JEEP CHEROKEE 1994 Service Repair Manual

²allow stripe/decal removal solution to remain on
the stripe/decal for 20 minutes;
²after 20 minutes, peel the stripe/decal away from
flange area;
²if there is difficulty with peeling the stripe/decal
away from the body panel, use a squeegee (Fig. 73).
²with the stripe/decal removed, scrape all the
stripe/decal solution from the panel surface before
proceeding.
WARNING: USE THE ADHESIVE REMOVAL SOLU-
TION IN A WELL-VENTILATED AREA ONLY.
(4) After the stripe/decal is removed, remove any
adhesive remaining with a removal solution.
Allow the adhesive removal solution to re-
main on the panel for 3 to 5 minutes only.
(5) After 3 to 5 minutes, use a squeegee to remove
the adhesive (Fig. 74).
(6) Remove the masking tape and mask from the
panel.
(7) Wipe the panel with a cloth saturated with an
adhesive cleaning solution.
BODY PANEL SURFACE PREPARATION
(1) The area that will be covered by the tape
stripe/decal must be cleaned with cleaning solution.
(2) Freshly painted surfaces must be thoroughly
dry.
(3) Clean the painted surface with a commercial
wax and silicone removal solution. Wipe the surface
with a clean cloth and allow it to dry.
REPLACEMENT ON ONE PANEL
For tape stripes/decals, use a clean sponge and ap-
ply the wetting solution:
²to the adhesive side of the tape stripe/decal, and
²to the painted panel surface.
The wetting solution will permit ease of tape
stripe/decal movement when positioning it.
(1) Align a straight edge with the existing tape
stripe/decal ends (Fig. 75).
If applicable, the body panel character line
can be used as the tape stripe/decal alignment
reference.
Fig. 71 Stripe/Decal Removal Solution Application
Fig. 72 Body Stripe/Decal Removal
Fig. 73 Body Stripe/Decal Removal With A Squeegee
Fig. 74 Adhesive Removal With A Squeegee
23 - 26 BODY COMPONENTSÐXJ VEHICLESJ

(2) Position the tape stripe/decal and carrier on the
body panel and the mark length with a wax pencil.
(3) Cut the stripe/decal and carrier at the required
length with scissors.
(4) Position the stripe/decal and carrier on the
body panel and hold it in-place with masking tape
(Fig. 76).
(5) Lift the bottom edge of tape stripe/decal and
carrier. Use the tape sections as hinges, and reverse
the position of stripe/decal and carrier.
CAUTION: Always remove the carrier from the tape
stripe/decal, never remove the tape stripe/decal
from carrier
(6) Bend a corner of carrier outward and then,
with a flick of the finger, separate the corner of car-
rier from the decal.
(7) Separate approximately 15 cm (6 in) of the car-
rier from one end of the tape stripe/decal.
(8) Return the tape stripe/decal back to its original
position. If a solution is being used, position adhesiveside of the tape stripe/decal on panel. Apply the so-
lution to the outside of the tape stripe/decal.
(9) Hold the tape stripe/decal against the panel sur-
face while separating the carrier from the stripe/decal.
Fig. 75 Stripe/Decal Alignment Reference Mark
Fig. 76 Tape Stripe/Decal And Carrier Retained On
Body Panel
Fig. 77 Tape Stripe/Decal And Carrier Reversed On
Body Panel
Fig. 78 Tape Stripe/Decal and Carrier Separated
Fig. 79 Tape Stripe/Decal Installation
JBODY COMPONENTSÐXJ VEHICLES 23 - 27

(10) Where applicable, extend the tape stripe/decal
12 mm (1/2 in) beyond door edge. Wrap it around the
edge and press it to the door flange.
(11) If applicable, remove the cover from face of
tape stripe/decal.
(12) Inspect the tape stripe/decal with reflected
light to find any damage. Remove all the air and/or
moisture bubbles.
COMPLETE REPLACEMENT
The following procedure will simplify the installa-
tion of a complete or very large section.
(1) Place the tape stripe/decal on a clean, flat sur-
face with the carrier side facing upward.
CAUTION: Always remove the carrier from tape
stripe/decal, never remove the tape stripe/decal
from the carrier.(2) Bend a corner of the carrier inward and then,
with a flick of the finger, separate the corner of car-
rier from the tape stripe/decal.
(3) Retain the tape stripe/decal firmly against flat
surface and separate the carrier from tape stripe/de-
cal.
(4) Use a sponge and apply solution to the tape
stripe/decal adhesive and to panel surface.
(5) Position the adhesive side of tape stripe/decal
on the panel with the bottom aligned with the char-
acter line.
²align the end of the replacement tape stripe/decal
with the end of existing tape stripe/decal, and
²correctly align the index darts and index notches.
Fig. 80 Tape Stripe/Decal Installation On Door
Flange
Fig. 81 Tape StripesÐXJ
Fig. 82 Upper and Lower Body Side Tape
StripesÐXJ Vehicles
Fig. 83 Hood Tape StripesÐXJ Vehicles
23 - 28 BODY COMPONENTSÐXJ VEHICLESJ

(6) If a complete replacement tape stripe/decal is
not being installed:
²position the replacement tape stripe/decal section
at the center of the repair area,
²align it with the existing tape stripe/decal, and
²allow at least 12 mm (1/2 in) of the tape stripe/de-
cal section to overlap the tape stripe/decal edges.
(7) Apply the wetting solution to the outer side of
the tape stripe/decal.
CAUTION: Avoid unnecessary pulling and stretch-
ing at the ends.
(8) Slide a squeegee from the center to the ends of
the tape stripe/decal. Use firm strokes to remove all
of the air bubbles.(9) If a wrinkle is trapped in the tape stripe/decal
stop immediately. Lift the wrinkled area and re-align
it with the character line to remove the wrinkle.Do
not lift the tape stripe/decal if only a few air
bubbles exist.
(10) Where applicable, allow 12 mm (1/2 in) extra
tape stripe/decal to extend beyond edges.
(11) Fold the excess tape onto the inside flange and
adhere it with finger pressure.
(12) Inspect the tape stripe/decal installation with
the reflected light to find any damage.
(13) Remove all the air and moisture bubbles from
the tape stripe/decal with a needle or pin.
(14) Install any removed components and clean the
vehicle as necessary.
QUARTER WINDOW APPLIQUEÐXJ VEHICLES
REMOVAL/INSTALLATION
(1) Remove nuts from inside vehicle.
(2) Carefully pry the applique the from panel.
(3) Position the replacement applique the on panel
and install the nuts.
DRIP RAIL MOULDINGÐXJ VEHICLES
REMOVAL
(1) Pry the clips from the roof flange.
(2) Remove the clips and moulding from the roof
flange.
(3) Remove the remaining sealant and clean the
roof flange.
Fig. 84 Tailgate Tape StripesÐXJ Vehicles
Fig. 85 Tape Stripes and DecalÐXJ Sport
Fig. 86 Quarter Window Applique and Drip Moulding
JBODY COMPONENTSÐXJ VEHICLES 23 - 29

INSTALLATION
(1) Position the drip rail moulding with clips at
the roof flange and force the clips onto the roof
flange.
(2) Apply sealant to the inner side of the moulding
to seal the roof flange.
AIR EXHAUST GRILLEÐXJ VEHICLES
REMOVAL
(1) Remove the screw that attaches the grille to
door the opening panel (Fig. 87).
(2) Pry the bottom edge of the grille from the door
opening panel.
(3) Pull downward and remove the grille from ex-
haust port in the door opening panel.
INSTALLATION
(1) Position the slot located in the upper end of re-
placement grille at the exhaust port and insert edge
in the slot.
(2) Push inward and seat the grille in the exhaust
port.
(3) Install the screw to attach the grille to the door
opening panel.
EXTERIOR NAMEPLATES
SERVICE INFORMATION
All of nameplates, with the exception of the JEEP
nameplate located on the grille are attached with ad-
hesive.
GRILLE OPENING PANEL NAMEPLATE
REMOVAL
(1) Remove the grille opening panel (GOP) support
bracket.
(2) As applicable, remove the nut(s) from the let-
ter(s) that must be replaced.(3) Remove the nameplate letter(s) from GOP.
INSTALLATION
(1) Clean the panel surface.
(2) Position the replacement letter(s) on the GOP.
(3) Install the nut(s) and tighten.
ADHESIVE-BACKED NAMEPLATES
REMOVAL/INSTALLATION
(1) Pry the nameplate from vehicle panel.
(2) Clean the panel surface.
(3) Position the replacement nameplate on the
panel push inward to seat it.
FUEL FILLER NOZZLE/TUBE
REMOVAL
(1) Remove the fuel filler door from the quarter
panel (Fig. 89).
(2) For XJ vehicles, remove the fuel filler hose
splash shield from the quarter inner panel and frame
rail (Fig. 89).
Fig. 89 Fuel Filler DoorÐTypical
Fig. 87 Door Opening Air Exhaust Grille
Fig. 88 XJ Exterior Nameplates
23 - 30 BODY COMPONENTSÐXJ VEHICLESJ

(3) Remove the cap from the nozzle.
(3) Loosen the clamps and separate the hoses from
the tubes.
(4) Remove the screws that attach the nozzle to
the housing.
(5) Remove the nozzle/tube from the fuel filler
housing.
INSTALLATION
(1) Insert the fuel filler nozzle/tube into the hous-
ing.
(2) Install the screws to attach the nozzle/tube to
the housing. Tighten screws to 2 Nzm (20 in-lbs)
torque.
(3) Attach the hoses to the tubes with clamps.
Tighten the clamp screws to 4 Nzm (35 in-lbs) torque.
(4) Install the cap on nozzle.
(5) For XJ vehicles, install the fuel filler hose
splash shield on the quarter inner panel and frame
rail.
(6) Install the fuel filler door on the quarter panel.
FUEL FILLER DOOR BUMPERS
REPLACEMENT
(1) Grasp the bumper with pliers and pull outward
to remove it from the hole.
It may be necessary to remove the door to re-
place the door-stop bumper.
(2) Insert bumpers in the holes and force them in-
ward until they are seated in the holes.
EXTERNAL MIRRORS
SERVICE INFORMATION
Service procedures for all external rear view mir-
rors are below.
REMOTE AND POWER/MANUAL MIRRORS
REMOVAL
(1) Remove the door trim panel.
(2) Remove the mirror inside trim cover screw.
Fig. 90 Fuel Filler Hose Splash ShieldÐXJ Vehicles
Fig. 91 Fuel Filler Nozzle/TubeÐXJ Vehicles
Fig. 92 Fuel Filler Nozzle/Tube
Removal/InstallationÐXJ Vehicles
Fig. 93 Fuel Filler Door Bumpers
JBODY COMPONENTSÐXJ VEHICLES 23 - 31

(3) For power/manual mirrors, remove the inside
trim cover.
(4) For remote control mirrors, loosen the toggle
control setscrew.
(5) For remote control mirrors, remove the inside
trim cover.
(6) Remove the mirror screws.
(7) Remove the mirror from the door. Refer to
Group 8ÐElectrical.
INSTALLATION
(1) Position the mirror adjacent to the vent win-
dow.
(2) Install the mirror screws. Tighten the screws
securely.
(3) For remote mirrors, position the inside trim
cover over the toggle control and tighten the set-
screw.
(4) Install the inside trim cover.
(5) Install the inside trim cover screw.
(6) Install the door trim panel.
LUGGAGE RACKÐXJ VEHICLES
REMOVAL
(1) Remove the slide rail screws.
(2) Remove the luggage rack from the roof.
The skid strips are attached to the roof panel
with adhesive.
(3) Loosen each skid strip with a heat gun.
(4) Lift one edge of each skid strip with a putty
knife and peel it from the roof panel.
(5) Remove the original adhesive from the roof
with an adhesive removal solution.
(6) If the original skid strips are installed, remove
all the original adhesive from them.
INSTALLATION
(1) Install 3M 06379 double-sided tape, or an
equivalent on skid strips.
Fig. 94 Fuel Filler Door-Stop Bumper
Fig. 95 Remote and Power/Manual Mirrors
Fig. 96 Remote Mirror Toggle Control Set Screw
Fig. 97 Trim Covers Without External Mirror
23 - 32 BODY COMPONENTSÐXJ VEHICLESJ

(2) Remove the backing from the double-sided
tape, align each skid strip on the roof, and position it
on the roof panel.
(3) Verify that each skid strip is properly aligned.
(4) Press each skid strip onto the roof panel with a
roller (or use hand pressure).To prevent water leaks, apply 3M Drip-Chek
Sealant, or equivalent.
(5) Position the luggage rack on the roof with the
screw holes aligned.
(6) Install and tighten the slide rail screws to 3
Nzm (28 in-lbs) torque.
Fig. 114 Luggage RackÐXJ VehiclesFig. 115 Skid Strip Installation
JBODY COMPONENTSÐXJ VEHICLES 23 - 33

DOORS
INDEX
page page
Door Alignment AdjustmentÐMajor........... 47
Door Alignment AdjustmentÐMinor........... 46
Door Edge Guard/Edge Protector Strip........ 61
Door External Handle..................... 55
Door Hinge/Hinge Pin Replacement........... 58
Door Inside Latch Release and Lock Rods..... 57
Door Key Lock Cylinder................... 54
Door Latch............................. 56
Door Latch Adjustment.................... 55
Door Removal/Installation.................. 40
Door Restraint Replacement................ 47
Door Trim Panel......................... 35
Door Window Exterior Mouldings............. 61
Door Window Glass and Door Opening
Weatherstrip Seals...................... 62
Front Door Spacer BlocksÐTwo-Door Vehicles . . 60
Front Door Vent Window................... 50
Front Door Window Glass.................. 49Front Door Window Glass Regulator.......... 48
Liftgate Adjustment....................... 70
Liftgate Hinge........................... 67
Liftgate Latch/Key Lock Cylinder/Striker........ 68
Liftgate License Plate Lamp Housing.......... 72
Liftgate License Plate Screw Anchor and Bumper . 72
Liftgate Opening Weatherstrip Seal........... 70
Liftgate Removal/Installation................ 65
Liftgate Service InformationÐXJ Vehicles...... 65
Liftgate Support Rod Ball Stud Replacement.... 70
Liftgate Support Rod Cylinder............... 69
Liftgate Support Rod Cylinder Disposal........ 70
Liftgate Trim Panel....................... 66
Rear Door Fixed Window Glass............. 53
Rear Door Window Glass.................. 52
Rear Door Window Glass Regulator.......... 51
Service Information....................... 34
SERVICE INFORMATION
The door service procedures includes removal, in-
stallation and/or replacement of the following door
components:
²door handles,
²armrests,²trim panels,
²waterdams,
²door restraints,
²front doors,
²rear doors (XJ vehicles only),
²window glass regulators,
Fig. 1 Front Door Trim Panel
23 - 34 BODY COMPONENTSÐXJ VEHICLESJ

²door vent and window glass,
²key lock cylinders,
²door half-hinges,
²liftgate (XJ vehicles only),
²liftgate hinges (XJ vehicles only),
²
liftgate gas support rod cylinders (XJ vehicles only),
²rocker panel seals, and
²mouldings/weatherstrip seals.
DOOR TRIM PANEL
SERVICE INFORMATION
All attached components can be removed from door
trim panels (Figs. 1 and 2).
REMOVAL
(1) Remove the door inside latch release handle
screws (Figs. 3 and 4).
(2) Move the door handle outward and disconnect
the handle-to-latch rods (Fig. 5). For vehicles
equipped with power door locks/windows, disconnect
the wire harness connector (Fig. 6).
(3) Remove the regulator handle (Fig. 7) or, if
equipped, power window switches and bezel.
(4) Remove the armrest lower screws.
(5) Pull armrest straight outward from panel and
remove the bezel.
Fig. 2 Rear Door Trim Panel
Fig. 3 Front Door Inside Latch Release Handle
Fig. 4 Rear Door Inside Latch Release Handle
JBODY COMPONENTSÐXJ VEHICLES 23 - 35