JEEP CHEROKEE 1994 Service Repair Manual

(2) Cover the interior and exterior body surface ar-
eas with a protective covering.
(3) Remove the windshield wiper arms, reveal
moulding, interior trim mouldings and rearview mir-
ror.
(4) Make a cut around theperimeterof the wind-
shield glass along the glass edge with a razor knife
(Fig. 9).
(5) Clean the blade of the hot knife with solvent
and a cloth. Sharpen the blade with a fine-tooth file.
CAUTION: When cutting through urethane with a
hot knife, do not allow the knife blade to remain
stationary at any location. Excessive heat will per-
manently soften urethane and cause complete re-
placement of the urethane.
(6) Start the hot knife blade between the glass and
the urethane. Next, cut the adhesive as close to the
glass edge as possible (Fig. 10). Allow as much adhe-
sive to remain on the pinchweld flange as possible.
For best cutting results, clean the knife blade
frequently with steel wool while the blade is
hot.
(7) Remove the windshield glass from the body
opening.
(8) After the hot knife blade has cooled, clean the
blade with solvent and a clean cloth.
INSTALLATIONÐSHORT METHOD
Normally, after a replacement windshield glass is
installed, the rearview mirror bracket also requires
Fig. 9 Cutting Urethane Along the Glass Edge
Fig. 10 Cutting Glass Urethane Adhesive With Hot Knife
23 - 76 BODY COMPONENTSÐXJ VEHICLESJ

installation.Do not install the bracket until after
the windshield glass installation is completed.
(1) Inspect the windshield opening pinchweld
flanges (Fig. 11). Prime any bare spots with urethane
primer. Allow a minimum of 18 minutes for dry time.
(2) Inspect urethane bead for high spots. Level
bead by shaving off high spots with a razor knife.
(3) Inspect the reveal moulding retainer clips. Re-
place any broken, or loose clips (Fig. 12).
(4) Clean the outer edge of windshield glass with
naphtha or a equivalent product.
(5) Prime outer perimeter of interior side of glass
16 mm (5/8 inch) from edge. Use a wipe-off type ure-
thane primer and wipe glass dry after primer appli-
cation.(6) Install two support spacers at the bottom of the
windshield glass (Fig. 13).
(7) Place the glass on the pinchweld flanges and
inspect for gaps in the urethane. Gaps in excess of 3
mm (1/8 inch) must be filled with urethane.
(8) Adjust windshield glass position until it is
aligned with the flanges and adhesive. Next, make
alignment marks on the glass and body.
(9) Remove the windshield glass (but not the sup-
port spacers) and position it on a flat surface.
(10) If the replacement windshield glass does not
have blackout primer:
²attach a 25 mm (1 in) wide masking tape band
around the interior side of the glass 16 mm (5/8 in)
from the edge of the glass (Fig. 14);
²do not attach tape along the bottom of the glass
andattach it only to the inside of the glass;
²clean the 16-mm (5/8-in) wide surface area around
the glass with isopropyl alcohol;
Fig. 13 Windshield Glass Bottom Support Spacers
Fig. 14 Masking Tape Location For Blackout Primer
Fig. 11 Pinchweld Flanges
Fig. 12 Reveal Moulding Clip
JBODY COMPONENTSÐXJ VEHICLES 23 - 77

CAUTION: Avoid spilling or dripping primer on
painted surfaces. Clean spills or drips immediately.
The primer will damage the paint if it remains on
the surface for any length of time.
²thoroughly mix and apply glass blackout primer to
the 16 mm (5/8 in) surface area around the interior
side of the glass (Fig. 15); then
²allow the primer to dry for at least 10-12 minutes.
(11) Cut the urethane adhesive applicator nozzle
according to the instructions in Figure 16.
(12) Apply a continuous, 6-mm (1/4-in) diameter
bead of urethane adhesive to the surface area.
CAUTION: Be prepared to install glass immediately
after applying the adhesive. The adhesive begins to
cure within 10-15 minutes.(13) Align the glass with the reference marks and po-
sition the glass on the pinchweld flanges. Ensure that
the windshield glass is correctly seated on the support
spacers.
(14) Force the windshield glass inward just enough
to wet-out and set the urethane. Use care to avoid
excessive squeeze-out of adhesive.
(15) Water test the windshield with a water spray
after installation. Do not direct high pressure
streams of water directly at urethane. If any leaks
are detected, apply urethane as necessary.
(16) Install reveal mouldings and (if used) remove
the masking tape from the inner surface of the glass.
(17) Install all components and clean the vehicle.
(18) Open the vehicle windows to prevent interior
pressure while the urethane is curing.If not
vented, pressure in the interior of the vehicle
may interfere with proper glass bonding.
(19) Install the rearview mirror on the bracket and
tighten mirror setscrew to 2 Nzm (15 in-lbs) torque.
INSTALLATIONÐEXTENDED METHOD
Normally, after a windshield is installed, the rear-
view mirror bracket also requires installation.Do not
install the bracket until after the windshield in-
stallation is completed.
(1) Remove the all of urethane from all pinchweld
flanges. Use an electric hot knife and a plow-type
knife blade to remove the adhesive.
(2) Inspect and repair the windshield opening and
pinchweld flanges (Fig. 11).
(3) Inspect and replace any reveal moulding clips if
bent, distorted, broken or loose (Fig. 12).
(4) Prime the pinchweld flanges with a urethane
base primer (Fig. 17). However, if the flange is color-
coated with paint, prime the flanges with a paint fin-
ish primer.This is important because urethane
adhesive will not adhere to all color-coat
paints.Allow primer sufficient time to dry.
Fig. 15 Blackout Primer Application
Fig. 16 Applicator Nozzle Preparation
Fig. 17 Pinchweld Flange Primer
23 - 78 BODY COMPONENTSÐXJ VEHICLESJ

(5) Install the bottom support spacers and the
stand-off spacers on the pinchweld flanges (Fig. 18).
Ensure that all spacers are water soluble.
(6) Install and inspect the fit of the windshield on
the pinchweld flanges as follows:
²position windshield on spacers (Fig. 19) and adjust
the position until it is aligned within windshield
opening;
²measure the gap between the pinchweld flanges
and glass around perimeter of the glass and flange;²the gap should be at least 3 mm (1/8 in), but no
more than 6 mm (1/4 in) at any point around the pe-
rimeter; and
²the flanges should also extend above the glass
edge equally around the perimeter of the opening.
(7) If the pinchweld flanges require repair, remove
the windshield glass and straighten, align, or repair
the flange(s) as necessary.
(8) Position the windshield on the spacers and in-
spect the windshield fit again. Mark the windshield
final position on the glass and body with a wax pen-
cil (or use masking tape). The marks (or masking
tape) will be used for installation alignment refer-
ence.
(9) If the replacement windshield does not have
blackout primer:
²attach a 25-mm (1-in) wide masking tape band
around the interior side of glass 16 mm (5/8 in) from
edge of glass (Fig. 14);
²do not attach tape along the bottom of the glass
andattach only to the inside of glass;
²thoroughly mix and apply blackout primer to the
16 mm (5/8 in) surface area around the interior side
of the glass (Fig. 15); then
²allow the primer to dry for at least 10-12 minutes.
(10) Cut the urethane applicator nozzle according
to the instructions in Figure 16.
(11) Apply a continuous bead of urethane to the
surface area with blackout primer on the interior
side of glass. The bead should be 6-mm (1/4-in) wide
by 9-mm (3/8-in) deep for best results.
CAUTION: Be prepared to install the windshield im-
mediately after applying the urethane adhesive.
Most urethane adhesive begins to cure within 10-15
minutes.
(12) Align the windshield with the wax pencil in-
stallation alignment reference marks (or the tape
strips). Position the windshield on pinchweld flanges
and spacers (Fig. 20).
(13) Force the windshield inward just enough to
wet-out and set the urethane. Use care to avoid ex-
cessive squeeze-out of adhesive.
(14) Water test the windshield with a water spray
after installation. Do not direct high pressure
streams of water directly at the urethane. If any
leaks are detected, apply urethane as necessary.
(15) Install the windshield reveal mouldings and
(if used) remove the masking tape from the inner
surface of glass.
(16) Install all components and clean the vehicle. If
necessary, refer to the installation procedures.
(17) Open the vehicle windows to prevent interior
pressure while the urethane adhesive is curing.If
not vented, pressure in the interior of vehicle
will interfere with glass bonding.
Fig. 18 Bottom Support and Stand-Off Spacers
Fig. 19 Windshield Glass On Spacers
JBODY COMPONENTSÐXJ VEHICLES 23 - 79

(18) Install the rearview mirror on the bracket and
tighten the mirror setscrew to 2 Nzm (15 in-lbs) torque.
REAR QUARTER VENT WINDOW GLASSÐXJ
VEHICLES
REMOVAL
(1) Remove the vent window handle retaining pin
and nut (Fig. 21).
(2) Remove the hinge-to-glass screws and remove the
window glass. If glass adheres to the hinges, remove the
glass by carefully pushing out hinge screw inserts.
INSTALLATION
(1) Position the vent window glass at the hinges
and install the screws.
(2) Install the handle, pin and nut (Fig. 21).
(3) Test the vent window for water leaks.
REAR QUARTER WINDOW GLASS/REAR QUARTER
PLASTIC INSERT ÐXJ VEHICLES
REMOVAL
(1) If equipped, remove the quarter window reveal
moulding (Fig. 22).
(2) Remove the quarter window interior trim covers.
(3) Separate the weatherstrip seal lip from the
window opening flanges. Use a pry tool and carefully
push the window glass and seal outward.
(4) Remove the weatherstrip seal and window
glass from window opening.
(5) Remove the weatherstrip seal from the window
glass (Fig. 23).
INSTALLATION
(1) Clean the original sealant from the weather-
strip channels and window opening flanges.
(2) Apply a 4-mm (1/6-in) diameter bead of sealant
to the window channel in the weatherstrip seal.
(3) Install the weatherstrip on the window glass.
Install the seal installation cord in the window open-
ing flange channel (Fig. 24) using as follows:
²moisten a length of 6-mm (1/4-in) diameter cord
with a soap and water solution;
²ensure that the cord is long enough to go all the
way around the perimeter of the weatherstrip; and
²insert the cord into the window opening flange
channel in the weatherstrip seal.
(4) Apply a 6-mm (1/4-in) diameter bead of sealant
to the window opening flanges.
(5) For two-door vehicles, apply a 3-mm (1/8-in) di-
ameter bead of sealant at the quarter panel applique
and liftgate pillar seam.
Fig. 20 Windshield Glass Installation
Fig. 21 Vent Window Handle Removal/Installation
Fig. 22 Quarter Window Reveal Moulding, Glass and Seal
23 - 80 BODY COMPONENTSÐXJ VEHICLESJ

(6) Position the quarter window glass and the weather-
strip seal in the window opening (Figs. 25 and 26) with the
free ends of the cord inside the vehicle (Fig. 27).
(7) Pull on each end of the cord to pull the weather-
strip seal channel lip over the window opening flanges.
(7) Test the vent window for water leaks.
(8) Install the interior trim cover.
(9) If equipped, install the quarter window reveal
moulding.
LIFTGATE WINDOW GLASSÐXJ VEHICLES
REMOVAL
(1) If equipped, remove the liftgate window reveal
moulding (Fig. 30).
(2) Remove the interior trim panels.
(3) Use a pry tool to separate the weatherstrip seal
lip from the window opening flanges. Push the glass
and weatherstrip seal outward from the top toward
the rear of the vehicle.
Fig. 23 Quarter Window Glass and Seal
Fig. 25 Quarter Window With Vent
Fig. 26 Quarter Window Glass and Seal In Window
Opening
Fig. 27 Quarter Window Glass and Seal Installation
Fig. 24 Weatherstrip Seal and Cord Installation
JBODY COMPONENTSÐXJ VEHICLES 23 - 81

(4) Remove the glass and weatherstrip seal from
the liftgate (Fig. 30).
(5) Remove the weatherstrip seal from the window glass.
(6) Clean the weatherstrip channels and window
opening flanges.
INSTALLATION
(1) Apply a 4-mm (1/6-in) diameter bead of sealant
to liftgate glass channel in the weatherstrip seal
(Fig. 30).
(2) Install weatherstrip seal on the glass (Fig. 31).
Install the seal installation cord in the window open-
ing channel as follows:
²moisten a length of 6-mm (1/4-in) diameter cord
with a soap and water solution;
²insert the cord into the window opening flange
channel in the weatherstrip seal.
Fig. 29 Quarter Window Glass With Vent Installed
Fig. 30 Liftgate Window Glass Reveal Moulding, Glass and Seal
Fig. 28 Quarter Window Glass and Seal Installed
23 - 82 BODY COMPONENTSÐXJ VEHICLESJ

(3) Apply a 6-mm (1/4-in) diameter bead of sealant
around the perimeter of the window opening flange
in the liftgate (Fig. 30).
(4) Install the window glass and the weatherstrip
seal in the window opening with the cord according
to the following instructions:
²position the window glass and the weatherstrip
seal in the window opening with the free ends of the
cord inside the vehicle (Fig. 32); and
²
pull on each end of the cord to pull the weatherstrip seal
channel lip over the window opening flange (Fig. 33).
(5) Test the liftgate window for water leaks.
(6) Install the interior trim covers.
(7) If equipped, install the liftgate window reveal
moulding (Fig. 30).
FIXED GLASS WATER LEAK DETECTION AND REPAIR
SERVICE INFORMATION
Water leaks around the windshield or a fixed window
glass can be sealed without removing the glass. If thewindshield/window glass is bonded and only has a small
leak, seal it with a liquid butyl sealant. If the weather-
strip seal or urethane adhesive has a large break, a ure-
thane adhesive must be used to seal the leak.
LEAK TEST
Water test the windshield/window with a spray only.
Do not use hard streams of water.Work from the
bottom to the top of windshield/window glass.
If a water leak exists between the glass and weath-
erstrip seal (or between the seal and a body flange):
²push the glass outward at the leak area, and
²determine the extent of the gap.
Push the glass outward while a helper sprays the
windshield/window with water.
SEALING MINOR LEAK AREAS
(1) Thoroughly clean and remove all foreign material
from the leak area. Dry area with compressed air.
(2) Seal the leak area with butyl sealant. Allow the
sealant to cure for at least 1/2 hour. Next, water test
the glass to ensure that the leak is sealed.
SEALING MAJOR LEAK AREAS
(1) Thoroughly clean the leak area.
(2) As applicable, apply primer to either the wind-
shield/window or weatherstrip seal leak area. Use
blackout primer on the windshield/window and ure-
thane primer on the weatherstrip seal.
(3) Apply urethane adhesive to the leak area. Use
an adhesive cartridge with a pointed nozzle.
(4) Water test the windshield/window immediately
with cold water spray. Allow water to spill over the
edge of the windshield/window and weatherstrip seal.
Do not direct a hard stream of water on re-
cently applied urethane.
(5) Apply additional urethane adhesive, if necessary.
(6) Remove any excess urethane adhesive.
Fig. 31 Weatherstrip Seal and Cord Installation
Fig. 32 Liftgate Window Glass Installation With Cord
Fig. 33 Liftgate Window Glass and Weatherstrip Seal
JBODY COMPONENTSÐXJ VEHICLES 23 - 83

UNDERBODY COMPONENTS
INDEX
page page
Catalytic Converter/Muffler/Tailpipe Support
Brackets............................. 85
Front Skid Plate......................... 84
Fuel and Brake Fluid Tube Retainer Clip....... 86
Fuel Filler Hose Splash ShieldÐXJ Vehicles.... 86
Fuel Filter Bracket........................ 86Fuel Tank Skid Plate...................... 84
Fuel Tank Support Strap................... 86
Rear Tow HookÐXJ Vehicles............... 87
Service Information....................... 84
Trailer Hitches........................... 88
Transfer Case Skid Plate.................. 84
SERVICE INFORMATION
In some cases, components in the following proce-
dures either support, or are concealed by other com-
ponents. When necessary, refer to component
removal procedure for service access.
FRONT SKID PLATE
REMOVAL
(1) Remove the screws that attach skid plate to
side sills (Fig. 1).
(2) Remove the nuts that attach the skid plate to
the crossmember (Fig. 1).
(3) Remove the skid plate from the vehicle (Fig. 1).
INSTALLATION
(1) Position the skid plate at front crossmember
and side sills (Fig. 1).
(2) Install the nuts to attach the skid plate to
crossmember.(3) Install the screws to attach skid plate to side
sills.
TRANSFER CASE SKID PLATE
REMOVAL
(1) Support the skid plate.
(2) Remove the bolts that attach the skid plate to
the transmission support crossmember and frame sill
(Fig. 2).
(3) Remove the support and skid plate from the ve-
hicle.
INSTALLATION
(1) Position and support the skid plate at the
frame sill and transmission support crossmember
(Fig. 2).
(2) Attach the skid plate to the frame sill and
crossmember with bolts. Tighten bolts to 22 Nzm (16
ft-lbs) torque.
FUEL TANK SKID PLATE
REMOVALÐXJ VEHICLES
(1) Position a support under skid plate.
(2) Remove the bolts that attach skid plate to un-
derbody side rails (Figs. 3 and 4).
Fig. 1 Front Skid Plate Removal/Installation
Fig. 2 Transfer Case Skid Plate
23 - 84 BODY COMPONENTSÐXJ VEHICLESJ

(3) Remove the support and the skid plate from
the vehicle.
INSTALLATIONÐXJ VEHICLES
(1) Position and support skid plate under fuel
tank.
(2) Install bolts to attach the skid plate to under-
body rails. Tighten the bolts to 50 Nzm (37 ft-lbs)
torque.
(3) Remove the support from under skid plate.
CATALYTIC CONVERTER/MUFFLER/TAILPIPE
SUPPORT BRACKETS
REMOVAL
(1) As applicable, detach the catalytic converter,
muffler or tailpipe support bracket from insulator.
Remove the insulator from bracket.
(1) As applicable, install nuts and bolts, or screws
that attach bracket to frame. Tighten nuts/screws to
21 Nzm (16 ft-lbs) torque.(2) Install insulator on support bracket.
Fig. 1 Catalytic Converter Support Bracket
Fig. 2 Muffler/Tailpipe Support BracketÐXJ Vehicles
Fig. 3 Tailpipe Support BracketÐXJ Vehicles
Fig. 3 Fuel Tank Skid Plate W/O Trailer Hitch Or Tow
Hook
Fig. 4 Fuel Tank Skid Plate With Trailer Hitch Or
Tow Hook
JBODY COMPONENTSÐXJ VEHICLES 23 - 85