JEEP CHEROKEE 1994 Service Repair Manual

flare to the fender outer panel;
²remove the rivets that attach the flare to the air
deflector;
²remove the retainers that attach the fender liner
to the fender inner panel;
²remove the nuts that attach the fender liner to the
fender outer panel and flare retainers;
²remove the fender liner from between the fender
panels;
²remove the push-nuts that attach the retainers to
the fender outer panel; and
²remove the retainers and flare from the fender
outer panel.
(7) Remove the grille opening panel (GOP).
(8) Remove the air deflector.
(9) Remove the rocker panel moulding from the
fender.(10) Remove all the fender braces (Fig. 49).
(11) Remove the fender lower screws (Fig. 49).
(12) Remove the fender top, front and the rear
screws. Remove the fender from the inner fender
panel (Fig. 49).INSTALLATION
(1) Position the fender on the inner fender panel.
(2) Install all of the fender screws finger-tight.
(3) Install the fender braces.
(4) Align the fender with the body panels and
tighten the fender screws to 8.5 Nzm (76 in-lbs)
torque.
(5) Install the grille opening panel (GOP).
(6) Install the air deflector.
(7) Install the fender flare and retainers (Fig. 50).
Then install the fender liner.
²position the retainers and the flare on the fender;
²install the push-nuts to attach the retainers to the
fender;
²position the fender liner between the fender and
fender inner panel (Fig. 51);
Fig. 44 Speed Servo
Fig. 45 Vapor Canister
Fig. 46 Daytime Running Light (DRL) Module
Fig. 47 Hood Bumper
23 - 16 BODY COMPONENTSÐXJ VEHICLESJ

²install the nuts to attach the fender liner to the
fender and flare retainers (Fig. 48);
²install the retainers to attach the fender liner to
the fender inner panel;
²install the rivets to attach the flare to the air de-
flector (Figs. 48 and 50); and
²install the screws to attach the flare to the fender.
Tighten the screws to 1 Nzm (13 in-lbs) torque.
(8) Connect the front lamp wire harness connectors
to the engine wire harness connectors (Fig. 52).(9) Install the front lamps.
(10) Install the front bumper.
(11) Install the wheel, remove the support and
lower the vehicle.
(12) Right fender only: install the hood support rod
on the fender inner panel.
(13) Install the hood bumper on the fender inner
panel.
(14) Right fender only: install the Daytime Run-
ning Light (DRL) module on fender inner panel.
Fig. 48 Fender Flare & Liner Removal/Installation
Fig. 49 Fender Removal/Installation
JBODY COMPONENTSÐXJ VEHICLES 23 - 17

(15) Right fender only: install the A/C Receiver/
Drier on the fender inner panel.
(16) Right fender only: install the vapor canister
on the fender inner panel. Tighten the vapor canister
screws to 5 Nzm (45 in-lbs) torque.
(17) Right fender only: install the PDC, coolant recov-
ery bottle and speed servo on the fender inner panel.
(18) Right fender only: install the hood ajar switch,
if equipped. Tighten the screws to 2 Nzm (15 in-lbs)
torque.
(19) Right fender only: install the windshield
washer fluid reservoir on the inner panel (Fig. 39).
(20) Right fender only: install the battery tray and
battery on the inner panel.
(21) Right fender only: if equipped, install the ra-
dio antenna. Tighten the nut/escutcheon to 4.5 Nzm
(40 in-lbs) torque. Tighten the power antenna bracket
screws to 2 Nzm (20 in-lbs) torque.
REAR WHEELHOUSE FLARES AND LINERS
REMOVAL
(1) Remove the flare and liner lower screws.Fig. 50 Fender Flare & Retainers
Fig. 51 Fender Liner and Retainers
Fig. 52 Front Lamp Wire Harness Connectors
Fig. 53 Rear Wheelhouse Flare, Retainers and Liner
Fig. 54 Rear Wheelhouse LinerÐXJ Vehicles
23 - 18 BODY COMPONENTSÐXJ VEHICLESJ

(2) Remove the nuts that attach the liner to the
wheelhouse.
(3) Remove the liner from the wheelhouse.
(4) Remove the push-nuts that attach the flare re-
tainers to the wheelhouse.
(5) Remove the flare and retainers from the wheel-
house.
INSTALLATION
(1) Position the flare and retainers at the wheel-
house.
(2) Install the push-nuts to attach the flare retain-
ers to the wheelhouse.
(3) Position the liner in the wheelhouse.
(4) Install the nuts to attach the liner to the
wheelhouse and flare retainers.
(5) Install the flare and liner lower screws. Tighten
the screws to 1 Nzm (13 in-lbs) torque.
BODY SIDE MOULDING/CLADDING
REMOVAL
(1) Loosen the vinyl body side moulding with a
heat gun.
(2) Lift edge of moulding with a putty knife and
peel moulding from body panel. Apply heat to any lo-
cation where the moulding remains adhered to a
panel.
(3) Remove the adhesive from the body panel with
3M All Purpose Cleaner, or an equivalent cleaner.
(4) If the original moulding will be installed, also
remove all adhesive from it.
INSTALLATION
(1) Install 3M 06379 double-sided tape on the
moulding.
(2) For vertical alignment, use masking tape or a
string as reference.
(3) Remove the backing from the tape, align the
moulding and position it on the body panel.(4) Press the moulding onto the body panel with a
roller or hand pressure.
WOODGRAIN MOULDING
SERVICE INFORMATION
Woodgrain mouldings are attached to the vehicle
outer panels by four types of fasteners (Fig. 58):
Fig. 56 Body Side MouldingÐ2-Door XJ Vehicles
Fig. 57 Body Side Moulding/CladdingÐ4-Door XJ
Vehicles
Fig. 55 Rear Wheel Opening FlareÐXJ Vehicles
JBODY COMPONENTSÐXJ VEHICLES 23 - 19

²tubular clips,
²screws,
²nuts, and
²rivets.
Ensure that the method of moulding attachment is
known (Fig. 62) before attempting removal.
FRONT FENDER MOULDINGS
REMOVAL/INSTALLATION
(1) Pry the moulding off outer fender panel.(2) Align the moulding with retainers and with the
clips in the fender panel. Press the moulding into
place on the fender panel.
DOOR MOULDINGS
REMOVAL
(1) Remove the screw that attaches the moulding
to the door panel edge.
(2) Pry the moulding off the door panel.
INSTALLATION
(1) Align the moulding with the clips in the door
panel. Press the moulding into place on the door
panel.
(2) Install the screw to attach the moulding to door
panel edge. Tighten screw to 1 Nzm (9 in-lbs) torque.
QUARTER PANEL MOULDINGS
REMOVAL/INSTALLATION
(1) Pry the moulding off the quarter panel.
(2) Align the moulding with clips in the quarter
panel then press the moulding into place on the
quarter panel.
Fig. 59 Woodgrain MouldingÐXJ
Fig. 58 Woodgrain Moulding Attaching Methods
23 - 20 BODY COMPONENTSÐXJ VEHICLESJ

LIFTGATE UPPER MOULDING
REMOVAL
(1) Remove the screws that attach the moulding to
the liftgate panel edge.
(2) Pry the moulding off the liftgate panel.
INSTALLATION
(1) Align the moulding with the retainer on the
liftgate panel. Press the moulding into place on the
liftgate panel.
(2) Install screws to attach the moulding to the liftgate
panel edge. Tighten screws to 1 Nzm (9 in-lbs) torque.
LIFTGATE LOWER MOULDING
REMOVAL
(1) Remove screw that attaches the moulding to
the liftgate panel edge.
(2) Remove nut that attaches the inboard end of
moulding to the liftgate panel.
(3) Pry the moulding off the liftgate panel.
INSTALLATION
(1) Align the moulding with the clips in liftgate panel.
Press the moulding into place on the liftgate panel.
(2) Install the screw and nut to attach the ends of
moulding. Tighten screw to 1 Nzm (9 in-lbs) torque.
Tighten the nut to 3 Nzm (27 in-lbs) torque.
LICENSE PLATE SURROUND MOULDING
REMOVAL
(1) Remove the screw that attaches upper end of
the moulding.(2) Remove the nut that attaches the inboard end
of the moulding.
(3) Pry the moulding off the liftgate panel.
INSTALLATION
(1) Align the moulding with the clip in the liftgate
panel. Press the moulding into place.
(2) Install the screw and nut to attach the ends of
the moulding. Tighten the screw to 1 Nzm (9 in-lbs)
torque. Tighten nut to 3 Nzm (27 in-lbs) torque.
LICENSE PLATE VISOR APPLIQUE
REMOVAL
(1) Drill the heads and remove the rivets that attach
the outboard ends of the applique to the tailgate.
Fig. 61 License Plate Surround MouldingÐXJ
Fig. 62 License Plate Visor Applique
Fig. 60 Liftgate MouldingsÐXJ
JBODY COMPONENTSÐXJ VEHICLES 23 - 21

(2) Carefully pry the applique off the license plate
visor and tailgate (Fig. 62).
INSTALLATION
(1) Align the moulding with the visor and then
press the applique into place.
(2) Install the rivets to attach the outboard tabs on
applique to the tailgate.
WOODGRAIN OVERLAY
SERVICE INFORMATION
Exterior woodgrain overlay is a weather-resistant
vinyl. The adhesive backing is protected by a paper
liner until removed for installation.
OVERLAY REPAIR
Small nicks and scratches on an overlay can be
touched-up with paint.
To eliminate blisters and air bubbles, pierce them
with a needle or pin. Force the trapped air out of the
hole and press firmly on the overlay. Heat also can
be applied to remove small wrinkles.
Whenever an overlay must be stretched, do
not slit or cut it. Instead, apply heat and press
or squeegee the overlay into place.
INSTALLATION REQUIREMENTS
Overlay replacement requires metal repair and
paint refinish to be completed before the overlay is
installed.
The work area temperature should be between
18ÉC (65ÉF) and 32ÉC (90ÉF).A woodgrain overlay
should not be replaced if the work area temper-
ature is less than 18ÉC (65ÉF).
The following equipment and material are neces-
sary for overlay installation:
²a commercial woodgrain overlay removal solution;
²a commercial adhesive removal solution;
²liquid dish detergent (for wetting solution);
²a mixture of wetting solution;
²a commercial wax and silicone removal solution;
²isopropyl alcohol (rubbing alcohol);
²a squeegee (4 to 5 inches wide, plastic or hard rub-
ber);
²a water bucket and sponge;
²sandpaper (no. 360 or no. 400, wet or dry type);
²a heat gun (or infra-red heat bulb);
²clean wiping rags or paper towels;
²a pair of scissors;
²a needle or pin; and
²a wax pencil.
Using a wetting solution helps the installation of
an overlay. Prepare a solution by mixing two or three
teaspoons of dish detergent with 1 gallon of water.
Do not use soap.
Too much detergent will reduce the effective-
ness of the mixture.
OVERLAY REMOVAL
(1) Remove the adjacent moulding from panel.
(2) Start at one corner and apply heat with a heat
gun. Slowly peel the overlay from the panel (Fig. 63).
WARNING: USE THE WOODGRAIN OVERLAY AND
ADHESIVE REMOVAL SOLUTIONS IN A WELL-VEN-
TILATED AREA ONLY.
(3) A commercial solution can be used for overlay
removal where a heat gun is ineffective.
(4) Remove any adhesive remaining with a com-
mercial solution.
(5) Wipe the panel with a cloth saturated with a
cleaning solution.
OVERLAY INSTALLATION
The panel area that will be covered by the
woodgrain overlay must be scuff sanded and then
cleaned with a cleaning solution.
SURFACE PREPARATION
(1) Scuff-sand the painted surface with no. 360 or
400 sandpaper.Freshly painted surfaces must be
dry.
(2) Clean the painted surface with a commercial
wax and silicone removal solution. Wipe the surface
with a clean cloth and allow it to dry.
OVERLAY PREPARATION
(1) If a complete panel overlay is not to be in-
stalled, position the overlay on the panel surface to
be covered:
²mark the approximate outline on the overlay with
a wax pencil;
Fig. 63 Woodgrain Overlay Removal
23 - 22 BODY COMPONENTSÐXJ VEHICLESJ

²ensure that 12 mm (1/2 in) excess overlay material
is allowed for wrapping around the door and fender
flanges; and
²cut the overlay to the approximate size with scis-
sors.
(2) Place the overlay on a clean, flat surface with
the paper liner facing upward.
(3) Bend the corner of the overlay toward the
woodgrain side and, with a flick of the finger, sepa-
rate the paper liner from the overlay.
OVERLAY APPLICATION
(1) Use a clean sponge and apply the wetting solu-
tion to the overlay adhesive and to the painted panel
surface.
(2) Position the adhesive side of the overlay on the
panel.
(3) Apply solution to the woodgrain side of the
overlay.
(4) For a complete, or a large section of overlay,
the following method should be used:
²position a squeegee at the center and slide it
across a short horizontal area of overlay;
²lift the right or left edge of the overlay, align it
with the panel. Slide the squeegee toward the lifted
edge with firm strokes;
²avoid stretching the overlay at its lifted edge;
²continue until all of the air bubbles and wetting
solution are removed from the underside of the over-
lay.
If a wrinkle is trapped in the overlay, stop im-
mediately. Lift the wrinkled area and re-align it
to remove the wrinkle. Do not lift the overlay if
only a few air bubbles exist.
(5) Notch the corner and curved edges of the over-
lay and trim the excess.
(6) Allow 12 mm (1/2 in) extra overlay to extend
beyond the edges.CAUTION: Use extreme care to avoid spilling iso-
propyl (rubbing) alcohol on the moulding or painted
surfaces. Wipe spills immediately.
(7) Wipe the adhesive side of edges with isopropyl
alcohol.
(8) Heat the overlay edges with a heat gun to
soften and make them more pliable.
(9) Fold the edges over onto the panel flange area
and press the overlay into place. Alternately heat
and press the edge until it is bonded to the flange
area.
(10) Carefully cut away the excess from panel the
openings with a knife.
(11) Inspect the overlay. Remove all the air and
moisture bubbles with a needle or pin.
(12) Install all the removed components and clean
the vehicle as necessary.
FRONT FENDER OVERLAY APPLICATION
Install a complete front fender overlay according to
the following instructions.
(1) Position the top edge of the front fender overlay
at the character line and rear edge at the panel
welds.
(2) Wipe the adhesive side of fender overlay edges
with isopropyl alcohol.
(3) Heat the fender overlay edges with a heat gun
to soften and make them more pliable.
CAUTION: Avoid unnecessary pulling and stretch-
ing at the ends.
(4) Fold the edges over onto the fender panel
flange and press them into place.
(5) Install the fender moulding.
DOOR OVERLAY APPLICATION
Install a complete front or rear door overlay accord-
ing to the following instructions.
Fig. 64 Woodgrain OverlayÐXJ Vehicles
Fig. 65 Woodgrain Overlay Installation
JBODY COMPONENTSÐXJ VEHICLES 23 - 23

(1) Position the top edge of the door overlay at the
character line and the front edge at the panel welds.
(2) Wipe the adhesive side of the door overlay
edges with isopropyl alcohol.
(3) Heat the door overlay edges with a heat gun to
soften and make them more pliable.
CAUTION: Avoid unnecessary pulling and stretch-
ing at the ends.
(4) Fold edges over onto the door panel flange ar-
eas and press them into place.
(5) Install the overlay retainer at door front flange
with rivets (Fig. 66).
(6) Install the door edge guard (Fig. 67).
(7) Install the door moulding.QUARTER PANEL OVERLAY APPLICATION
(1) Position the top edge of quarter panel overlay
at character line and the rear edge at panel welds.
(2) Wipe the adhesive side of quarter panel overlay
edges with isopropyl alcohol.
(3) Heat the quarter panel overlay edges with a
heat gun to soften and make them more pliable.
CAUTION: Avoid unnecessary pulling and stretch-
ing at ends.
(4) Firmly fold the edges over onto quarter panel
flange areas and press them into place.
(5) Install the overlay retainer at the rear door
opening with rivets.
(6) Cut an opening in the overlay for the fuel filler
opening.
(7) Install the overlay retainer at the fuel filler
opening with rivets.
(8) Install the quarter panel moulding.
Fig. 66 Overlay Retainer At Door Front Flange
Fig. 67 Door Edge Guards
Fig. 68 Rear Door Opening Overlay Retainer
Fig. 69 Fuel Filler Opening Overlay Retainer
23 - 24 BODY COMPONENTSÐXJ VEHICLESJ

FUEL FILLER DOOR OVERLAY APPLICATION
(1) Clean the door flange with an appropriate solu-
tion.
(2) Position the top edge of the overlay at the char-
acter line and notches at door edge.
(3) Wipe the adhesive side of fuel filler door over-
lay edges with isopropyl alcohol.
(4) Heat the door overlay edges with a heat gun to
soften and make them more pliable.
CAUTION: Avoid unnecessary pulling and stretch-
ing at the ends.
(5) Fold the overlay edges over onto the door panel
flange areas and press them into place.
LIFTGATE OVERLAY APPLICATION
(1) Position the top edge of the overlay at charac-
ter line and inner edges at the license plate recess.
(2) Wipe the adhesive side of the liftgate overlay
edges with isopropyl alcohol.
(3) Heat the liftgate overlay edges with a heat gun
to soften and make them more pliable.
CAUTION: Avoid unnecessary pulling and stretch-
ing at the ends.
(4) Fold the overlay edges over onto liftgate panel
flange and press them into place.
(6) Install the liftgate moulding.
(7) Install the license plate visor applique.
BODY STRIPES/DECALS
SERVICE INFORMATION
XJ body stripes and decals are weather resistant
tape with a adhesive backing.
REPAIR
Small nicks, scratches and other surface marks in
a body stripe/decal can be touched-up with paint.To eliminate blisters and air bubbles in a body
stripe/decal, pierce them with a needle or pin.
A heat gun can also be used to remove small wrin-
kles in a stripe/decal.
REQUIREMENTS
Body stripe/decal replacement requires that the
metal repair and paint refinish be completed first.
The work area temperature should be between
18ÉC (65ÉF) and 32ÉC (90ÉF).A tape stripe/decal
should not be replaced if the work area temper-
ature is less than 18ÉC (65ÉF).
The following equipment and material are neces-
sary for removal and installation:
²a commercial tape stripe/decal removal solution;
²a commercial adhesive removal solution;
²liquid dish detergent (for the wetting solution);
²a mixture of wetting solution;
²a commercial wax and silicone removal solution;
²isopropyl (rubbing) alcohol;
²a small squeegee (plastic or hard rubber);
²a water bucket and sponge;
²clean wiping rags or paper towels;
²a heat gun (or infra-red heat bulb);
²a wax pencil;
²a sharp knife, single edge razor blade or X-acto
knife;
²a pair of scissors; and
²a needle or pin.
The use of a wetting solution aids the installation
of a tape stripe/decal on a painted panel. Prepare the
wetting solution by mixing two or three teaspoons of
dish detergent with 1 gallon of water.Do not use
soap.
Too much detergent will reduce the effective-
ness of the mixture.
REMOVAL
(1) Clean the repaired surface, adjacent panels and
door the openings as necessary.
(2) Start at one end of the tape stripe/decal and
apply heat with a heat gun. Slowly peel the stripe/
decal from the panel by pulling it back.Do not pull
the tape stripe/decal outward from panel.
WARNING: USE TAPE STRIPE/DECAL REMOVAL
SOLUTION IN A WELL-VENTILATED AREA ONLY.
(3) A tape stripe/decal removal solution can be
used for removal at areas where a heat gun is inef-
fective:
²Mask-off the body panel area surrounding the tape
stripe/decal (Fig. 71);
²move solution spray across the complete length of
stripe/decal with a steady motion;
²ensure that the complete stripe/decal is covered
with solution;
Fig. 70 Liftgate Overlay Side Retainers
JBODY COMPONENTSÐXJ VEHICLES 23 - 25