heating JEEP CHEROKEE 1995 Service Manual PDF

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

(4) Remove the blower motor fan from the motor
shaft for access to the motor attaching nuts (Fig. 11).
To install the blower fan and motor, reverse the re-
moval procedures.
4.0L ENGINE
(1) Remove the washer fluid tank.
(2) Disconnect the blower motor wires (Fig. 9).
(3) Remove the blower motor mounting bolts (Fig.
10).
(4) Remove the blower motor and fan assembly.(5) Remove the blower motor fan from the motor
shaft for access to the motor attaching nuts (Fig. 11).
To install the blower fan and motor, reverse the re-
moval procedures.The ears (A) and (B) of the re-
tainer clip must be over the flat surface on the
motor shaft (Fig. 11).
Fig. 8 Control Cable and Ring
Fig. 9 Blower Motor Connector
Fig. 10 Blower Motor Mounting Screws
Fig. 11 Blower Fan
JHEATING AND AIR CONDITIONING 24 - 25

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

(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

(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