JEEP CHEROKEE 1994 Service Repair Manual

(3) Disconnect the handle-to-latch rod from the
handle latch release lever arm.
(4) Remove the nuts and handle from the door.
(5) Remove the gaskets from the door outer panel
surface, if necessary.
INSTALLATION
(1) Assemble the replacement door handle, if nec-
essary (Fig. 73). Apply silicone spray lubricant to the
components.
(2) If the original gaskets were removed, position
the replacement gaskets on the handle. Position the
handle on the door outer panel.
(3) Install and tighten the handle nuts.
(4) Connect the latch-to-handle rod to the handle
latch release lever arm.
(5) Install the door waterdam and trim panel.(6) Adjust the door latch as described in DOOR
LATCH ADJUSTMENT.
DOOR LATCH
REMOVAL
(1) Remove the access plug located at the upper
end of the door (Fig. 74).
(2) Remove the door trim panel and waterdam.
(3) Remove the door external handle from the door
outer panel.
(4) Remove the door latch screws (Fig. 75).
(5) Remove the retainer clip and key lock cylinder
from the door outer panel.
(6) Disconnect all the rods from the door latch
(Fig. 76).
Fig. 72 Door External Handle Removal/Installation
Fig. 73 Door Handle Components
Fig. 74 Access Plug
Fig. 75 Door Latch Retaining Screws
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(7) Remove the door latch from the door face.
(8) For vehicles equipped with power door locks,
remove the lock motor rivets. Remove the motor and
latch as a unit from the door. Detach the rod and mo-
tor from the latch (Fig. 77).
INSTALLATION
(1) If necessary, install a replacement latch
striker.
(2) For vehicles equipped with power door locks,
attach the rod and lock motor to the latch. Attach
the lock motor to the door panel with either rivets or
with bolts and nuts (Fig. 77).
(3) Install the door latch at the door face and con-
nect all the rods to the latch (Fig. 76).
(4) Install the latch screws. Tighten the screws to
9Nzm (77 in-lbs) torque.
(5) Install the external handle.
(6) Install the latch-to-door handle rod.
(7) Install the key lock cylinder and retainer clip.
(8) Install the door waterdam and trim panel.
(9) Install the door access plug.(10) Adjust the door latch as described in DOOR
LATCH ADJUSTMENT.
DOOR INSIDE LATCH RELEASE AND LOCK RODS
REMOVAL
(1) Remove the door inside latch release handle
screws (Figs. 79 and 80).
(2) Move the door release handle outward and dis-
connect the handle-to-latch rods (Fig. 81). For vehi-
cles equipped with power door locks/windows, also
disconnect the wire harness connector (Fig. 82).
(3) Remove the door trim panel and waterdam.
(4) Drill-out the rivet heads and remove the rod
guide bracket rivets from the door inner panel (Figs.
83 and 84).
(5) Remove the rod guide brackets and rods from
the door.
Fig. 76 Door Latches
Fig. 77 Door Lock Motor
Fig. 78 Door Latch Striker Removal/Installation
Fig. 79 Front Door Inside Latch Release Handle
JBODY COMPONENTSÐXJ VEHICLES 23 - 57

INSTALLATION
(1) Position the rod guide brackets and rods in the
door.
(2) Install rod the guide bracket rivets in the door
inner panel (Fig. 85).
(3) Install the door trim panel and waterdam.
(4) Adjust the door latch as described in DOOR
LATCH ADJUSTMENT.
DOOR HINGE/HINGE PIN REPLACEMENT
REMOVAL
(1) Remove the door restraint (check) retaining pin
(Fig. 86) with a punch.
(2) Front door: open the door wide for access and
remove the door hinge pin and bushing with a
punch.(3) Rear door: with the door closed, remove the
door hinge pin and bushing with a punch (Fig. 87).
(4) Remove the door hinge bolts, plates and shims
(Fig. 88).
(5) Retain the door hinge plates and shims for cor-
rect installation.
(6) Separate the hinge halves.
Fig. 80 Rear Door Inside Latch Release Handle
Fig. 81 Door Inside Latch Release Rods
Fig. 82 Power Switch Wire Harness Connector
Fig. 83 Front Door Rod Guide Bracket and Rods
Fig. 84 Rear Door Rod Guide Bracket and Rods
23 - 58 BODY COMPONENTSÐXJ VEHICLESJ

INSTALLATION
(1) Position the hinge plates, shims and replace-
ment hinge-half on the door face.
(2) Align the door hinges, plates and shims with
bolt holes and install hinge bolts (Fig. 88).
(3) Insert a bushing in both body hinge halves
from the bottom (Fig. 89).
(4) Allow the bushing material to stick out of the
top of the hinge. Use the round end of a ball-peen
hammer, lightly tap the bushing material to begin to
roll it outward (Fig. 90).
(5) When the entire edge of the bushing is rolled
outward, turn the hammer over and lightly tap the
bushing material to form a flat head (Fig. 91). The
head must be flat without overlapping or distorting
the bushing material.(6) Slide the door half of the upper and lower
hinges onto the body half of both hinges and align
the hinge pin holes.
(7) Carefully start the hinge pins through the
hinges (they will fit snugly) and then use a two
pound hammer, carefully seat both hinge pins (Fig.
Fig. 85 Rod Guide Bracket Installation
Fig. 86 Door Restraint (Check) Retaining Pin
Fig. 87 Rear Door Hinge
Fig. 88 Door Hinges, Bolts, Plates and Shims
JBODY COMPONENTSÐXJ VEHICLES 23 - 59

92). Be careful not to bend the hinge when driving
the hinge pin, support may be required under the
hinge.
(8) Adjust/align latch striker and latch as neces-
sary.(9) Install the door restraint (check) retaining pin
with a punch.
FRONT DOOR SPACER BLOCKSÐTWO-DOOR
VEHICLES
REMOVAL
(1) Upper spacer block: drill-out the rivet heads
and remove them from the reinforcement plate
(Fig.93).
(2) Lower spacer block: remove the screws from the
door face Fig. 94).
(3) As applicable, remove the spacer block from the
door window frame or door face.
INSTALLATION
(1) As applicable, position the spacer block on the
door window frame or door face.
(2) Upper spacer block: Install the replacement riv-
ets in the spacer block and reinforcement plate.
Fig 89 Install Bushing In Hinge
Fig. 90 Begin To Roll Bushing Material Outward
Fig. 91 Forming A Head On The Bushing
Fig. 92 Installing The Hinge Pin
Fig. 93 Front Door Upper Spacer BlockÐTwo-Door
Vehicles
23 - 60 BODY COMPONENTSÐXJ VEHICLESJ

(3) Lower spacer block: install the screws in the
door face. Tighten the screws to 1 Nzm (11 in-lbs)
torque.
DOOR EDGE GUARD/EDGE PROTECTOR STRIP
REPLACEMENT
(1) Pull outward and remove the door edge guard
strip from the door edge (Fig. 95).
(2) Position the door edge guard strip on the door
edge.
(3) Force the door edge guard strip inward until it
is seated on the door edge.
DOOR WINDOW EXTERIOR MOULDINGS
REMOVAL
(1) When removing the front or rear door window
exterior moulding, open the window completely (Figs.
96 and 97).
(2) Pry and pull the moulding sections from the
door panel flange and clips.
Fig. 95 Door Edge Guard/Protector Strip
Fig. 96 Front Door Window Exterior Moulding
Fig. 94 Front Door Lower Spacer BlockÐTwo-Door
Vehicles
JBODY COMPONENTSÐXJ VEHICLES 23 - 61

INSTALLATION
(1) When installing window mouldings, start at
the forward end of the upper moulding.
(2) Force the moulding onto the door panel and con-
tinue rearward until it is completely seated on the
flange.
(3) Mate the rear moulding with the upper mould-
ing and force the moulding edge inward.
(4) Continue pressing and moving downward to
complete the installation.
(5) Position the lower moulding on the clips and
force it downward.
DOOR WINDOW GLASS AND DOOR OPENING
WEATHERSTRIP SEALS
REMOVAL
When removing the front or rear door window
glass weatherstrip seals, open the window.
The window weatherstrip seals can be removed by
hand or with the aid of a small putty knife (or sim-
ilar tool).
Fig. 97 Rear Door Window Exterior Moulding
Fig. 98 Front Door Window Glass Weatherstrip
SealsFig. 99 Rear Door Window Glass Weatherstrip Seals
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The door opening weatherstrip seal is attached to
the periphery of the door opening in the body. The
retaining push-studs can be removed with an appro-
priate pry tool. The front door secondary seal is at-
tached to the A-pillar with plastic blind rivets (Fig.
100).
The door-to-rocker panel seals are attached to the
door inner panels with rivets (Fig. 101). The rivets
can be removed with an appropriate pry tool.WINDOW GLASS WEATHERSTRIP SEAL
INSTALLATION
When installing front or rear door window glass
weatherstrip seals, open the window completely.
(1) To install a front door window glass channel
weatherstrip seal, start at the upper, rear corner
(Fig. 102).
(2) To install a rear door window glass channel
weatherstrip seal, start at the upper, front corner
(Fig. 103).
(3) A small amount of adhesive can be used to hold
the weatherstrip seal in-place, if necessary.
(4) As applicable, move forward or rearward and
downward evenly until the weatherstrip seal is fully
seated in the channel.
Fig. 100 Door Opening Weatherstrip Seals
Fig. 101 Door-To-Rocker Panel Seals
Fig. 102 Front Door Window Glass Channel
Weatherstrip Seal
Fig. 103 Rear Door Window Glass Channel
Weatherstrip Seal
JBODY COMPONENTSÐXJ VEHICLES 23 - 63

(5) Position the belt weatherstrip seals at the win-
dow edge (Figs. 104, 105 and 106) and force them
downward until seated on the flange.
DOOR OPENING WEATHERSTRIP SEAL
INSTALLATION
The weatherstrip seal is attached to the flange
around the perimeter of the door opening with adhe-
sive and plastic push-studs.
(1) When installing a door opening weatherstrip
seal, start at the door sill center line.
(2) Use adhesive along with the push-studs to aid
in retaining a weatherstrip seal.
(3) Move upward and around the perimeter of the
door opening and seat the weatherstrip seal on
flange (Fig. 108).
(4) Install the front door secondary seal with plas-
tic blind rivets.
DOOR-TO-ROCKER PANEL SEAL
INSTALLATION
(1) Position the seal on the door inner panel with
the holes aligned.(2) Attach the seal to the door inner panel with
truss rivets.
Fig. 105 Front Door Belt Outer Weatherstrip Seal
Fig. 106 Front Door Belt Inner Weatherstrip Seal
Fig. 107 Rear Door Belt Outer and Inner
Weatherstrip Seal
Fig. 108 Door Opening Weatherstrip Seals
23 - 64 BODY COMPONENTSÐXJ VEHICLESJ

LIFTGATE SERVICE INFORMATIONÐXJ VEHICLES
The liftgate components are illustrated in Figure 109.
LIFTGATE REMOVAL/INSTALLATION
REMOVAL
WARNING: DO NOT DISCONNECT THE SUPPORT
ROD CYLINDERS WITH THE LIFTGATE CLOSED.
THE SUPPORT ROD PISTONS ARE OPERATED BY
HIGH PRESSURE GAS. THIS COULD CAUSE DAM-
AGE AND/OR PERSONAL INJURY IF THEY ARE RE-
MOVED WHILE PISTONS ARE COMPRESSED.
(1) Open the liftgate.
(2) Remove the liftgate trim panel (Fig. 110).
(3) Remove the retainer clips that secure the sup-
port rod cylinders to the ball studs (Fig. 111).
(4) Remove the support rod cylinders from the ball
studs.(5) Remove the screws and the wire harness trim
cover from the liftgate header (Fig. 112).
(6) Disconnect the connectors and remove the wire
harness from the liftgate (Fig. 113).
(7) Remove the hinge-to-liftgate screws.
(8) Remove the liftgate from the vehicle.INSTALLATION
(1) Position and support the liftgate at the opening
in the body and install the hinge-to-liftgate screws.
(2) Adjust the liftgate to fit properly in the body
opening. Refer to Liftgate Adjustment.
(3) Tighten the hinge-to-liftgate screws to 9 Nzm(7
ft-lbs) torque.
(4) Connect the liftgate rod cylinders to the ball
studs and install the rod cylinder retainer clips.
(5) Insert and connect the wire harness connectors.
(6) Position the wire harness trim cover on the
header and install the screws. Tighten the screws to
1Nzm (11 in-lbs) torque.
Fig. 109 Liftgate Components
JBODY COMPONENTSÐXJ VEHICLES 23 - 65