Jeep XJ. Manual — part 513
lator outlet tube refrigerant line coupler. See Refrig-
erant Line Coupler in this group for the procedures.
(5) Plug the wire harness connector into the low
pressure cycling clutch switch.
(6) Connect the battery negative cable.
(7) Evacuate the refrigerant system. See Refriger-
ant System Evacuate in this group for the proce-
dures.
(8) Charge the refrigerant system. See Refrigerant
System Charge in this group for the procedures.
NOTE: If the accumulator is replaced, add 120 mil-
liliters (4 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
BLEND-AIR DOOR MOTOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS,
REFER
TO
GROUP
8M
-
PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING
WHEEL,
STEERING
COLUMN,
OR
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) Disconnect the wire connector from the blend-
air door motor.
(3) Remove the screws that secure the blend-air
door motor to the housing (Fig. 15).
(4) Remove the blend-air door motor.
INSTALLATION
(1) Reverse the removal procedures for installa-
tion.
(2) Install and tighten the screws that secures the
blend-air door motor to the housing. Tighten the
mounting screws to 1 N·m (10 in. lbs.).
(3) Connect the battery negative cable.
BLOWER MOTOR
REMOVAL
(1) If the vehicle is equipped with air conditioning,
recover the refrigerant from the refrigerant system.
See Refrigerant Recovery in this group for the proce-
dures.
(2) Disconnect and isolate the battery negative
cable.
(3) If the vehicle is equipped with air conditioning,
the accumulator must be relocated in order to service
the blower motor. This is done by loosening the accu-
mulator retaining band screw and disconnecting the
accumulator inlet tube from the evaporator outlet
tube. The accumulator can then be moved far enough
to access and remove the blower motor. See Accumu-
lator in this group for the procedures.
(4) Unplug the blower motor wire harness connec-
tor (Fig. 16).
(5) Remove the three screws that secure the
blower motor and wheel assembly to the heater-A/C
housing.
(6) Rotate and tilt the blower motor unit as needed
for clearance to remove the blower motor and wheel
from the heater-A/C housing.
INSTALLATION
(1) Align and install the blower motor and wheel
assembly into the heater-A/C housing.
(2) Install and tighten the three screws that secure
the blower motor and wheel assembly to the heater-
A/C housing. Tighten the mounting screws to 2.2
N·m (20 in. lbs.).
(3) Plug in the blower motor wire harness connec-
tor.
(4) If the vehicle is equipped with air conditioning,
connect the accumulator inlet tube to the evaporator
outlet tube and tighten the accumulator retaining
band screw. See Accumulator in this group for the
procedures.
(5) Connect the battery negative cable.
Fig. 15 Blend-Air Door Motor
1 – ELECTRICAL CONNECTOR
2 – BLEND-AIR DOOR MOTOR
3 – SCREW MOUNTING POINTS
24 - 26
HEATING AND AIR CONDITIONING
XJ
REMOVAL AND INSTALLATION (Continued)
(6) If the vehicle is equipped with air conditioning,
evacuate the refrigerant system. See Refrigerant Sys-
tem Evacuate in this group for the procedures.
(7) If the vehicle is equipped with air conditioning,
charge the refrigerant system. See Refrigerant Sys-
tem Charge in this group for the procedures.
BLOWER MOTOR RELAY
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS,
REFER
TO
GROUP
8M
-
PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING
WHEEL,
STEERING
COLUMN,
OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Roll the glove box down from the instrument
panel. Refer to Glove Box in Group 8E - Instrument
Panel Systems for the procedures.
(3) Reach through the instrument panel glove box
opening to locate the blower motor relay (Fig. 17).
(4) Unplug the blower motor relay from its wire
harness connector.
(5) Install the blower motor relay by aligning the
relay terminals with the cavities in the wire harness
connector and pushing the relay firmly into place.
(6) Roll the glove box back up into the instrument
panel. Refer to Glove Box in Group 8E - Instrument
Panel Systems for the procedures.
(7) Connect the battery negative cable.
(8) Test the relay operation.
BLOWER MOTOR RESISTOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS,
REFER
TO
GROUP
8M
-
PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING
WHEEL,
STEERING
COLUMN,
OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(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) Pull out the lock on the blower motor resistor
wire harness connector to unlock the connector latch
(Fig. 18).
(4) Depress the latch on the blower motor resistor
wire harness connector and unplug the connector
from the resistor.
(5) Remove the two screws that secure the resistor
to the heater-A/C housing.
(6) Remove the resistor from the heater-A/C hous-
ing.
(7) Reverse the removal procedures to install.
Tighten the mounting screws to 2.2 N·m (20 in lbs.).
Fig. 16 Blower Motor Remove/Install
1 – BLOWER MOTOR
2 – WIRE HARNESS CONNECTOR
3 – MOUNTING SCREWS
Fig. 17 Blower Motor Relay Remove/Install
1 – BLOWER MOTOR RELAY
2 – VACUUM HARNESS
3 – HEATER-A/C WIRE HARNESS CONNECTOR
4 – HEATER-A/C HOUSING
XJ
HEATING AND AIR CONDITIONING
24 - 27
REMOVAL AND INSTALLATION (Continued)
COMPRESSOR
The compressor may be removed and repositioned
without disconnecting the refrigerant lines or dis-
charging the refrigerant system. Discharging is not
necessary if servicing the compressor clutch or clutch
coil, the engine, the cylinder head, or the generator.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
REMOVAL
(1) Recover the refrigerant from the refrigerant
system. See Refrigerant Recovery in this group for
the procedures.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the serpentine drive belt. Refer to
Group 7 - Cooling System for the procedures.
(4) Unplug the compressor clutch coil wire harness
connector.
(5) Remove the suction and discharge refrigerant
line manifold from the compressor. See Suction and
Discharge Line in this group for the procedures.
Install plugs in, or tape over all of the opened refrig-
erant fittings.
(6) Remove the four bolts that secure the compres-
sor to the mounting bracket (Fig. 19).
(7) Remove the compressor from the mounting
bracket.
INSTALLATION
NOTE: If
a
replacement
compressor
is
being
installed, be certain to check the refrigerant oil
level. See Refrigerant Oil Level in this group for the
procedures. Use only refrigerant oil of the type rec-
ommended for the compressor in the vehicle.
(1) Install the compressor to the mounting bracket.
Tighten the four mounting bolts as follows:
• All 2.5L and 4.0L engines - 27 N·m (20 ft. lbs.)
(2) Remove the tape or plugs from all of the
opened refrigerant line fittings. Install the suction
and discharge line manifold to the compressor. See
Suction and Discharge Line in this group for the pro-
cedures.
(3) Install the serpentine drive belt. Refer to
Group 7 - Cooling System for the procedures.
(4) Plug in the compressor clutch coil wire harness
connector.
(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. See Refriger-
ant System Evacuate in this group for the proce-
dures.
(7) Charge the refrigerant system. See Refrigerant
System Charge in this group for the procedures.
Fig. 18 Blower Motor Resistor Remove/Install
1 – SCREWS
2 – WIRE HARNESS CONNECTOR
3 – CONNECTOR LOCK
4 – HEATER-A/C HOUSING
5 – BLOWER MOTOR RESISTOR
Fig. 19 Compressor Remove/Install - All 2.5L/4.0L
Engines
1 – BOLT
2 – MOUNTING BRACKET
3 – ENGINE
4 – COMPRESSOR
24 - 28
HEATING AND AIR CONDITIONING
XJ
REMOVAL AND INSTALLATION (Continued)
COMPRESSOR CLUTCH
The refrigerant system can remain fully-charged
during compressor clutch, pulley, or coil replacement.
The compressor clutch can be serviced in the vehicle.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the serpentine drive belt. Refer to
Group 7 - Cooling System for the procedures.
(3) Unplug the compressor clutch coil wire harness
connector.
(4) Remove the four bolts that secure the compres-
sor to the mounting bracket.
(5) Remove the compressor from the mounting
bracket. Support the compressor in the engine com-
partment while servicing the clutch.
(6) Insert the two pins of the spanner wrench
(Special Tool C-4489) into the holes of the clutch
plate. Hold the clutch plate stationary and remove
the hex nut (Fig. 20).
(7) Remove the clutch plate with a puller (Special
Tool C-6461) (Fig. 21).
(8) Remove the compressor shaft key and the
clutch shims.
(9) Remove the external front housing snap ring
with snap ring pliers (Fig. 22).
(10) Install the lip of the rotor puller (Special Tool
C-6141-1) into the snap ring groove exposed in the
previous step, and install the shaft protector (Special
Tool C-6141-2) (Fig. 23).
(11) Install the puller through-bolts (Special Tool
C-6461) through the puller flange and into the jaws
of the rotor puller and tighten (Fig. 24). Turn the
puller center bolt clockwise until the rotor pulley is
free.
(12) Remove the screw and retainer from the
clutch coil lead wire harness on the compressor front
housing (Fig. 25).
(13) Remove the snap ring from the compressor
hub and remove the clutch field coil (Fig. 26). Slide
the clutch field coil off of the compressor hub.
INSPECTION
Examine the friction surfaces of the clutch pulley
and the front plate for wear. The pulley and front
plate should be replaced if there is excessive wear or
scoring.
If the friction surfaces are oily, inspect the shaft
and nose area of the compressor for oil. Remove the
Fig. 20 Clutch Nut Remove
1 – CLUTCH PLATE
2 – SPANNER
Fig. 21 Clutch Plate Remove
1 – CLUTCH PLATE PULLER
2 – CLUTCH PLATE
Fig. 22 External Snap Ring Remove
1 – PULLEY
2 – SNAP RING PLIERS
XJ
HEATING AND AIR CONDITIONING
24 - 29
REMOVAL AND INSTALLATION (Continued)
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