warning JEEP CHEROKEE 1995 Service Repair Manual

INTERIOR COMPONENTS
INDEX
page page
Add-A-TrunkÐYJ........................ 157
Bucket SeatsÐYJ........................ 153
CarpetÐYJ............................. 156
Floor ConsolesÐYJ...................... 155
Front Shoulder BeltsÐYJ.................. 154
Glove BoxÐYJ.......................... 152
Instrument Cluster and Gauge HousingsÐYJ.... 151Instrument Cluster BezelÐYJ............... 151
Instrument Panel ComponentsÐYJ........... 152
Instrument PanelÐYJ..................... 151
Rear Bench SeatÐYJ..................... 153
Rear Shoulder BeltsÐYJ................... 154
SeatsÐYJ............................. 153
SunvisorsÐYJ.......................... 155
INSTRUMENT PANELÐYJ
The instrument panel is constructed of sheet metal
and is attached to cowl panel with screws. The in-
strument panel and defroster grille pad is attached
to the instrument panel with screws.
INSTRUMENT CLUSTER AND GAUGE HOUSINGSÐ
YJ
REMOVAL
(1) Remove the instrument cluster and gauge
housing attaching screws (Fig. 1, 2 and 3).
(2) Disconnect the switch illumination bulb socket
from the instrument cluster housing (Fig. 4). Remove
the housings from the instrument panel (Fig. 1).
INSTALLATION
(1) Position the instrument cluster and gauge
housings on the instrument panel (Fig. 1). Connect
the switch illumination bulb socket to the instrument
cluster housing (Fig. 4).
(2) Install the attaching screws (Fig. 1, 2 and 3).
Tighten the screws to 3 Nzm (24 in-lbs) torque.
INSTRUMENT CLUSTER BEZELÐYJ
REMOVAL
(1) Remove the instrument cluster housing attach-
ing screws (Fig. 1, 2 and 3).
(2) Disconnect the switch illumination bulb from
instrument cluster (Fig. 4). Remove the housing from
the instrument panel (Fig. 1).
(3) Remove the bezel retaining screws.
(4) Disconnect the accessory switch, warning indi-
cator, rheostat and lamp wire harness connectors
from the bezel (Fig. 5).
(5) Remove the bezel from the instrument panel
(Fig. 6).
INSTALLATION
(1) Position bezel at the instrument panel and con-
nect accessory switch, warning indicator, rheostat
and lamp wire harness to bezel.
Fig. 1 Instrument Cluster/Gauge Housing and Radio
Fig. 2 Instrument Cluster Housing Lower Screws
JINTERIOR COMPONENTSÐYJ 23 - 151

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

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

WARNINGS, CAUTIONS AND SERVICE PRECAUTIONS
WARNINGS
WARNING: THE AIR CONDITIONING SYSTEM CON-
TAINS REFRIGERANT UNDER HIGH PRESSURE.
SEVERE PERSONAL INJURY MAY RESULT FROM
IMPROPER SERVICE PROCEDURES. REPAIRS
SHOULD ONLY BE PERFORMED BY QUALIFIED
SERVICE PERSONNEL.
WARNING: AVOID BREATHING A/C REFRIGERANT
AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY
IRRITATE EYES, NOSE AND/OR THROAT. WEAR
EYE PROTECTION WHEN SERVICING THE AIR
CONDITIONING REFRIGERANT SYSTEM. SERIOUS
EYE INJURY CAN RESULT FROM EYE CONTACT
WITH REFRIGERANT. IF EYE CONTACT IS MADE,
SEEK MEDICAL ATTENTION IMMEDIATELY.
WARNING: DO NOT EXPOSE REFRIGERANT TO
OPEN FLAME. POISONOUS GAS IS CREATED
WHEN REFRIGERANT IS BURNED. AN ELEC-
TRONIC TYPE LEAK DETECTOR IS RECOM-
MENDED.
WARNING: IF ACCIDENTAL SYSTEM DISCHARGE
OCCURS, VENTILATE THE WORK AREA BEFORE
RESUMING SERVICE. LARGE AMOUNTS OF RE-
FRIGERANT RELEASED IN A CLOSED WORK AREA
WILL DISPLACE THE OXYGEN AND CAUSE SUFFO-
CATION.
WARNING: THE EVAPORATION RATE OF (R-134A)
REFRIGERANT AT AVERAGE TEMPERATURE AND
ALTITUDE IS EXTREMELY HIGH. AS A RESULT,
ANYTHING THAT COMES IN CONTACT WITH THE
REFRIGERANT WILL FREEZE. ALWAYS PROTECT
SKIN OR DELICATE OBJECTS FROM DIRECT CON-
TACT WITH REFRIGERANT.
WARNING: R-134A SERVICE EQUIPMENT OR VEHI-
CLE A/C SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED
AIR. SOME MIXTURES OF AIR AND R-134A HAVE
BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED
PRESSURES. THESE MIXTURES ARE POTENTIALLY
DANGEROUS AND MAY RESULT IN FIRE OR EX-
PLOSION CAUSING INJURY OR PROPERTY DAM-
AGE.
CAUTIONS
CAUTION: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with equipment being used.
CAUTION: DO NOT use R-12 equipment or parts on
the R-134a system. Damage to the system will re-
sult.
CAUTION: Never add R-12 to a system designed to
use R-134a. Damage to the system will result.
CAUTION: R-12 compressor oil can not be mixed
with the R-134a compressor oil. They ARE NOT
compatible.
CAUTION: Do not over charge refrigerant system.
This will cause excessive compressor head pres-
sure and can cause noise and system failure.
SERVICE PRECAUTIONS
Recover the refrigerant before opening any fitting
or connection. Open fittings with caution even after
the system has been discharged. Never open or
loosen a connection before recovering the refrigerant.
The A/C system must always be evacuated before
charging.
DO NOT open the refrigerant system or uncap a
replacement component until you are ready to service
the system. This will prevent contamination in the
system.
Before disconnecting a component clean the outside
of the fittings thoroughly to prevent contamination
entering the system.
Immediately after disconnecting a component from
the system, seal the open fittings with a cap or plug.
Before connecting an open fitting always install a
new seal/gasket. Coat the fitting and seal with clean
refrigerant oil before connecting.
When installing a refrigerant line avoid sharp
bends. Position the lines away from the exhaust or
any sharp edges which may chafe the line.
Tighten fittings only to the specified torque. The
aluminum fittings used in the A/C system will not
tolerate over tightening.
When disconnecting a fitting use a wrench on both
halves of the fitting. This will prevent twisting of the
refrigerant lines or tubes.
Refrigerant oil absorbs moisture from the atmo-
sphere if left uncapped. DO NOT open a container of
JHEATING AND AIR CONDITIONING 24 - 9

oil until you are ready to use it. Install the cap im-
mediately after using. Store the oil only in a clean
moisture-free container.
Keep service tools and the work area clean. Con-
tamination of A/C system through careless work hab-
its must be avoided.
COOLING SYSTEM
To maintain the performance level of the heating/
air conditioning system, the engine cooling system
must be properly maintained.
The use of a bug screen is not recommended. Any
obstructions in front of the radiator or condenser can
reduce the performance of the A/C and cooling sys-
tem. If a bug screen is used it must be cleaned fre-
quently.
COOLANT PRECAUTIONS
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY.
WARNING: WASH SKIN AND CLOTHING THOR-
OUGHLY AFTER COMING IN CONTACT WITH ETH-
YLENE GLYCOL.
WARNING: KEEP OUT OF REACH OF CHILDREN
AND PETS.
WARNING: DO NOT OPEN A COOLING SYSTEM
WHEN THE ENGINE IS AT RUNNING TEMPERA-
TURE. PERSONAL INJURY CAN RESULT.WARNING: DO NOT STORE IN OPEN OR UN-
MARKED CONTAINERS.
WARNING: HOT ENGINE COOLANT CAN CAUSE
SEVERE BURNS. DO NOT OPEN THE RADIATOR
DRAIN COCK WHEN THE COOLING SYSTEM IS
HOT AND PRESSURIZED. ALLOW THE COOLANT
TO DECREASE TO ROOM TEMPERATURE BEFORE
STARTING REPAIR OPERATIONS.
The engine cooling system is designed to develop
internal pressure of 97 to 124 kPa (14 to 18 psi). Al-
low the vehicle 15 minutes to cool down (or until a
safe temperature and pressure are attained) before
opening the cooling system. Refer to Group 7, Cooling
System.REFRIGERANT HOSES/TUBES PRECAUTIONS
Kinks or sharp bends in the refrigerant tubing or
hoses will reduce the capacity of the entire system.
High pressures are produced in the system when it is
operating. Extreme care must be exercised to make
sure that all connections are pressure tight. Dirt and
moisture can enter the system when it is opened for
repair.
A good rule for the flexible hose lines is to keep the
radius of all bends at least 10 times the diameter of
the hose. Sharp bends will reduce the flow of refrig-
erant. The flexible hose lines should be routed so
they are at least 80 mm (3 inches) from the exhaust
manifold. It is a good practice to inspect all flexible
hose lines at least once a year to make sure they are
in good condition and properly routed.
24 - 10 HEATING AND AIR CONDITIONINGJ

REFRIGERANT SERVICE AND PERFORMANCE TEST
INDEX
page page
Air Conditioning Performance Tests............ 12
Charging Refrigerant System................. 11
Evacuating Refrigerant System............... 11Leak Testing Refrigerant.................... 11
Recovering Refrigerant System............... 11
Refrigerant Oil........................... 12
LEAK TESTING REFRIGERANT
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE LEAK TESTING.
If A/C system is not cooling properly, determine if
system is fully charged. Refer to Refrigerant System
Diagnosis Chart. If the system is empty evacuate the
A/C system and charge system with 0.283 kPa (0.6
lbs. or 10 oz.) R-134a refrigerant. Refer to Charging
Refrigerant System for instructions. To detect a leak
in the system, perform the following procedures.
(1) Position the vehicle in a wind free work area.
This will aid in detecting small leaks.
(2) Bring A/C system up to operating temperature
and pressure. This is done by allowing the engine to
run with the A/C on for 5 to 7 minutes.
(3) Open hood 5 minutes prior to leak test. This
will dissipate any accumulated refrigerant in the en-
gine compartment.
(4) With the engine not running, use an R-134a
Electronic Leak Detector and search for leaks. Move
probe slowly along the bottom side of lines and fit-
tings, because R-134a is heavier than air. Fittings,
lines, or components that appear to be oily usually
indicates a refrigerant leak.
(5) To inspect the evaporator core for leaks. Set the
blower at low speed and the selector in PANEL and
RECIRC mode check for leaks at CENTER panel out-
lets.
RECOVERING REFRIGERANT SYSTEM
REVIEW WARNINGS AND CAUTIONS IN
GENERAL INFORMATION SECTION OF THIS
GROUP BEFORE DISCHARGING SYSTEM.
R-134a refrigerant is a hydrofluorocarbon (HFC)
that does not contain chlorine. R-134a refrigerant Re-
covery/Recycling Station that meets SAE standard
J2210 must be used to recover the refrigerant. Refer
to the operating instructions provided with the equip-
ment for proper operation.
EVACUATING REFRIGERANT SYSTEM
REVIEW WARNINGS AND CAUTIONS IN
GENERAL INFORMATION SECTION OF THIS
GROUP BEFORE EVACUATING SYSTEM.
If the A/C system has been open to the atmosphere,
it must be evacuated before the system can be
charged. Moisture and air mixed with refrigerant will
raise the compressor head pressure above acceptable
operating levels. This will reduce the performance of
the air conditioner and damage the compressor. Mois-
ture will boil at near room temperature when ex-
posed to vacuum. To evacuate the refrigerant system
use following procedure:
(1) Connect a suitable charging station and mani-
fold gauge set to the vehicle.
(2) Open the low and high side valves and start
vacuum pump. When suction gauge reads 88 kPa (26
in. Hg) vacuum or greater, close all valves and turn
off vacuum pump. If system fails to reach specified
vacuum, the system has a leak that must be cor-
rected. If system maintains the specified vacuum for
30 minutes, start the vacuum pump. Then open the
suction and discharge valves and evacuate an addi-
tional 10 minutes.
(3) Close all valves. Turn off and disconnect the
vacuum pump.
The system is now ready to be charged with refrig-
erant.
CHARGING REFRIGERANT SYSTEM
REVIEW WARNINGS AND CAUTIONS IN
GENERAL INFORMATION SECTION OF THIS
GROUP BEFORE CHARGING SYSTEM.
After the system has been tested for leaks and
evacuated, a refrigerant charge can be injected into
the system. Refer to refrigerant capacities for proper
amount of refrigerant charge. Charge the system us-
ing a Recovery/Recycling/Charging Station approved
for R-134a refrigerant. Refer to the instructions pro-
vided with the equipment for proper operation.
REFRIGERANT CHARGE CAPACITY
The R-134a system charge capacity is 0.9 kPa (32
oz.) for XJ and YJ vehicles.
JHEATING AND AIR CONDITIONING 24 - 11

COMPRESSOR SERVICE
DESCRIPTION
The A/C system uses a Sanden SD7H15 compres-
sor. The compressor is a 7 piston design.
The clutch used on the compressor consists of 3 ba-
sic components: the pulley and bearing hub, clutch
plate and field coil (Fig. 1). The pulley and field coil
are attached to the front of the compressor with ta-
pered snap rings. The compressor has a splined shaft
and the clutch plate is retained on the shaft with a
self-locking nut.
COMPRESSOR
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PROCEEDING WITH
THIS PROCEDURE.
REMOVAL
(1) Recover refrigerant from A/C system.
(2) Disconnect negative cable from battery.
(3) Disconnect the clutch lead wire.
(4) Remove the discharge and suction lines from
the compressor. Plug or tape all the openings.
(5) Remove the serpentine drive belt (refer to
Group 7, Cooling System for the proper procedure).
(6) Remove the bolts and lift the compressor from
the mounting bracket (Figs. 2 and 3).
INSTALLATION
If a replacement compressor is being in-
stalled; check the oil level. Add or subtract oil
as necessary and install the magnetic clutch on
the compressor.
(1) If the mounting bracket was removed, install
the bracket to the block. Tighten the mounting bolts
to 27 Nzm (20 ft. lbs.) torque.
(2) Install the compressor on the mounting
bracket. Tighten the bolts to 27 Nzm (20 ft. lbs.)
torque.(3) Install the serpentine drive belt (refer to Group
7, Cooling System for the proper procedure).
(4) Tighten the serpentine drive belt to the speci-
fied tension.
²New belt tensionÐ800-900 N (180-200 lb-f).
²Used belt tensionÐ623-712 N (140-160 lb-f).
(5) Remove the tape or plastic plugs from all the
suction and discharge openings and install lines on
the compressor.
(6) Connect the clutch lead wire.
(7) Connect negative cable to battery.
(8) Evacuate, charge and test the system for leaks.
Fig. 1 Compressor Clutch
Fig. 2 Compressor and Mounting Bracket (LH Drive
Vehicles)
Fig. 3 Compressor and Mounting Bracket (RH Drive
Vehicles)
JHEATING AND AIR CONDITIONING 24 - 19

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

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

(4) Plug the harness into the low pressure switch
(Fig. 16).
(5) Connect the A/C hoses to the condenser.
(6) Connect the transmission cooler lines (if
equipped with automatic transmission).
(7) Connect the fan shroud and the radiator hoses.
(8) Fill coolant system (Refer to cooling for proper
procedure).
(9) Evacuate and charge the A/C system.
CONDENSERÐ4.0L ENGINES
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THIS
OPERATION.
REMOVAL
(1) Recover refrigerant from the system.
(2) Remove the upper radiator support.
(3) Remove the fan shroud and remove electric fan
from the radiator (Fig. 17). Refer to Group 7 Cooling
for procedure.
(4) Remove fan from engine. Refer to Group 7
Cooling for procedure.
(5) Remove air cleaner assembly. Refer to Group 14
Fuel System for procedure.
(6) Remove grille.
(7) Remove brackets holding condenser to the radi-
ator.
(8) Carefully lift radiator and move toward engine.
(9) Remove A/C line brackets from the condenser
and disconnect A/C lines and plug the openings.
(10) Remove condenser.
INSTALLATION
Add 30 ml (1 fluid oz.) of refrigerant oil to the A/C
system if the condenser is replaced.
(1) Install the condenser to radiator and install in
vehicle.
(2) Remove the plugs from the openings. Connect
the A/C hoses to the condenser.
(3) Install the upper radiator support.
(4) Connect the fan shroud and electric fan to the
radiator.
(5) Connect the transmission cooler lines (if
equipped with automatic transmission).
(6) Fill coolant system (Refer to cooling for proper
procedure).
(7) Evacuate and charge the A/C system.
FILTER DRIERÐ4.0L ENGINES
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THIS
OPERATION.
REMOVAL
(1) Recover refrigerant from A/C system. Discon-
nect A/C lines from filter drier and plug the openings
(Fig. 18).
(2) Unplug the harness from the low pressure
switch.
(3) Remove the nut attaching the filter drier to the
side sill weld stud.
(4) Remove the filter drier.
INSTALLATION
Add 30 ml (1 fluid oz.) of refrigerant oil to the A/C
system if the filter drier is replaced.
Fig. 17 Fan and Shroud
Fig. 18 Condenser and Filter DrierÐLHD 4.0L
Engine
24 - 28 HEATING AND AIR CONDITIONINGJ