Jeep Cherokee (XJ): Compressor clutch relay. Condenser. Dual function high pressure switch/high pressure cut-off switch

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Heating and air conditioning > Removal and installation > Compressor clutch relay. Condenser. Dual function high pressure switch/high pressure cut-off switch

Compressor clutch relay

(1) Disconnect and isolate the battery negative cable.

(2) Remove the cover from the Power Distribution Center (PDC) (Fig. 30).

(3) Refer to the label on the PDC for compressor clutch relay identification and location.

(4) Unplug the compressor clutch relay from the PDC.

(5) Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place.

(6) Install the PDC cover.

(7) Connect the battery negative cable.

(8) Test the relay operation.

Fig. 30 Power Distribution Center
Fig. 30 Power Distribution Center

1 - RIGHT FENDER
2 - BATTERY
3 - POWER DISTRIBUTION CENTER

Condenser

WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION.

CAUTION: Before removing the condenser, note the location of each of the radiator and condenser air seals. These seals are used to direct air through the condenser and radiator. The air seals must be reinstalled in their proper locations in order for the air conditioning and engine cooling systems to perform as designed.

REMOVAL

(1) Disconnect and isolate the battery negative cable.

(2) Recover the refrigerant from the refrigerant system. See Refrigerant Recovery in this group for the procedures.

(3) Disconnect the discharge line refrigerant line fitting at the condenser inlet. See Refrigerant Line Coupler in this group for the procedures. Install plugs in, or tape over all of the opened refrigerant line fittings.

(4) Disconnect the liquid line (Left-Hand Drive) or liquid line jumper (Right-Hand Drive) refrigerant line fitting at the condenser outlet. See Refrigerant Line Coupler in this group for the procedures. Install plugs in, or tape over all of the opened refrigerant line fittings.

(5) Remove the radiator and the condenser from the vehicle as a unit. Refer to Group 7 - Cooling System for the procedures.

(6) Remove the two nuts that secure the condenser studs to the upper brackets of the radiator (Fig. 31).

Fig. 31 Condenser Remove/Install
Fig. 31 Condenser Remove/Install

1 - NUT
2 - RADIATOR
3 - GROMMET
4 - LOWER CROSSMEMBER
5 - CONDENSER
6 - STUDS

(7) Slide the condenser down from the radiator far enough for the condenser studs to clear the upper radiator bracket holes, and for the lower condenser bracket holes to clear the dowel pins on the bottom of the radiator.

(8) Remove the condenser from the radiator.

INSTALLATION

(1) Install the holes of the condenser lower brackets over the dowel pins on the bottom of the radiator.

(2) Slide the condenser upwards until both of the condenser studs are installed through the holes in the radiator upper brackets. Tighten the mounting nuts to 5.3 N·m (47 in. lbs.).

(3) Renstall the radiator and condenser unit in the vehicle. Refer to Group 7 - Cooling System for the procedures.

(4) Remove the tape or plugs from the refrigerant line fittings on the condenser outlet and the liquid line (Left-Hand Drive) or the liquid line jumper (Right-Hand Drive). Install the liquid line or the liquid line jumper to the condenser outlet. See Refrigerant Line Coupler in this group for the procedures.

(5) Remove the tape or plugs from the refrigerant line fittings on the condenser inlet and the discharge line. Connect the discharge line to the condenser inlet. See Refrigerant Line Coupler in this group for the procedures.

(6) Connect the battery negative cable.

(7) Evacuate the refrigerant system. See Refrigerant System Evacuate in this group for the procedures.

(8) Charge the refrigerant system. See Refrigerant System Charge in this group for the procedures.

NOTE: If the condenser is replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle.

Dual function high pressure switch/high pressure cut-off switch

REMOVAL

(1) Disconnect and isolate the battery negative cable.

(2) Unplug the wire harness connector from the dual function high pressure switch or the high pressure cut-off switch, which is mounted to a fitting on the non-flexible section of the discharge line nearest the compressor.

(3) Unscrew the high pressure switch from the discharge line fitting.

(4) Remove the high pressure switch from the vehicle.

(5) Remove the O-ring seal from the discharge line fitting and discard.

INSTALLATION

(1) Lubricate a new O-ring seal with clean refrigerant oil and install it on the discharge line 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 compressor in the vehicle.

(2) Install and tighten the high pressure switch on the discharge line fitting.

(3) Plug the wire harness connector into the high pressure cut-off switch.

(4) Connect the battery negative cable.

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