Jeep Wrangler TJ. Manual — part 597
connect the demister ducts from the demister outlets
and the defroster duct as necessary (Fig. 37).
DEMISTER OUTLETS
NOTE: Take the proper precautions to protect the
front face of the instrument panel from cosmetic
damage while performing this procedure.
(1) Remove the instrument panel assembly and
place it on a workbench (Refer to 23 - BODY/IN-
STRUMENT
PANEL/INSTRUMENT
PANEL
ASSEMBLY - REMOVAL)
(2) Disconnect the demister ducts from the demis-
ter outlets as necessary (Fig. 38).
(3) Remove the screw that secures each demister
outlet to the instrument panel duct as necessary.
(4) Remove the demister outlets from the instru-
ment panel as necessary.
INSTALLATION
NOTE: The two demister ducts can be serviced
without removing the instrument panel. However, if
either of the demister outlets require servicing, the
instrument panel must be removed.
Fig. 37 Demister Ducts - IP Removed for Clarity
1 - SCREW (2)
2 - RH DEMISTER OUTLET
3 - SCREW (10)
4 - RH DEMISTER DUCT
5 - INSTRUMENT PANEL
6 - RADIO REAR SUPPORT BRACKET
7 - RADIO
8 - LH DEMISTER DUCT
9 - LH DEMISTER OUTLET
10 - INSTRUMENT PANEL DUCT
Fig. 38 Demister Outlet - Right Side shown, Left
Side similar
1 - DEMISTER HOSE (2)
2 - DEMISTER OUTLET (2)
3 - INSTRUMENT PANEL
4 - SCREW (2)
5 - INSTRUMENT PANEL DUCT
24 - 54
DISTRIBUTION
TJ
INSTRUMENT PANEL DEMISTER DUCTS (Continued)
DEMISTER DUCTS
(1) Reach through the glove box opening and/or
the cluster opening of the instrument panel to con-
nect the demister ducts to the demister outlets and
the defroster duct as necessary.
(2) If removed, install the top cover, knee blocker
and instrument cluster (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL TOP
COVER - INSTALLATION), (Refer to 23 - BODY/IN-
STRUMENT PANEL/KNEE BLOCKER - INSTALLA-
TION)
and
(Refer
to
8
-
ELECTRICAL/
INSTRUMENT CLUSTER - INSTALLATION).
(3) If removed, install the glove box (Refer to 23 -
BODY/INSTRUMENT
PANEL/GLOVE
BOX
-
INSTALLATION).
(4) Reconnect the negative battery cable.
DEMISTER OUTLETS
(1) Position the demister outlets into the instru-
ment panel as necessary.
(2) Install the screw that secures each demister
outlet to the instrument panel duct as necessary.
(3) Connect the demister ducts to the demister
outlets as necessary.
(4) Install the instrument panel assembly (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
INSTRUMENT PANEL DUCTS
REMOVAL
WARNING: On vehicles equipped with airbags, dis-
able the airbag system before attempting any steer-
ing wheel, steering column, or instrument panel
component diagnosis or service. Disconnect and
isolate the battery negative (ground) cable, then
wait two minutes for the airbag system capacitor to
discharge before performing further diagnosis or
service. This is the only sure way to disable the air-
bag system. Failure to take the proper precautions
could result in accidental airbag deployment and
possible personal injury or death.
NOTE: The air ducts for the instrument panel out-
lets are integral to each other and cannot be ser-
viced separately.
NOTE: Take the proper precautions to protect the
front face of the instrument panel from cosmetic
damage while performing this procedure.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the instrument panel and place it on a
workbench (Refer to 23 - BODY/INSTRUMENT PAN-
EL/INSTRUMENT
PANEL
ASSEMBLY
-
REMOVAL).
(3) Remove the center bezel from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT
PANEL
CENTER
BEZEL
-
REMOVAL).
(4) Remove the accessory switch bezel, A/C-heater
control, radio and radio rear support bracket from
the instrument panel (Refer to 23 - BODY/INSTRU-
MENT
PANEL/ACCESSORY
SWITCH
BEZEL
-
REMOVAL), (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS/A/C HEATER CONTROL -
REMOVAL) and (Fig. 39) (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - REMOVAL).
(5) Remove the demister ducts and the demister
outlets (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION/INSTRUMENT
PANEL
DEMISTER DUCTS - REMOVAL).
(6) Disconnect the instrument panel wire harness
connectors from the left and right side courtesy
lamps located at the bottom of the instrument panel.
(7) Disengage the instrument panel wire harness
retainers from the instrument panel duct and posi-
tion the wire harness out of the way.
(8) Remove the ten screws that secure the instru-
ment panel duct to the instrument panel and remove
the duct.
TJ
DISTRIBUTION
24 - 55
INSTRUMENT PANEL DEMISTER DUCTS (Continued)
INSTALLATION
(1) Position the instrument panel duct into the
instrument panel.
(2) Install the ten screws that secure the instru-
ment panel duct to the instrument panel. Tighten the
screws to 2 N·m (17 in. lbs.).
(3) Engage the instrument panel wire harness
retainers to the instrument panel duct and connect
the wire harness to the left and right courtesy lamps.
(4) Install the demister outlets and the demister
ducts (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION/INSTRUMENT
PANEL
DEMISTER DUCTS - INSTALLATION.
(5) Install the accessory switch bezel, A/C-heater
control and the radio and the radio rear support
bracket into the instrument panel (Refer to 23 -
BODY/INSTRUMENT
PANEL/ACCESSORY
SWITCH BEZEL - INSTALLATION), (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS/A/C
HEATER CONTROL - INSTALLATION) and (Refer
to 8 - ELECTRICAL/AUDIO/RADIO - INSTALLA-
TION).
(6) Install the center bezel onto the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - INSTAL-
LATION).
(7) Install the instrument panel (Refer to 23 -
BODY/INSTRUMENT
PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
(8) Reconnect the negative battery cable.
Fig. 39 Instrument Panel Duct - LHD shown, RHD typical
1 - SCREW (2)
2 - RH DEMISTER OUTLET
3 - SCREW (10)
4 - RH DEMISTER DUCT
5 - INSTRUMENT PANEL
6 - RADIO REAR SUPPORT BRACKET
7 - RADIO
8 - LH DEMISTER DUCT
9 - LH DEMISTER OUTLET
10 - INSTRUMENT PANEL DUCT
24 - 56
DISTRIBUTION
TJ
INSTRUMENT PANEL DUCTS (Continued)
PLUMBING
TABLE OF CONTENTS
page
page
PLUMBING
. . . . . . . . . . . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . 60
REFRIGERANT SYSTEM CHARGE LEVEL
A/C COMPRESSOR
. . . . . . . . . . . . . . . . . . . . 64
. . . . . . . . . . . . . . . . . . . . 64
. . . . . . . . . . . . . . 64
. . . . . . . . . . . . . . . . . . . . . . . . . 65
. . . . . . . . . . . . . . . . . . . . . . . . . 66
. . . . . . . . . . . . . . . . . . . . . . . . . 67
. . . . . . . . . . . . . . . . . . . . . . . . . 67
A/C CONDENSER
. . . . . . . . . . . . . . . . . . . . . . . . . 68
. . . . . . . . . . . . . . . . . . . . . . . . . . . 68
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
. . . . . . . . . . . . . . . . . . . . . . . . . 69
A/C DISCHARGE LINE
. . . . . . . . . . . . . . . . . . . . . . . . . 70
. . . . . . . . . . . . . . . . . . . . . . . . . 70
. . . . . . . . . . . . . . . . . . . . . . . . . 71
. . . . . . . . . . . . . . . . . . . . . . . . . 71
. . . . . . . . . . . . . . . . . . . . . . . . . 72
A/C EVAPORATOR
. . . . . . . . . . . . . . . . . . . . . . . . . 72
. . . . . . . . . . . . . . . . . . . . . . . . . . . 73
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
. . . . . . . . . . . . . . . . . . . . . . . . . 73
A/C ORIFICE TUBE
. . . . . . . . . . . . . . . . . . . . . . . . . 73
. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
. . . . . . . . . . . . . . . . . . . . 74
ACCUMULATOR
. . . . . . . . . . . . . . . . . . . . . . . . . 74
. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
. . . . . . . . . . . . . . . . . . . . . . . . . 76
HEATER CORE
. . . . . . . . . . . . . . . . . . . . . . . . . 76
. . . . . . . . . . . . . . . . . . . . . . . . . . . 76
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
. . . . . . . . . . . . . . . . . . . . . . . . . 77
LIQUID LINE
. . . . . . . . . . . . . . . . . . . . . . . . . 77
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
. . . . . . . . . . . . . . . . . . . . . . . . . 78
REFRIGERANT
. . . . . . . . . . . . . . . . . . . . . . . . . 79
. . . . . . . . . . . . . . . . . . . . . . . . . . . 79
REFRIGERANT LINE COUPLER
. . . . . . . . . . . . . . . . . . . . . . . . . 79
. . . . . . . . . . . . . . . . . . . . . . . . . . . 80
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
. . . . . . . . . . . . . . . . . . . . . . . . . 81
REFRIGERANT OIL
. . . . . . . . . . . . . . . . . . . . . . . . . 81
. . . . . . . . . . . . . . . . . . . . . . . . . . . 81
. . . . . . . . . . . . . . 81
SERVICE PORT VALVE CORE
. . . . . . . . . . . . . . . . . . . . . . . . . 82
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
. . . . . . . . . . . . . . . . . . . . . . . . . 82
SUCTION LINE
. . . . . . . . . . . . . . . . . . . . . . . . . 83
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
. . . . . . . . . . . . . . . . . . . . . . . . . 84
TJ
PLUMBING
24 - 57
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