JEEP XJ 1995 Service And Repair Manual

REAR QUARTER VENT WINDOW GLASSÐXJ
REMOVAL
(1) Remove the vent window handle retaining pin
and nut (Fig. 8).
(2) Remove the hinge-to-glass screws and remove
the window glass. If glass adheres to the hinges, re-
move 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. 8).
(3) Test the vent window for water leaks.
REAR QUARTER WINDOW GLASS/REAR QUARTER
PLASTIC INSERTÐXJ
REMOVAL
(1) If equipped, remove the quarter window reveal
molding (Fig. 9).
(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.
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 as follows:
Fig. 8 Vent Window Handle Removal/Installation
Fig. 9 Quarter Window Reveal Molding, Glass and Seal
JSTATIONARY WINDOW GLASSÐXJ 23 - 731995 Jeep Cherokee/Wrangler
Publication No. 81-370-5146
TSB 26-05-95 July, 1995

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.
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.
(6) Position the quarter window glass and the
weatherstrip seal in the window opening (Fig. 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 weath-
erstrip 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
molding.
LIFTGATE WINDOW GLASSÐXJ
REMOVAL
(1) If equipped, remove the liftgate window reveal
molding (Fig. 28).
(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.
(4) Remove the glass and weatherstrip seal from
the liftgate (Fig. 28).
(5) Remove the weatherstrip seal from the window
glass.
Fig. 23 Quarter Window Glass and Seal
Fig. 24 Weatherstrip Seal and Cord Installation
Fig. 25 Quarter Window With Vent
Fig. 26 Quarter Window Glass and Seal In Window
Opening
23 - 74 STATIONARY WINDOW GLASSÐXJJ

(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. 28).
(2) Install weatherstrip seal on the glass (Fig. 29).
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.
(3) Apply a 6-mm (1/4-in) diameter bead of sealant
around the perimeter of the window opening flange
in the liftgate (Fig. 28).
(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. 30).
²Pull on each end of the cord to pull the weather-
strip seal channel lip over the window opening flange
(Fig. 31).
(5) Test the liftgate window for water leaks.
(6) Install the interior trim covers.
(7) If equipped, install the liftgate window reveal
molding (Fig. 28).
Fig. 28 Liftgate Window Glass Reveal Molding, Glass and Seal
Fig. 27 Quarter Window Glass and Seal Installation
JSTATIONARY WINDOW GLASSÐXJ 23 - 75

STATIONARY GLASS WATER LEAK DETECTION
AND REPAIRÐXJ
SERVICE INFORMATION
Water leaks around the windshield or a stationary
window glass can be sealed without removing the
glass. If the windshield/window glass is bonded and
only has a small leak, seal it with a liquid butyl seal-
ant. If the weatherstrip seal or urethane adhesive
has a large break, a urethane 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 de-
termine 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 mate-
rial 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 neces-
sary.
(6) Remove any excess urethane adhesive.
Fig. 29 Weatherstrip Seal and Cord Installation
Fig. 30 Liftgate Window Glass Installation With Cord
Fig. 31 Liftgate Window Glass and Weatherstrip
Seal
23 - 76 STATIONARY WINDOW GLASSÐXJJ

TRAILER HITCH
TRAILER HITCHÐXJ
CLASS III HITCH
A class III weight-distributing/equalizer type hitch
can be used to tow a trailer:
²Having a maximum gross weight of 5,000 lbs/2250
kg.
²Having a maximum tongue weight of 750 lbs/332
kg).
The following vehicle basic equipment is required
for class III trailer towing:
²P205/75R15 or larger tires.
²Full size spare tire.
²Trailer sway control.
²Trailer tow wire harness and connector.
²Heavy duty turn signal flasher element.
²Heavy duty axle (with synthetic lubricant).
²Heavy duty cooling system.
²Heavy duty generator/battery.
²Auxiliary automatic transmission fluid cooler.
²I-6, 4.0L engine.
Wide-angle type door mirrors are recommended but
not required.
WIRE HARNESS CONNECTORS
CLASS I HITCH CONNECTOR
The trailer tow wire harness connector for class I
trailer hitches is a 5-terminal, in-line type connector.
Terminal 5 is the source for vehicle ground (Fig. 1)
CLASS III HITCH CONNECTOR
The trailer tow wire harness connector for class III
trailer-tow hitches is a 7-terminal, circular type con-
nector (Fig. 2).
The 12-volt circuit for the trailer is protected
from overloads. A auto-reset type circuit
breaker is located in the trailer tow wire har-
ness near the plug-in relays.
CAUTION: The trailer tow wire harness package
does not include a vehicle battery isolator unit. Be-
cause of this, the trailer battery can totally dis-
charge the vehicle battery if the engine is not
operated for an extended period of time.
A blue wire (without a connector) located under in-
strument panel near fuse panel is available for
trailer electric brake control unit.
Fig. 1 Trailer Tow Wire Harness Connectors
JTRAILER HITCH 23 - 77

The stop lamp and turn signal plug-in relays are
located behind left quarter trim panel (Fig. 3).
HITCH REMOVALÐXJ VEHICLES
An XJ class III, weight-distributing/equalizer type
hitch (Fig. 4)is comprised of:
²Towing tube with a ball mount receptacle.
²Various reinforcement/support brackets that are
attached to the vehicle frame sills and rear cross-
member with bolts.(1) If necessary, remove the trailer tow wire har-
ness connector from the hitch (Fig. 5).
(2) Support the hitch.
(3) Remove the bolts that attach the towing tube to
the frame sills and reinforcement bracket. If
equipped, remove the fuel tank skid plate.
The reinforcement brackets are held on the
frame sills with two blind rivets.
(4) Remove the bolts from the plate bracket and
rear crossmember and lower the support and hitch.
Fig. 4 Equalizer Type HitchÐXJ Vehicles
Fig. 2 Class III Trailer Tow Wire Harness and
ConnectorsFig. 3 Class III Trailer Tow Wire Harness Plug-In
Relays
23 - 78 TRAILER HITCHJ

INSTALLATIONÐXJ VEHICLES
(1) Install frame reinforcement brackets, if re-
moved. Slide the brackets through the vehicle rear
sill openings and hold in position on the frame sills
with blind rivets (Fig. 6).(2) Place hitch on a lifting device. Raise, position
hitch at the proper location for installation on vehicle
and support it.
(3) If equipped, position fuel tank skid plate on ve-
hicle frame sills.
(4) Loosely install the bolts to attach the towing
tube (and the skid plate) to frame sills and reinforce-
ment brackets.
(5) Position the plate bracket and install the at-
taching bolts through the vehicle rear crossmember.
(6) Tighten all bolts/nuts to the specified torque:
²Towing tube-to-reinforcement bracket bolt, 50 Nzm
(37 ft. lbs.).
²Plate bracket-to-rear crossmember nut, 52 Nzm (40
ft. lbs.).
(7) Remove the lift/support and, if removed, attach
the trailer wire harness connector to the hitch.
Fig. 6 Reinforcement Bracket and Hitch Installation
Fig. 5 Trailer Tow Wire Harness Connector
JTRAILER HITCH 23 - 79

INTERIOR COMPONENTS
INDEX
page page
Assist HandleÐXJ........................ 89
B/C-Pillar and Liftgate Pillar Trim CoversÐXJ.... 88
Bucket Seat Cushion and CoverÐXJ........... 81
Bucket Seat PlatformÐXJ................... 82
Bucket Seatback Cover and FrameÐXJ........ 81
Cargo BarrierÐXJ........................ 101
Cargo LampÐXJ......................... 94
Carpets and Floor MatsÐXJ................. 99
Dome LampÐXJ......................... 93
Front Bucket SeatsÐXJ.................... 81
Front Carpet/MatÐXJ...................... 99
Front Inner Scuff Plate/Cowl Side Trim PanelÐXJ . 86
Front Shoulder Belt/BuckleÐXJ............... 90
Full Floor ConsoleÐXJ..................... 95
HeadlinerÐXJ............................ 92
I/P Ash Receiver Tray LampÐXJ.............. 80
Instrument Cluster BezelÐXJ................ 80
Interior Trim Panels and Scuff PlatesÐXJ....... 84
Jack StorageÐXJ......................... 97
Keyless Entry ReceiverÐXJ................. 93Mini-Console with Floor ShiftÐXJ............. 94
Mini-Floor ConsoleÐXJ..................... 94
Outer Scuff PlatesÐXJ..................... 89
Overhead ConsoleÐXJ..................... 93
Parking Brake Handle CoverÐXJ............. 94
Quarter and Wheelhouse Trim PanelsÐXJ...... 87
Quarter Trim Panel ExtensionÐXJ............. 87
Rear Carpet/MatÐXJ..................... 100
Rear Seat Cushion CoverÐXJ............... 82
Rear Seat CushionÐXJ.................... 82
Rear Seatback CoverÐXJ................... 84
Rear Seatback Latch Striker and BumperÐXJ.... 84
Rear SeatbackÐXJ........................ 83
Rear Shoulder/Lap Belt/BuckleÐXJ............ 91
Sound BarÐXJ........................... 94
Spare Tire/Wheel Holddown and Floor
BracketsÐXJ........................... 98
SunvisorsÐXJ........................... 93
Windshield Side MoldingÐXJ................ 86
INSTRUMENT CLUSTER BEZELÐXJ
REMOVAL
(1) Remove the bezel retaining screws (Fig. 1).
(2) Separate the bezel from the U-clips and remove
it from the upper section of the instrument panel.
(3) If necessary, remove or install rocker switch
cover plates.
INSTALLATION
(1) Position the bezel on the upper instrument
panel and engage it with the U-clips.
(2) Install the bezel retaining screws. Tighten thescrews with 1 Nzm (11 in-lbs) torque.
For service procedures regarding individual I/P
components refer to Group 8, Electrical.
I/P ASH RECEIVER TRAY LAMPÐXJ
REMOVAL
(1) Remove the ash receiver tray from instrument
panel (Fig. 2).
(2) Remove the lamp retaining screw from the ash
receiver tray cavity (Fig. 3).
(3) Disconnect the lamp wire harness connector
and remove the lamp from the instrument panel.
Fig. 1 Instrument Bezel Removal/Installation
Fig. 2 Ash Receiver Tray
23 - 80 INTERIOR COMPONENTSÐXJJ

INSTALLATION
(1) Position the lamp under the instrument panel
and connect the lamp wire harness connector.
(2) Install the lamp retaining screw in the ash re-
ceiver tray cavity.
(3) Install the ash receiver tray in the instrument
panel.
FRONT BUCKET SEATSÐXJ
REMOVAL
Bucket seat platforms are attached to the floor
panel with bolts (Fig. 1).
(1) Remove seat frame bolts.
(2) For power seats, disconnect wire harness con-
nector.
(3) Separate seat from floor panel.
INSTALLATION
(1) Position seat on floor panel.
(2) Install seat frame bolts. Tighten to 32 Nzm (24
ft-lbs) torque.(3) For power seats, connect wire harness connec-
tor.
BUCKET SEAT CUSHION AND COVERÐXJ
REMOVAL
(1) Remove the seat from vehicle (Fig. 1). If neces-
sary, refer to removal procedure.
(2) Remove seat trim cover.
(3) Remove wire support rod and rear carpet seat
track cover, and flap retainer.
(4) For power seats, remove control housing from
seat cushion.
(5) Unclip skirt from seat cushion and seat frame.
(6) Remove seat cushion cover retaining screws
and wire rods from cushion cover. Remove cover from
cushion frame.
INSTALLATION
(1) Install seat cushion cover on cushion frame. In-
stall wire rods and retaining screws. Tighten screws
to2Nzm (13 in-lbs) torque.
(2) Install cushion and retaining screws on seat
frame.
(3) Clip skirt onto seat cushion and seat frame.
(4) For power seats, install control housing on seat
cushion. Tighten screws to 2 Nzm (13 in-lbs) torque.
(5) Install rear carpet seat track cover and support
rod and flap retainer.
(6) Install seat trim cover and screws onto seat
platform.
(7) Install seat in vehicle (Fig. 1). If necessary, re-
fer to removal procedure.
BUCKET SEATBACK COVER AND FRAMEÐXJ
REMOVAL
(1) Remove seat from vehicle. If necessary, refer to
removal procedure.
(2) Remove seat cushion from frame. If necessary,
refer to removal procedure.
(3) If equipped, remove headrest. Twist knob under
headrest and pull up and out of cylinders in seat-
back.
(4) Remove headrest latch release lever bezel from
seatback.
(5) Squeeze plastic retainers together. Detach
lower flap from front of cover.
(6) Remove cover retainer clips and remove cover
from seatback.
(7) For power seats, remove retaining screws and
remove the seat control from seat track/platform.
(8) Remove retaining screws and nuts. Remove
seat frame from seat track/platform.
INSTALLATION
(1) Position seat frame on seat track/platform. In-
stall retaining screws and nuts.
Fig. 3 Ash Receiver Tray Lamp
Fig. 1 Bucket Seat
JINTERIOR COMPONENTSÐXJ 23 - 81

(2) For power seats, position seat control on seat
track/platform. Install retaining screws. Tighten
screws securely.
(3) Position cover on seatback. Install cover re-
tainer clips.
(4) Attach cover bottom elastic band or attach Vel-
cro flap to front of cover.
(5) Install seatback insert.
(6) Install headrest latch release lever bezel.
(7) Install headrest by pushing it down into seat-
back cylinders.
(8) Install cushion on frame. If necessary, refer to
installation procedure.
(9) Install seat in the vehicle. If necessary, refer to
the installation procedure.
(10) For power seats, test seat operation.
BUCKET SEAT PLATFORMÐXJ
REPLACEMENT
Bucket seat platforms are not repairable. If the
seat platform is damaged, replace platform as a unit.
REAR SEAT CUSHIONÐXJ
REMOVAL
(1) Disengage the seat cushion at the rear by pull-
ing upward on the release strap (Fig. 1).
(2) Tilt the seat cushion forward.
(3) Disengage the seat cushion latch with the re-
lease lever (Fig. 2 and 3). Separate the right side
latch and then the left side seat bracket from the
floor anchor bolts, and remove the cushion from the
vehicle.
INSTALLATION
(1) Position the seat cushion in the vehicle (Fig. 3).
(2) Insert the left pivot in the anchor grommet.
(3) Force the right side latch onto the anchor bolt
and pivot the seat cushion to the horizontal position.
(4) Lock the seat cushion in-place by pressing
firmly on the center of the cushion until the latch en-
gages.
REAR SEAT CUSHION COVERÐXJ
REMOVAL
(1) Remove the seat cushion from the vehicle.
(2) Remove the cover side, front and rear retaining
clips from the wire retainers with an appropriate re-
moval tool (Fig. 4).
(3) Remove the serrated retainers from the front
ends of the cover with a trim panel removal tool (Fig.
5).
(4) Remove the seat cover from the cushion.Fig. 1 Seat Cushion Disengagement At Rear
Fig. 2 Seat Cushion Disengagement At Front
Fig. 3 Rear Seat Cushion Removal/Installation
23 - 82 INTERIOR COMPONENTSÐXJJ