Jeep XJ. Manual — part 515
(3) Remove the three screws that secure the
defrost duct/demister adapter to the instrument
panel.
(4) Remove the defrost duct/demister adapter from
the instrument panel.
(5) Reverse the removal procedures to install.
Tighten the mounting screws to 2.2 N·m (20 in. lbs.).
DEMISTER HOSES
(1) Remove the instrument panel assembly from
the vehicle. Refer to Instrument Panel Assembly in
Group 8E - Instrument Panel Systems for the proce-
dures.
(2) Disconnect the ends of the demister hose from
the demister duct (Fig. 34) and the defrost duct/de-
mister adapter (Fig. 33).
(3) Reverse the removal procedures to install.
DEMISTER DUCTS
(1) Remove the instrument panel assembly from
the vehicle. Refer to Instrument Panel Assembly in
Group 8E - Instrument Panel Systems for the proce-
dures.
(2) Remove the end cap from the instrument
panel. Refer to Instrument Panel End Cap in Group
8E - Instrument Panel Systems for the procedures.
(3) Disconnect the demister hoses from the demis-
ter duct (Fig. 34).
(4) Remove the two screws that secure the demis-
ter duct to the top of the instrument panel.
(5) Remove the demister duct from the instrument
panel.
(6) Reverse the removal procedures to install.
Tighten the mounting screws to 2.2 N·m (20 in. lbs.).
CONSOLE REAR DUCT
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the floor console from the floor panel
transmission tunnel (Fig. 35). Refer to Group 23 -
Body for the procedures.
(3) Lift the rear of the console rear duct out of the
console rear mounting bracket on the floor panel
transmission tunnel and slide the duct rearward to
disengage it from the floor duct and adapter.
(4) Remove the console rear duct from the vehicle.
(5) Reverse the removal procedures to install.
FLOOR DUCT AND ADAPTER
(1) Remove the instrument panel from the vehicle.
Refer to Instrument Panel Assembly in Group 8E -
Instrument Panel Systems for the procedures.
(2) Remove the heater-A/C housing from the vehi-
cle. See Heater-A/C Housing in this group for the
procedures.
(3) Remove the three screws that secure the floor
duct and adapter to the heater-A/C housing (Fig. 35).
(4) Remove the floor duct and adapter from the
heater-A/C housing.
(5) Reverse the removal procedures to install.
Tighten the mounting screws to 2.2 N·m (20 in. lbs.).
Fig. 33 Defrost Duct/Demister Adapter
1 – HOSE
2 – INSTRUMENT PANEL
3 – DEFROST DUCT/DEMISTER ADAPTER
4 – SCREW
5 – HOSE
Fig. 34 Demister Duct Remove/Install
1 – DEMISTER DUCT
2 – SCREWS
3 – DEMISTER HOSE
24 - 34
HEATING AND AIR CONDITIONING
XJ
REMOVAL AND INSTALLATION (Continued)
EVAPORATOR COIL
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) Remove and disassemble the heater-A/C hous-
ing. See Heater-A/C Housing in this group for the
procedures.
(2) Lift the evaporator coil unit out of the lower
half of the heater-A/C housing (Fig. 36).
(3) Reverse the removal procedures to install. Be
certain that the evaporator foam insulator wrap and
rubber tube seal are reinstalled.
NOTE: If the evaporator is replaced, add 60 millili-
ters (2 fluid ounces) of refrigerant oil to the refrig-
erant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
FIXED ORIFICE TUBE
The fixed orifice tube is located in the liquid line
(Left-Hand Drive) or the liquid line jumper (Right-
Hand Drive) near the condenser. The orifice has filter
screens on the inlet and outlet ends of the tube body.
If the fixed orifice tube is faulty or plugged, the liq-
uid line unit or liquid line jumper unit must be
replaced. See Liquid Line in this group for the ser-
vice procedures.
HEATER-A/C CONTROL
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) Roll down the glove box 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 access and unplug the two halves of the
heater-A/C vacuum harness connector.
Fig. 35 Floor Duct and Console Rear Duct Remove/
Install
1 – FLOOR CONSOLE
2 – SCREW
3 – FLOOR DUCT AND ADAPTER
4 – CONSOLE REAR DUCT
Fig. 36 Evaporator Coil Remove/Install
1 – EVAPORATOR COIL
2 – TUBE SEAL
3 – CONDENSATE DRAIN TUBE
4 – FOAM INSULATOR WRAP
XJ
HEATING AND AIR CONDITIONING
24 - 35
REMOVAL AND INSTALLATION (Continued)
(4) Remove the center bezel from the instrument
panel. Refer to Instrument Panel Center Bezel in
Group 8E - Instrument Panel Systems for the proce-
dures.
(5) Release the vacuum harness push-in retainer
from the instrument panel directly beneath the heat-
er-A/C control.
(6) Remove the four screws that secure the heater-
A/C control to the instrument panel (Fig. 37).
(7) Pull the heater-A/C control assembly away
from the instrument panel far enough to access the
connections on the back of the control.
(8) Unplug the wire harness connectors from the
back of the heater-A/C control (Fig. 38).
(9) Reach through the instrument panel glove box
opening to guide the heater-A/C control half of the
vacuum harness around any obstacles while pulling
the heater-A/C control out from the front of the
instrument panel.
INSTALLATION
(1) Plug the wire harness connectors into the back
of the heater-A/C control.
(2) Route the vacuum harness through the instru-
ment panel opening and reinstall the vacuum har-
ness push-in retainer.
(3) Reach through the instrument panel glove box
opening to reconnect the two halves of the heater-A/C
vacuum harness connector.
(4) Roll the glove box back up into the instrument
panel. Refer to Glove Box in Group 8E - Instrument
Panel Systems for the procedures.
(5) Position the heater-A/C control in the instru-
ment panel and secure it with four screws. Tighten
the screws to 2.2 N·m (20 in. lbs.).
(6) Reinstall the center bezel onto the instrument
panel. Refer to Instrument Panel Center Bezel in
Group 8E - Instrument Panel Systems for the proce-
dures.
(7) Connect the battery negative cable.
HEATER-A/C HOUSING
The heater-A/C housing assembly must be removed
from the vehicle and the two halves of the housing
separated for service access of the heater core, evap-
orator coil, blend-air door, and each of the various
mode control doors.
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) Remove the instrument panel from the vehicle.
Refer to Instrument Panel Assembly in Group 8E -
Instrument Panel Systems for the procedures.
Fig. 37 Heater-A/C Control Remove/Install
1 – MOUNTING HOLES
2 – CONTROL HEAD
3 – HEATER-A/C CONTROL HEAD
4 – MOUNTING HOLES
5 – VACUUM HARNESS
6 – TEMPERATURE SELECT CONTROL
7 – MODE SELECT CONTROL
8 – BLOWER SPEED CONTROL
Fig. 38 Heater-A/C Control Connections
1 – HEATER-A/C CONTROL HEAD
2 – MODE SELECT CONTROL
3 – BLOWER SPEED CONTROL
4 – ELECTRICAL CONNECTORS
5 – VACUUM HARNESS
6 – TEMPERATURE SELECT CONTROL
24 - 36
HEATING AND AIR CONDITIONING
XJ
REMOVAL AND INSTALLATION (Continued)
(3) If the vehicle is not equipped with air condi-
tioning, go to Step 6. If the vehicle is equipped with
air conditioning, recover the refrigerant from the
refrigerant system. See Refrigerant Recovery in this
group for the procedures.
(4) Disconnect the liquid line refrigerant line fit-
ting from the evaporator inlet tube. See Refrigerant
Line Coupler in this group for the procedures. Install
plugs in, or tape over all of the opened refrigerant
line fittings.
(5) Disconnect the accumulator inlet tube refriger-
ant line fitting from the evaporator outlet tube. See
Refrigerant Line Coupler in this group for the proce-
dures. Install plugs in, or tape over all of the opened
refrigerant line fittings.
(6) Drain the engine cooling system. Refer to
Group 7 - Cooling System for the procedures.
(7) Disconnect the heater hoses from the heater
core tubes. Refer to Group 7 - Cooling System for the
procedures. Install plugs in, or tape over the opened
heater core tubes.
(8) Unplug the heater-A/C system vacuum supply
line connector from the tee fitting near the heater
core tubes.
(9) Unplug the heater-A/C unit wire harness con-
nector, which is fastened to the heater-A/C housing
next to the blower motor relay (Fig. 39).
(10) Remove the five nuts from the heater-A/C
housing mounting studs on the engine compartment
side of the dash panel (Fig. 40). Remove or reposition
the evaporation canister for additional access, if
required.
(11) Pull the heater-A/C housing rearward far
enough for the mounting studs and the evaporator
condensate drain tube to clear the dash panel holes.
(12) Remove the heater-A/C housing from the vehi-
cle.
DISASSEMBLY
(1) Remove the heater-A/C housing from the vehi-
cle and place it on a work bench.
(2) Unplug the vacuum harness connectors from
the floor door actuator and, if the unit is so equipped,
the recirculation air door actuator.
(3) Disengage the vacuum harness from any rout-
ing clips located on the lower half of the heater-A/C
housing.
(4) Disengage the heater-A/C wire harness connec-
tor and the blower motor relay wire harness connec-
tor push-in retainers from their mounting holes on
the heater-A/C housing.
(5) Remove the blower motor and blower wheel
unit from the heater-A/C housing. See Blower Motor
in this group for the procedures.
(6) Carefully remove the foam seal from the flange
around the blower motor opening in the heater-A/C
housing. If the seal is deformed or damaged, it must
be replaced.
(7) Pull the vacuum supply line and connector
through the foam seal on the heater core and evapo-
rator coil tube mounting flange of the heater-A/C
housing (Fig. 41).
(8) If the unit is equipped with air conditioning,
remove the screw that secures the clamp to the evap-
orator coil tubes and remove the clamp.
Fig. 39 Heater-A/C Unit Connector
1 – BLOWER MOTOR RELAY
2 – VACUUM HARNESS
3 – HEATER-A/C WIRE HARNESS CONNECTOR
4 – HEATER-A/C HOUSING
Fig. 40 Heater-A/C Housing Remove/Install
1 – HEATER-A/C HOUSING
2 – STUD
3 – NUT
4 – STUD
5 – RIGHT FRONT FENDER
XJ
HEATING AND AIR CONDITIONING
24 - 37
REMOVAL AND INSTALLATION (Continued)
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