Jeep Cherokee (XJ): Kick cover. Mode door vacuum actuator. Refrigerant line coupler

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Heating and air conditioning > Removal and installation > Kick cover. Mode door vacuum actuator. Refrigerant line coupler

Kick cover

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, 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 PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG 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 under the passenger side end of the instrument panel (Fig. 51).

Fig. 51 Kick Cover Remove/Install
Fig. 51 Kick Cover Remove/Install

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

(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 AIRBAGS, 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 PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG 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 procedures.

(3) Unplug the two vacuum harness connectors from the defrost door actuator (Fig. 52).

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

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

(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 as 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 i Group 8E - Instrument Panel Systems for the procedures.

Fig. 53 Vacuum Actuator Remove/Install - Typical
Fig. 53 Vacuum Actuator Remove/Install - Typical

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

(3) Unplug the vacuum harness connector from the floor 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 as 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 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.

(4) Rotate and tilt the vacuum actuator as 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 conditioning 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 procedures.

(3) Unplug the vacuum harness connector from the recirculation air door actuator (Fig. 54).

Fig. 54 Recirculation Air Door Vacuum Actuator Remove/Install
Fig. 54 Recirculation Air Door Vacuum Actuator Remove/Install

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

(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 as required to disengage the hole on the end of the 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 CAUTIONS IN THE GENERAL INFORMATION SECTION NEAR THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION.

REMOVAL

(1) Recover the refrigerant from the refrigerant system. See Refrigerant Recovery in the Service Procedures 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).

Fig. 55 Refrigerant Line Spring-Lock Coupler Disconnect
Fig. 55 Refrigerant Line Spring-Lock Coupler Disconnect

(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 disconnect 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 coupler fitting.

CAUTION: Use only the specified O-rings as they are made of a special material for the R-134a system.

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 refrigerant oil. Use only refrigerant oil of the type recommended 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 springlock coupler cage.

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