blower and Air Inlet Assembly
²Heater Core and Air Distribution Assembly
These unit may be removed separately from under
the instrument panel for service.
HEATER AND A/C CONTROL REPLACEMENT
(1) Disconnect negative cable from battery.
(2) Remove the instrument panel bezel attaching
screws and remove the instrument panel bezel (Fig.
1). Bezel is snap fit at locations shown.(3) Remove the radio attaching screws (Fig. 2).
(4) Disconnect the radio electrical connector,
ground lead and antenna lead (Fig. 3).
Fig. 1 Instrument Bezel
Fig. 2 Radio Mounting Screws
Fig. 3 Radio Wiring Harness
JHEATING AND AIR CONDITIONING 24 - 23

(5) Remove the A/C-heater control panel screws
(Fig. 4).
(6) Remove the electrical connectors (Fig. 5).
(7) Disconnect the vacuum hoses by releasing the
locking tabs (Fig. 6).
(8) Remove the control cable locking tab by using a
screwdriver to release the tab (Fig. 7).
(9) Remove the ring on the end of the control cable
from the arm on the bottom of the control panel (Fig.
8).To Install the A/C-heater control panel, reverse the
removal procedures.
BLOWER MOTOR/FAN REPLACEMENT
2.5L ENGINE
(1) Disconnect the blower motor wires (Fig. 9).
(2) Remove the blower motor mounting bolts (Fig.
10).
(3) Remove the blower motor and fan assembly.
Fig. 4 Control Panel Mounting Screws
Fig. 5 Electrical Connectors
Fig. 6 Vacuum Hose Connector
Fig. 7 Control Cable Locking Tab
24 - 24 HEATING AND AIR CONDITIONINGJ

HEATER CORE
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THIS
OPERATION.
REMOVAL
(1) Drain the radiator.
(2) Disconnect heater hoses at heater core tubes.
(3) Remove heater/evaporator housing side cover.
(4) Remove retaining screws and remove heater core
by pulling it straight out of the housing (Fig. 12).
INSTALLATION
(1) Install the heater core into the housing and in-
stall the screws.
(2) Install the evaporator/blower housing side cover.
(3) Install heater hoses to the heater core.
(4) Fill the cooling system.
HEATER HOUSING REPLACEMENT
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THIS
OPERATION.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove center console. Refer to Group 23 body
for procedure.
(3) Remove instrument panel refer to Group 23.
(4) Remove heater hoses.
(5) Recover refrigerant system and remove A/C
lines if equipped.
(6) Remove heater/evaporator housing side cover.
(7) Remove the heater core.
(8) Remove the defroster duct.
(9) Disconnect the vacuum hoses from the heater
core housing vacuum motors.(10) Remove the housing retaining nuts in the en-
gine compartment. Remove the heater core housing.
INSTALLATION
(1) Transfer the vacuum motors, etc. to the re-
placement housing.
(2) Install the heater core housing and heater
housing retaining nuts in the engine compartment.
(3) Install the vacuum hoses.
(4) Install the defroster duct.
(5) Install the heater core.
(6) Install heater/evaporator housing side cover.
(7) Remove heater hoses.
(8) Install A/C lines if equipped and evacuate and
charge refrigerant system.
(9) Remove instrument panel refer to Group 23.
(10) Install center console. Refer to Group 23 body
for procedure.
(11) Install negative cable from battery.
(12) Fill coolant system.
HEATER/DEFROSTER/INSTRUMENT PANEL OUTLET
VACUUM MOTOR REPLACEMENT
(1) Remove center console. Refer to Group 23 body
for procedure.
(2) Remove the lower instrument panel.
(3) Disconnect the vacuum hose(s) from the vac-
uum motor.
(4) Remove the vacuum motor attaching nuts and
remove the vacuum motor from the bracket.
(5) Remove the vacuum motor linkage retaining
clip and remove the rod from the door actuating lever
(Fig. 13).
To install a vacuum motor, reverse the removal
procedure.
Fig. 12 Heater Core
Fig. 13 Vacuum Motor
24 - 26 HEATING AND AIR CONDITIONINGJ

(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

(2) Install housing retaining screws and rear hous-
ing clip.
CAUTION: When installing evaporator/blower hous-
ing, DO NOT trap wires between fresh air inlet
housing and dash panel.
(3) Install housing retaining nuts on the engine
compartment side of the dash panel.
(4) Connect the A/C hoses to the expansion valve
and connect the heater blower motor wires.
(5) Attach wire connections at blower motor resis-
tors and cycling clutch switch.
(6) Connect vacuum hose at the vacuum motor and
attach heater control cable.
(7) Install instrument panel bolt and kick panel.(8) Install lower instrument panel.
(9) Install the console.
(10) Connect negative cable to battery.
(11) Evacuate and charge A/C system.
(12) Start the vehicle and check for proper opera-
tion at all vacuum motors.
EVAPORATOR COIL
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THIS
OPERATION.
REMOVAL
(1) Remove the evaporator/blower housing.
(2) Remove the top housing retaining screws. Re-
move the top of the evaporator housing (Fig. 24).
(3) Remove the cycling clutch switch from evapora-
tor.
(4) Remove evaporator retaining screws and lift
the evaporator out of the housing (Fig. 25).
Fig. 22 Evaporator Housing Alignment Tab
Fig. 23 Evaporator Housing
Fig. 24 Top of Housing
Fig. 25 Evaporator
24 - 30 HEATING AND AIR CONDITIONINGJ

COMPONENT SERVICEÐYJ VEHICLES
INDEX
page page
A/C Blower Motor......................... 35
A/C Condenser........................... 34
Blower Motor (Heating)..................... 33
Blower Motor/Air Door Motor Switch Replacement . 32
Defroster Nozzle and Duct.................. 33
Description.............................. 32
Evaporator and Housing.................... 35
Expansion Valve.......................... 35Fresh Air Door Vacuum Motor................ 34
Fresh Air Intake Duct...................... 34
Heater Control Replacement................. 32
Heater Core and Housing................... 33
Receiver-Drier Replacement................. 35
Temperature Control Thermostat.............. 34
Vent Door Control Cables................... 32
DESCRIPTION
The air conditioning evaporator housing is
mounted to the bottom of instrument panel. The
evaporator, blower motor, thermostat, and expansion
valve are located in the evaporator housing. The com-
pressor, condenser, receiver-dryer and refrigerant
lines are located in the engine compartment.
The heater housing is mounted to the dash panel
behind the instrument panel.
HEATER CONTROL REPLACEMENT
(1) Remove instrument cluster bezel attaching
screws (Fig. 1).
(2) Remove instrument cluster bezel.
(3) Remove screws attaching the heater control
panel to the instrument panel.
(4) Slide control panel outward and disconnect the
cables, vacuum hoses and electrical wires from the
control panel.
(5) Remove control panel.
To install control panel, reverse the removal proce-
dures.
BLOWER MOTOR/AIR DOOR MOTOR SWITCH
REPLACEMENT
(1) Remove heater control panel (Fig. 2).
(2) Remove air door motor switch.
(3) Remove control knob from the blower switch.(4) Remove screws that attach the switch to the
control panel.
(5) Remove switch from the control panel.
To install switches, reverse the removal procedures.
VENT DOOR CONTROL CABLES
REMOVAL
(1) Disconnect cable from the vent door.
(2) Disconnect cable from the heater control panel
lever. The cables are attached to the control panel le-
vers with plastic tabs. Press the tabs together and
lift the cable upward to disengage it from the lever.
(3) Remove the cable. The clip on the cable wire
has 2 functions. It attaches the cable to the vent door
and is also the self adjusting mechanism. The left ca-
ble operates the right cable. The cables must be in-
stalled as outlined to maintain the self adjusting
feature and ensure proper vent door operation.
Fig. 1 Instrument Cluster Bezel
Fig. 2 Control Switches
24 - 32 HEATING AND AIR CONDITIONINGJ

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

(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