Content .. 515 516 517 518 ..

Jeep XJ. Manual - part 517

(3) Evacuate the refrigerant system. See Refriger-

ant System Evacuate in this group for the proce-
dures.

(4) Charge the refrigerant system. See Refrigerant

System Charge in this group for the procedures.

LOW PRESSURE CYCLING CLUTCH SWITCH

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Unplug the wire harness connector from the

low pressure cycling clutch switch on the top of the
accumulator (Fig. 50).

(3) Unscrew the low pressure cycling clutch switch

from the fitting on the top of the accumulator.

(4) Remove the O-ring seal from the accumulator

fitting and discard.

INSTALLATION

(1) Lubricate a new O-ring seal with clean refrig-

erant oil and install it on the accumulator fitting.
Use only the specified O-rings as they are made of a

special material for the R-134a system. Use only
refrigerant oil of the type recommended for the com-
pressor in the vehicle.

(2) Install and tighten the low pressure cycling

clutch switch on the accumulator fitting. The switch
should be hand-tightened onto the accumulator fit-
ting.

(3) Plug the wire harness connector into the low

pressure cycling clutch switch.

(4) Connect the battery negative cable.

KICK COVER

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS,

REFER

GROUP

PASSIVE

RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING

WHEEL,

STEERING

COLUMN,

INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Loosen the two screws that secure the upper

half of the kick cover to the heater-A/C housing

Fig. 49 Liquid Line Remove/Install

1 – LIQUID LINE WITH ORIFICE TUBE
2 – CLIP
3 – CONDENSER
4 – OUTLET TUBE
5 – STUD
6 – CLIP
7 – CLIP
8 – EVAPORATOR INLET

Fig. 50 Low Pressure Cycling Clutch Switch

Remove/Install - Typical

1 – WIRE HARNESS CONNECTOR
2 – ACCUMULATOR
3 – LOW PRESSURE CYCLING CLUTCH SWITCH

24 - 42

HEATING AND AIR CONDITIONING

REMOVAL AND INSTALLATION (Continued)

under the passenger side end of the instrument panel
(Fig. 51).

(3) Remove the two screws that secure the lower

half of the kick cover to the heater-A/C housing.

(4) Pull the kick cover down towards the floor

panel to disengage the slotted upper mounting tabs
from under the two loosened heater-A/C housing
screws.

(5) Remove the kick cover from the heater-A/C

housing.

INSTALLATION

(1) Position the slotted upper kick cover mounting

tabs under the heads of the two loosened heater-A/C
housing screws. Tighten the screws to 2.2 N·m (20 in.
lbs.).

(2) Install the two screws that secure the lower

kick cover to the heater-A/C housing. Tighten the
screws to 2.2 N·m (20 in. lbs.).

(3) Connect the battery negative cable.

MODE DOOR VACUUM ACTUATOR

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS,

REFER

GROUP

PASSIVE

RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING

WHEEL,

STEERING

COLUMN,

INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

DEFROST DOOR ACTUATOR

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the instrument panel assembly from

the vehicle. Refer to Instrument Panel Assembly in
Group 8E - Instrument Panel Systems for the proce-
dures.

(3) Unplug the two vacuum harness connectors

from the defrost door actuator (Fig. 52).

(4) Insert a trim stick or another suitable wide

flat-bladed tool into the latch hole on the heater-A/C
housing actuator mount (Fig. 53). Gently pry the
actuator latch while pulling firmly outwards on the
actuator to remove the actuator from the mount.

(5) Rotate

and

tilt

the

vacuum

actuator

required to disengage the hole on the end of the
actuator link from the hooked pin on the end of the
defrost door lever.

(6) Remove the defrost door vacuum actuator from

the vehicle.

(7) Reverse the removal procedures to install.

FLOOR DOOR ACTUATOR

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the instrument panel assembly from

the vehicle. Refer to Instrument Panel Assembly in

Fig. 51 Kick Cover Remove/Install

1 – HEATER-A/C HOUSING
2 – MOUNTING SCREWS
3 – KICK COVER

Fig. 52 Defrost, Floor, and Panel/Demist Door

Vacuum Actuators

1 – PANEL/DEMIST DOOR ACTUATOR
2 – DEFROST DOOR ACTUATOR
3 – FLOOR DOOR ACTUATOR

HEATING AND AIR CONDITIONING

24 - 43

REMOVAL AND INSTALLATION (Continued)

Group 8E - Instrument Panel Systems for the proce-
dures.

(3) Unplug the vacuum harness connector from the

floor door actuator (Fig. 52).

(4) Insert a trim stick or another suitable wide

(5) Rotate

and

tilt

the

vacuum

actuator

required to disengage the hole on the end of the
actuator link from the hooked pin on the end of the
floor door lever.

(6) Remove the floor door vacuum actuator from

the vehicle.

(7) Reverse the removal procedures to install.

PANEL/DEMIST DOOR ACTUATOR

(1) Remove the defrost door actuator from the

heater-A/C housing. See Defrost Door Actuator in
this group for the procedures.

(2) Unplug the vacuum harness connector from the

panel/demist door actuator (Fig. 52).

(3) Insert a trim stick or another suitable wide

(4) Rotate

and

tilt

the

vacuum

actuator

required to disengage the hole on the end of the
actuator link from the hooked pin on the end of the
panel/demist door lever.

(5) Remove the panel/demist door vacuum actuator

from the vehicle.

(6) Reverse the removal procedures to install.

RECIRCULATION AIR DOOR ACTUATOR

A recirculation air door and vacuum actuator are

used only on models with the optional air condition-
ing system.

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the kick cover from the heater-A/C

housing. See Kick Cover in this group for the proce-
dures.

(3) Unplug the vacuum harness connector from the

recirculation air door actuator (Fig. 54).

(4) Insert a trim stick or another suitable wide

(5) Rotate

and

tilt

the

vacuum

actuator

required to disengage the hole on the end of the

Fig. 53 Vacuum Actuator Remove/Install - Typical

1 – ACTUATOR MOUNT LATCH HOLE
2 – TRIM STICK
3 – ACTUATOR LATCH

Fig. 54 Recirculation Air Door Vacuum Actuator

Remove/Install

1 – HOOK
2 – LEVER
3 – RECIRCULATION AIR DOOR ACTUATOR
4 – BLOWER MOTOR RESISTOR

24 - 44

HEATING AND AIR CONDITIONING

REMOVAL AND INSTALLATION (Continued)

actuator link from the hooked pin on the end of the
recirculation air door lever.

(6) Remove the recirculation air door vacuum

actuator from the vehicle.

(7) Reverse the removal procedures to install.

REFRIGERANT LINE COUPLER

WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE GENERAL INFORMATION SECTION
NEAR THE FRONT OF THIS GROUP BEFORE PER-
FORMING THE FOLLOWING OPERATION.

REMOVAL

(1) Recover the refrigerant from the refrigerant

system. See Refrigerant Recovery in the Service Pro-
cedures section of this group.

(2) Remove the secondary clip from the spring-lock

coupler.

(3) Fit the proper size A/C line disconnect tool

(Special Tool Kit 7193) over the spring-lock coupler
cage (Fig. 55).

(4) Close the two halves of the A/C line disconnect

tool around the spring-lock coupler.

(5) Push the A/C line disconnect tool into the open

side of the coupler cage to expand the garter spring.
Once the garter spring is expanded and while still
pushing the disconnect tool into the open side of the
coupler cage, pull on the refrigerant line attached to
the female half of the coupler fitting until the flange
on the female fitting is separated from the garter

spring and cage on the male fitting within the dis-
connect tool.

NOTE: The garter spring may not release if the A/C
line disconnect tool is cocked while pushing it into
the coupler cage opening.

(6) Open and remove the A/C line disconnect tool

from the disconnected spring-lock coupler.

(7) Complete the separation of the two halves of

the coupler fitting.

INSTALLATION

(1) Check to ensure that the garter spring is

located within the cage of the male coupler fitting,
and that the garter spring is not damaged.

(a) If the garter spring is missing, install a new

spring by pushing it into the coupler cage opening.

(b) If the garter spring is damaged, remove it

from the coupler cage with a small wire hook (DO
NOT use a screwdriver) and install a new garter
spring.
(2) Clean any dirt or foreign material from both

halves of the coupler fitting.

(3) Install new O-rings on the male half of the cou-

pler fitting.

CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a sys-
tem. The use of any other O-rings may allow the
connection to leak intermittently during vehicle
operation.

(4) Lubricate the male fitting and O-rings, and the

inside of the female fitting with clean R-134a refrig-
erant oil. Use only refrigerant oil of the type recom-
mended for the compressor in the vehicle.

(5) Fit the female half of the coupler fitting over

the male half of the fitting.

(6) Push together firmly on the two halves of the

coupler fitting until the garter spring in the cage on
the male half of the fitting snaps over the flanged
end on the female half of the fitting.

(7) Ensure that the spring-lock coupler is fully

engaged by trying to separate the two coupler halves.
This is done by pulling the refrigerant lines on either
side of the coupler away from each other.

(8) Reinstall the secondary clip over the spring-

lock coupler cage.

SUCTION AND DISCHARGE LINE

Any kinks or sharp bends in the refrigerant plumb-

ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.

Fig. 55 Refrigerant Line Spring-Lock Coupler

Disconnect

HEATING AND AIR CONDITIONING

24 - 45

REMOVAL AND INSTALLATION (Continued)

Content .. 515 516 517 518 ..