dash panel JEEP CHEROKEE 1995 Service Owner's Guide

HOOD SAFETY LATCHÐYJ
REMOVAL
(1) Raise and support the hood.
(2) Remove the latch retaining screws from the
grille panel (Fig. 14).
(3) Remove the latch from the grille panel.
INSTALLATION
(1) Position the latch on the grille panel (Fig. 14).
(2) Install the latch retaining screws.
(3) Remove the support rod and close the hood.
COWL WEATHERSTRIP SEALÐYJ
REMOVAL/INSTALLATION
(1) Carefully separate the seal from the cowl/dash
panel flange (Fig. 15).
(2) Position the seal on the cowl/dash panel flange
(Fig. 15) and press it against the panel edge.
COWL GRILLE AND SCREENÐYJ
REMOVAL
(1) Remove the screws that attach the cowl air in-
take grille to the cowl and to the air intake duct (Fig.
16).(2) Remove the grille and screen from the cowl
(Fig. 16).INSTALLATION
(1) Position the cowl screen and grille on the cowl.
(2) Attach the grille and screen to the cowl and the
air intake duct with the screws (Fig. 16).
Fig. 14 Hood Safety Latch Removal/Installation
Fig. 15 Cowl Weatherstrip Seal
Fig. 16 Cowl Grille Removal/Installation
JEXTERIOR COMPONENTSÐYJ 23 - 109

PAINT
INTRODUCTION
Exterior vehicle body colors are identified on the
Vehicle Code plate. The plate is located on the left
side of the dash panel in the engine compartment.
The color code location is described in the Introduc-
tion of this manual. The color names provided in the
Paint and Trim Code Description chart are the color
names used on most repair product containers. The
color names in the new vehicle ordering guides may
vary depending on vehicle line but use the same color
code.
BASE COAT/CLEAR COAT FINISH
On most vehicles a two part paint application (base
coat/clear coat) is used. Color paint that is applied to
primer is called base coat. The clear coat protects the
base coat from ultra violet light and provides a dura-
ble high gloss finish.
WET SANDING,BUFFING AND POLISHING
Minor acid etching, orange peel or smudging in
clear coat can be reduced with light wet sanding,
hand buffing and polishing. If the finish has been
wet sanded in the past, it can not be repeated. Wet
sanding operation should be performed by a trained
automotive painter.
CAUTION: Do not remove clear coat finish, if
equipped. Base coat paint must retain clear coat to
shine.
PAINTED SURFACE TOUCH-UP
When a painted metal surface has been scratched
or chipped, it should be touched-up as soon as possi-ble to avoid corrosion. For best results, use Mopar
Scratch Filler/Primer, Touch-Up Paints and Clear Top
Coat. Refer to Introduction group of this manual for
Body Code Plate information.
TOUCH-UP PROCEDURE
(1) Scrape loose paint and corrosion from inside
scratch or chip.
(2) Clean affected area with Mopar Tar/Road Oil
Remover and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good sur-
face finish. The applicator brush should be wet
enough to puddle fill the defect without running. Do
not stroke brush applicator on body surface. Allow
the filler/ primer to dry hard.
(4) Cover the filler/primer with color touch-up
paint. Do not overlap touch-up color onto the original
color coat around the scratch or chip. Butt the new
color to the original color if possible. Do not stroke
applicator brush on body surface. Allow touch-up
paint to dry hard.
(5) On vehicles without clear coat, the touch-up
color can be lightly (600 grit) wet sanded and pol-
ished with rubbing compound.
(6) On vehicles with clear coat, Apply clear top
coat to touch-up paint with the same technique as
described in step 4. Allow clear top coat to dry hard.
If desired, step 5 can be performed on clear top coat.
23 - 158 PAINTÐXJÐYJJ

(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

(3) Install condenser attaching screws.
(4) Connect condenser A/C line.
(5) Install radiator and fan shroud.
(6) Fill coolant system (Refer to cooling for proper
procedure).
(7) Evacuate, charge and leak test the air condi-
tioning system.
RECEIVER-DRIER REPLACEMENT
REVIEW ALL WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THIS
OPERATION.
REMOVAL
(1) Recover refrigerant from A/C system.
(2) Disconnect A/C lines from the receiver-drier.
(3) Remove receiver-drier attaching screws and re-
move receiver-drier.
INSTALLATION
(1) Position receiver-drier in place and install re-
ceiver-drier attaching screws.
(2) Connect A/C lines to receiver-drier.
(3) Evacuate, charge and leak test the air condi-
tioning system.
EVAPORATOR AND HOUSING
REVIEW ALL WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THIS
OPERATION.
REMOVAL
(1) Recover refrigerant from A/C system.
(2) Disconnect A/C lines.
(3) Remove hose clamps and dash grommet retain-
ing screws.
(4) Remove the evaporator housing-to-instrument
panel attaching screws and the housing mounting
bracket screw (Fig. 3).
(5) Lower the evaporator housing and pull the
hoses and hose grommet through the dash opening.(6) Remove upper housing and remove evaporator.
The evaporator core, control switches, expansion
valve, blower motor and housing can be serviced af-
ter removing evaporator housing (Fig. 4).
INSTALLATION
Add 30 ml (1 fluid oz.) of refrigerant oil to the A/C
system if the evaporator is replaced.
(1) Install evaporator into housing and install up-
per housing.
(2) Push A/C hoses through the grommet openings
and install the hose grommet by pushing it toward
the engine compartment.
(3) Install hose grommet attaching screws.
(4) Raise evaporator housing and install the evap-
orator housing-to- instrument panel attaching
screws.
(5) Install A/C lines.
(6) Evacuate, charge and leak test the system.
EXPANSION VALVE
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THIS
OPERATION.
REMOVAL
(1) Recover refrigerant from A/C system.
(2) Remove evaporator housing
(3) Remove the insulation wrapped around the suc-
tion hose fitting, expansion valve and evaporator tub-
ing.
(4) Mark the capillary tube location on the evapo-
rator tubing.
(5) Disconnect inlet and outlet hose fittings, and
remove the capillary tube clamp.
(6) Disconnect and remove the expansion valve.
INSTALLATION
(1) Clean evaporator tubing to provide a positive
contact with the expansion valve capillary tube.
(2) Install expansion valve.
(3) Clamp the capillary tube at the marked loca-
tion on the evaporator tubing.
(4) Connect inlet and outlet hose fittings.The
capillary tube must be securely clamped and
have positive metal-to-metal contact with the
evaporator tubing.
(5) Wrap expansion valve, inlet hose fitting and
capillary tube with insulation.
(6) Install evaporator housing.
(7) Evacuate, charge and leak test the system.
A/C BLOWER MOTOR
It is not necessary to discharge the system to ser-
vice the blower motor. The evaporator housing need
only be lowered for access to the blower motor at-
taching screws.Fig. 3 Evaporator Housing
JHEATING AND AIR CONDITIONING 24 - 35

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

The relief valve used in fuel filler caps of all models
is calibrated at a pressure of 10 kPa (1.5 psi) or a
vacuum of 6 kPa (1.8 in. Hg). When the pressure or
vacuum is relieved, the valve returns to the normally
closed position.
CAUTION: The fuel filler cap must be removed prior
to disconnecting any fuel system component.
CRANKCASE VENTILATION SYSTEM
All 2.5L 4 cylinder and 4.0L 6 cylinder engines are
equipped with a Crankcase Ventilation (CCV) system(Figs. 8 or 9). The CCV system performs the same
function as a conventional PCV system, but does not
use a vacuum controlled valve.
On 4.0L 6 cylinder engines, a molded vacuum tube
connects manifold vacuum to top of cylinder head
(valve) cover at dash panel end. The vacuum tube
contains a fixed orifice of a calibrated size. It meters
the amount of crankcase vapors drawn out of the en-
gine.
On 2.5L 4 cylinder engines, a fitting on drivers side
of cylinder head (valve) cover contains the metered
orifice. It is connected to manifold vacuum.
A fresh air supply hose from the air cleaner is con-
nected to front of cylinder head cover on 4.0L en-
gines. It is connected to rear of cover on 2.5L
engines.
When the engine is operating, fresh air enters the
engine and mixes with crankcase vapors. Manifold
vacuum draws the vapor/air mixture through the
fixed orifice and into the intake manifold. The vapors
are then consumed during combustion.
Fig. 6 EVAP SystemÐTypical
Fig. 7 Air Cleaner VenturiÐTypical
Fig. 8 CCV SystemÐ2.5L EngineÐTypical
Fig. 9 CCV SystemÐ4.0L EngineÐTypical
JEMISSION CONTROL SYSTEMS 25 - 5