electrical JEEP CHEROKEE 1995 Service Owners Manual

INTERIOR COMPONENTS
INDEX
page page
Assist HandleÐXJ........................ 89
B/C-Pillar and Liftgate Pillar Trim CoversÐXJ.... 88
Bucket Seat Cushion and CoverÐXJ........... 81
Bucket Seat PlatformÐXJ................... 82
Bucket Seatback Cover and FrameÐXJ........ 81
Cargo BarrierÐXJ........................ 101
Cargo LampÐXJ......................... 94
Carpets and Floor MatsÐXJ................. 99
Dome LampÐXJ......................... 93
Front Bucket SeatsÐXJ.................... 81
Front Carpet/MatÐXJ...................... 99
Front Inner Scuff Plate/Cowl Side Trim PanelÐXJ . 86
Front Shoulder Belt/BuckleÐXJ............... 90
Full Floor ConsoleÐXJ..................... 95
HeadlinerÐXJ............................ 92
I/P Ash Receiver Tray LampÐXJ.............. 80
Instrument Cluster BezelÐXJ................ 80
Interior Trim Panels and Scuff PlatesÐXJ....... 84
Jack StorageÐXJ......................... 97
Keyless Entry ReceiverÐXJ................. 93Mini-Console with Floor ShiftÐXJ............. 94
Mini-Floor ConsoleÐXJ..................... 94
Outer Scuff PlatesÐXJ..................... 89
Overhead ConsoleÐXJ..................... 93
Parking Brake Handle CoverÐXJ............. 94
Quarter and Wheelhouse Trim PanelsÐXJ...... 87
Quarter Trim Panel ExtensionÐXJ............. 87
Rear Carpet/MatÐXJ..................... 100
Rear Seat Cushion CoverÐXJ............... 82
Rear Seat CushionÐXJ.................... 82
Rear Seatback CoverÐXJ................... 84
Rear Seatback Latch Striker and BumperÐXJ.... 84
Rear SeatbackÐXJ........................ 83
Rear Shoulder/Lap Belt/BuckleÐXJ............ 91
Sound BarÐXJ........................... 94
Spare Tire/Wheel Holddown and Floor
BracketsÐXJ........................... 98
SunvisorsÐXJ........................... 93
Windshield Side MoldingÐXJ................ 86
INSTRUMENT CLUSTER BEZELÐXJ
REMOVAL
(1) Remove the bezel retaining screws (Fig. 1).
(2) Separate the bezel from the U-clips and remove
it from the upper section of the instrument panel.
(3) If necessary, remove or install rocker switch
cover plates.
INSTALLATION
(1) Position the bezel on the upper instrument
panel and engage it with the U-clips.
(2) Install the bezel retaining screws. Tighten thescrews with 1 Nzm (11 in-lbs) torque.
For service procedures regarding individual I/P
components refer to Group 8, Electrical.
I/P ASH RECEIVER TRAY LAMPÐXJ
REMOVAL
(1) Remove the ash receiver tray from instrument
panel (Fig. 2).
(2) Remove the lamp retaining screw from the ash
receiver tray cavity (Fig. 3).
(3) Disconnect the lamp wire harness connector
and remove the lamp from the instrument panel.
Fig. 1 Instrument Bezel Removal/Installation
Fig. 2 Ash Receiver Tray
23 - 80 INTERIOR COMPONENTSÐXJJ

INSPECTION
Inspect the rear shoulder/lap belts and buckles. Re-
place any belt that is either cut, frayed, torn or dam-
aged in any way. Replace the shoulder belt if the
retractor is damaged or inoperative.
INSTALLATION
(1) Position the shoulder belt buckle and the lap
belt/buckle anchor plates on the floor panel.
(2) Install the anchor bolts. Tighten the bolts to 37
Nzm (27 ft-lbs) torque.
(3) Position the shoulder belt at the roof rail and
install the upper anchor bolt. Tighten the bolt to 37
Nzm (27 ft-lbs) torque.
(4) Route the shoulder belt through the quarter
trim panel slot. Install the retractor support on the
rear quarter rail. Tighten the screw to 5 Nzm (45 in-
lbs) torque.
(5) Install the quarter trim panel.
(6) Install the shoulder belt lower anchor bolt.
Tighten the bolt to 37 Nzm (27 ft-lbs) torque.
(7) Return the rear seat to the normal position and
engage the latch.
HEADLINERÐXJ
The upper trim moldings and the headliner are at-
tached to the roof rail with a combination of screws,
velcro strips, clip retainers and rail retainers (Fig. 1).
To remove a headliner, all of the upper trim mold-
ings must be removed from the perimeter of the
headliner along with (as applicable):
²Assist handles.
²Sunvisors.
²Dome/cargo lamps.
²Overhead console.
²Keyless entry receiver module.
²Sound bar.
²All other attached/overlapping components.
Refer to the appropriate removal and installation pro-
cedure locate in this section or in Group 8, Electrical.
REMOVAL
CAUTION: The headliner is a one-piece, molded
component. It has limited flexibility and must not be
bent during removal/installation.
(1) Remove the upper trim moldings from the pe-
rimeter of the headliner (Fig. 2 and 3).
Fig. 5 Shoulder Belt Retractor Support Removal/
InstallationFig. 1 Headliner Trim Moldings
Fig. 2 Upper Trim MoldingÐ4-Door XJ Vehicles
Fig. 3 Liftgate Trim Molding
23 - 92 INTERIOR COMPONENTSÐXJJ

(8) Separate the liftgate glass from the hard top.
(9) Remove the weatherstrip seal (Fig. 2), if neces-
sary.
INSTALLATION
(1) Assemble the liftgate components, if necessary
(2) Position the liftgate glass in the hard top open-
ing and install the hinge bolts. Do not tighten the
bolts.
(3) Adjust the liftgate glass to fit the hard top
opening.
(4) Tighten the hinge bolts to 11 Nzm (95 in-lbs)
torque.
(5) Position the support rod cylinders on the ball
studs.
(6) Install the support rod cylinder retainer clips.
(7) Connect the wiper motor wire harness connec-
tor and the washer fluid hose. Install the wiper mo-
tor cover (Fig. 1).
(8) Install the wiper arm and blade.
(9) Connect the rear window defroster/dome lamp
wire harness connectors.
DISASSEMBLY
(1) Remove retaining screws and the lower, inner
trim molding from the latch panel (Fig. 3).
(2) Remove the retaining screws and the latch
panel, inner gasket, outer gasket, and the lower,
outer liftgate molding from the liftgate (Fig. 3).
(3) Refer to Group 8, Electrical for service informa-
tion involving the wiper motor and the defroster.
(4) If necessary, remove the latch strikers and the
ball stud brackets from the hard top inner panel (Fig.
3).
ASSEMBLY
(1) If removed, install the latch strikers and the
ball stud brackets on the hard top inner panel (Fig.
3).(2) Position the latch panel, and gaskets, and lift-
gate molding on liftgate and install screws (Fig. 3).
Tighten the screws to 7 Nzm (60 in-lbs) torque.
(3) Position the lower, inner trim molding on the
latch panel. Install screws (Fig. 3). Tighten the
screws to 2 Nzm (12 in-lbs) torque.
LIFTGATE GLASS WEATHERSTRIP SEAL
REPLACEMENTÐYJ
REMOVAL
(1) Remove the liftgate glass from the hard top. If
necessary, refer to the removal procedure.
(2) Remove the retaining screws from the liftgate-
to-tailgate weatherstrip seal (Fig. 4).
(3) Carefully separate the seal and retainers from
the bottom of the liftgate glass.
(4) Remove the hard top weatherstrip seal retain-
ing screws from body rear panels.
(5) Carefully separate the weatherstrip seal from
the rear panels and the hard top.
(6) Remove the residual adhesive from the seal
contact areas.
INSTALLATION
(1) Remove the tape cover and position the liftgate-
to-tailgate weatherstrip seal at the bottom of the lift-
gate glass (Fig. 4).
(2) Carefully insert the retainers into the holes
and press the seal against the bottom of the liftgate
glass.
(3) Install the liftgate-to-tailgate weatherstrip seal
screws Tighten the screws securely.
Fig. 3 Liftgate and Components
Fig. 4 Liftgate Glass Weatherstrip Seals
JEXTERIOR COMPONENTSÐYJ 23 - 125

(2) Install the bezel screws. Tighten the screws to
3Nzm (24 in-lbs) torque.
(3) Position the instrument cluster housing on the
instrument panel (Fig. 1). Connect the switch illumi-
nation bulb socket to the instrument cluster housing
(Fig. 4).
(4) Install the attaching screws (Fig. 1, 2 and 3).
Tighten the screws to 3 Nzm (24 in-lbs) torque.
INSTRUMENT PANEL COMPONENTSÐYJ
For service procedures regarding individual I/P
components refer to Group 8, Electrical.
GLOVE BOXÐYJ
REMOVAL
(1) Remove the glove box-to-instrument panel re-
taining screws (Fig. 7).
(2) Pull the glove box housing out of the instru-
ment panel opening (Fig. 14).
INSTALLATION
(1) Position the glove box housing in the instru-
ment panel opening.
(2) Install the glove box-to-instrument panel
screws. Tighten the screws securely.
DOOR AND HINGE
The glove box door hinge attaching screw holes are
elongated for adjustment. The hinge screws can be
loosened and the door moved in direction for the best
fit within the door opening.
Fig. 3 Instrument Gauge Housing Screws
Fig. 4 Instrument Cluster Housing and Lamp
Fig. 5 Instrument Cluster Bezel
Fig. 6 Instrument Panel Components
23 - 152 INTERIOR COMPONENTSÐYJJ

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

(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

(5) Remove expansion valve from the evaporator.
INSTALLATION
Add 30 ml (1 fluid oz.) of refrigerant oil to the A/C
system if the evaporator is replaced.
(1) Install expansion valve on evaporator.
(2) Position evaporator in the housing. Install and
tighten the evaporator retaining screws.
(3) Install cycling clutch switch into evaporator. In-
stall the top of the evaporator housing.
(4) Install the evaporator/blower housing.
(5) Evacuate and charge A/C system as outlined in
this section.
EXPANSION VALVE
REVIEW ALL WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THIS
OPERATION.
REMOVAL
(1) Recover refrigerant from A/C system.
(2) Remove the coolant bottle and bracket.
(3) Disconnect A/C hoses from the expansion valve
(Fig. 26).
(4) Disconnect expansion valve from the evaporator
core inlet and outlet tubes. Remove the expansion
valve.
INSTALLATION
(1) Install the expansion valve. Connect the expan-
sion valve to the evaporator core inlet and outlet
tubes.
(2) Connect A/C hoses to the expansion valve.
(3) Install the coolant bottle and bracket.(4) Evacuate and charge A/C system as outlined in
this section.
(5) Preform the leak test.
BLOWER MOTOR RESISTORS REPLACEMENT
(1) Remove vacuum motor cover retaining screw
and lower the cover.
(2) Remove blower motor resistor connector, re-
move the resistor retaining screws, and remove resis-
tor.
To install the blower motor resistor reverse the re-
moval procedures.
FIN SENSING CYCLING CLUTCH SWITCH
REMOVAL
(1) Disconnect negative cable from battery.
(2) If equipped with center console remove the con-
sole. Refer to Group 23 body for proper procedure.
(3) Remove lower instrument panel.
(4) Pull the rosebud terminal out of the housing
(Fig. 27).
(5) Disconnect the electrical connection.
(6) Remove the wires from the retaining clip.
(7) Carefully remove the thermostat cycling clutch
switch from the evaporator (Fig. 27).
INSTALLATION
(1) Carefully install cycling switch.
(2) Connect the electrical connection.
(3) Snap the terminal into the hole in the housing.
(4) Install wiring connections.
(5) Install lower instrument panel.
(6) Install console if equipped.
(7) Install negative battery cable.
Fig. 26 Expansion Valve
Fig. 27 Fin Sensing Cycling Clutch Switch
JHEATING AND AIR CONDITIONING 24 - 31

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

EMISSION CONTROLS
INDEX
page page
Crankcase Ventilation System................. 5
EVAP (Evaporation) Control System............ 4
EVAP Canister............................ 4Fuel Tank Filler Tube Cap.................... 4
Oxygen (O2S) Sensor....................... 6
Pressure Relief/Rollover Valve................. 6
EVAP (EVAPORATION) CONTROL SYSTEM
GENERAL INFORMATION
The function of the EVAP control system is to pre-
vent the emissions of gasoline vapors from the fuel
tank into the atmosphere. When fuel evaporates in
the fuel tank, the vapors pass through vent hoses or
tubes to a carbon filled EVAP canister. They are tem-
porarily held in the canister until they can be drawn
into the intake manifold when the engine is running.
The EVAP canister is a feature on all models for
the storage of fuel vapors from the fuel tank.
The hoses used in this system are specially
manufactured. If replacement becomes neces-
sary, it is important to use only fuel resistant
hose.
EVAP CANISTER
A sealed, maintenance free, EVAP canister is used
on all vehicles. On XJ models, the EVAP canister is
located in the engine compartment on the passenger
side frame rail (Fig. 4). On YJ models, the EVAP can-
ister is located in the engine compartment on the
dash panel and below the brake master cylinder (Fig.
5). The EVAP canister is filled with granules of an
activated carbon mixture. Fuel vapors entering the
EVAP canister are absorbed by the charcoal granules.
CANISTER OPERATION
Vacuum is used to control and operate the
EVAP canister. No electrical circuitry is used to
control or operate the EVAP system.
The EVAP canister is equipped with a vacuum con-
trolled purge shutoff switch (orifice) (Figs. 4 or 5)
that controls canister purge operation. The switch is
open when manifold vacuum is applied to it. When
the engine is operating, the EVAP canister purge
function draws fresh air through the top of the can-
ister. This causes the stored vapors to be drawn out
of the canister and into the airstream in the air
cleaner snorkel (Fig. 6).
The air cleaner contains a venturi in the air
cleaner cover used as a purge line vacuum source
(Fig. 6). The venturi effect increases the speed of the
intake air flowing by the slots in the venturi wall.
This creates a low pressure area around the slots.
When the purge shutoff switch is open, vapors from
the canister are drawn through slots and into the air-
stream flowing through the venturi (Fig. 7). The va-
pors pass through the intake manifold into the
engine combustion chambers where they are con-
sumed during engine combustion.
FUEL TANK FILLER TUBE CAP
The fuel tank filler tube cap (fuel tank cap) incor-
porates a two-way pressure/relief valve that is closed
to atmosphere during normal operating conditions.Fig. 4 EVAP Canister LocationÐXJ Models
Fig. 5 EVAP Canister LocationÐYJ Models
25 - 4 EMISSION CONTROL SYSTEMSJ