JEEP CHEROKEE 1994 Service Repair Manual

(3) Attach catalytic converter, muffler or tailpipe
insulator to support hanger to insulator.
FUEL AND BRAKE FLUID TUBE RETAINER CLIP
REMOVAL
(1) Remove the fuel/brake fluid tubes from clip
grooves.
(2) As applicable, pry serrated clip outward and re-
move it from frame rail hole, or remove stand-off
bracket screw.
INSTALLATION
(1) Position clip at the frame/panel hole.
(2) As applicable, force serrated clip inward and
seat it against the frame/panel, or install the stand-
off bracket screw.
(3) Insert fuel/brake fluid tubes in clip grooves and
press inward to seat them.
FUEL FILTER BRACKET
REMOVAL
(1) Remove screws that attach fuel filter bracket to
frame rail.
(2) Remove the screw from fuel filter bracket
clamp.
(3) Remove the clamp and fuel filter from bracket.
(4) Remove the bracket from filter.
INSTALLATION
(1) Position fuel filter bracket on filter.
(2) Position clamp on bracket and install screw.
Tighten screw to 8 Nzm (74 in-lbs) torque.(3) Position fuel filter bracket on frame rail.
(4) Install the screws that attach bracket to frame
rail. Tighten screws to 42 Nzm (31 ft-lbs) torque.
FUEL FILLER HOSE SPLASH SHIELDÐXJ
VEHICLES
REMOVAL
(1) Remove the screws that attach fuel filler hose
splash shield to wheelhouse panel and frame rail.
(2) Remove the hose splash shield from wheelhouse
panel and frame rail (Fig. 7).
INSTALLATION
(1) Position fuel filler hose splash shield at wheel-
house panel and frame rail.
(2) Install screws to attach splash shield to wheel-
house panel and frame rail.
FUEL TANK SUPPORT STRAP
SERVICE INFORMATION
XJ fuel tank support straps are attached to the un-
Fig. 4 Fuel and Brake Tube Serrated/Bracket-Type
Retainer ClipsÐXJ Vehicles
Fig. 5 Fuel Filter Bracket Removal/Installation
Fig. 6 Fuel Filter Bracket Clamp
Removal/Installation
23 - 86 BODY COMPONENTSÐXJ VEHICLESJ

derside of the vehicle via T-slots and hole-slots in the
frame members.
REMOVAL
(1) If equipped, position a support under skid plate.
(2) If equipped, remove the bolts that attach skid
plate to underbody side rails.
(3) If applicable, remove the support and skid plate
from fuel tank.
(4) Support fuel tank.
(5) Loosen nut from fuel tank support strap bolt to
allow bolt head to be removed from hole-slot in frame
member.
(6) Remove the strap T-end from frame member
T-slot.
(7) Separate support strap from fuel tank and re-
move it from vehicle.
INSTALLATION
(1) Position support strap around fuel tank.
(2) Insert strap T-end in frame member T-slot.(3) Insert bolt in hole-slot in frame member.
Tighten nut on the bolt until bolt-head and T-end are
seat and strap is tight against the bottom of fuel
tank.
(4) Remove the support from the fuel tank.
(5) If removed, position and support and the fuel
tank skid plate under the fuel tank.
(6) If applicable, install the bolts that attach the
skid plate to the underbody side rails. Tighten the
bolts to 50 Nzm (37 ft-lbs) torque.
(7) Remove the support from under the skid plate.
REAR TOW HOOKÐXJ VEHICLES
REMOVAL
(1) Remove the bolts that attach tow hook bracket
to the frame rail and reinforcement bracket.
Fig. 7 Fuel Filler Hose Splash ShieldÐXJ Vehicles
Fig. 8 Fuel Tank Support StrapÐXJ Vehicles
Fig. 9 Fuel Tank Support StrapsÐXJ Vehicles
Fig. 10 Rear Tow HookÐXJ Vehicles
JBODY COMPONENTSÐXJ VEHICLES 23 - 87

The reinforcement bracket is held on the
frame rail with two blind rivets.
(2) Remove the bracket and tow hook from frame
rail.
INSTALLATION
(1) Position bracket and tow hook on the frame
rail.
(2) Install bolts that attach tow hook bracket to
frame rail and reinforcement bracket. Tighten bolts
to 75 Nzm (55 ft-lbs) torque.
TRAILER HITCHES
CLASS III HITCHÐXJ VEHICLES
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, and
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; and
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.
CLASS III HITCH CONNECTOR
The trailer tow wire harness connector for class III
trailer-tow hitches is a 7-terminal, circular type con-
nector.
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.
Fig. 11 Trailer Tow Wire Harness Connectors
23 - 88 BODY COMPONENTSÐXJ VEHICLESJ

A blue wire (without a connector) located under in-
strument panel near fuse panel is available for
trailer electric brake control unit.
The stop lamp and turn signal plug-in relays are
located behind left quarter trim panel.
HITCH REMOVALÐXJ VEHICLES
An XJ class III, weight-distributing/equalizer type
hitch is comprised of:
²a towing tube with a ball mount receptacle, and²various reinforcement/support brackets that are at-
tached to the vehicle frame sills and rear crossmem-
ber with bolts.
(1) If necessary, remove the trailer tow wire har-
ness connector from the hitch.
(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.
Fig. 14 Equalizer Type HitchÐXJ Vehicles
Fig. 12 Class III Trailer Tow Wire Harness and
ConnectorsFig. 13 Class III Trailer Tow Wire Harness Plug-In
Relays
JBODY COMPONENTSÐXJ VEHICLES 23 - 89

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.
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.(2) Place hitch on a lifting device. Raise, position
hitch at the proper location for installation on vehi-
cle 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, and
²plate bracket-to-rear crossmember nut.
(7) Remove the lift/support and, if removed, attach
the trailer wire harness connector to the hitch.
Fig. 15 Trailer Tow Wire Harness Connector
Fig. 16 Reinforcement Bracket and Hitch Installation
23 - 90 BODY COMPONENTSÐXJ VEHICLESJ

INTERIOR COMPONENTS
INDEX
page page
Assist HandleÐXJ Vehicles................ 118
B/C-Pillar and Liftgate Pillar Trim CoversÐ
XJ Vehicles.......................... 116
Bucket Seat Cushion and Cover............. 98
Bucket Seat Platform and Tracks........... 105
Bucket Seatback Cover and Frame.......... 100
Bucket Seatback Reconditioning............ 102
Carpets and Floor Mats................... 129
Dash Panel Insulation Panel................ 95
Front Bucket Seats....................... 97
Front Carpet/MatÐXJ Vehicles............. 129
Front Inner Scuff Plate/Cowl Side Trim PanelÐ
XJ Vehicles.......................... 114
Front Shoulder Belt/BuckleÐXJ Vehicles...... 119
Full Floor ConsoleÐXJ Vehicles............ 125
Headliner.............................. 121
I/P Ash Receiver Tray Lamp................ 92
I/P Tweeter Speaker/Courtesy Lamp Support
Bracket.............................. 95
Instrument Cluster Bezel................... 91
Instrument Cluster/Switch/Lighter/Radio/Hevac . . . 91
Instrument Panel......................... 93
Interior Trim Panels and Scuff PlatesÐXJ Vehicles. 112
Jack StorageÐXJ Vehicles................ 127
Mini-Floor ConsoleÐXJ Vehicles............ 124
Outer Scuff PlatesÐXJ Vehicles............ 118
Power Bucket Seat Components............ 106
Quarter and Wheelhouse Trim PanelsÐ
XJ Vehicles.......................... 115
Quarter Trim Panel ExtensionÐXJ Vehicles . . . 115
Rear Carpet/MatÐXJ Vehicles.............. 130
Rear Seat Cushion CoverÐXJ Vehicles...... 107
Rear Seat Cushion ReconditioningÐXJ Vehicles . 108
Rear Seat CushionÐXJ Vehicles............ 107
Rear Seatback CoverÐXJ Vehicles.......... 111
Rear Seatback Latch Striker and BumperÐ
XJ Vehicles.......................... 111
Rear Seatback ReconditioningÐXJ Vehicles . . . 111
Rear SeatbackÐXJ Vehicles............... 109
Rear Shoulder/Lap Belt/BuckleÐXJ Vehicles . . . 120
Spare Tire/Wheel Holddown and Floor BracketsÐ
XJ Vehicles.......................... 128
Sunvisors............................. 124
Windshield Side MouldingÐXJ Vehicles...... 114
INSTRUMENT CLUSTER BEZEL
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 (Fig. 2).
INSTALLATION
(1) Position the bezel on the upper instrument
panel and engage it with the U-clips.
(2) Install the bezel retaining screws. Tighten the
screws with 1 Nzm (11 in-lbs) torque.
INSTRUMENT CLUSTER/SWITCH/LIGHTER/RADIO/
HEVAC
REMOVAL
(1) Remove the screws and instrument cluster be-
zel from instrument panel (Fig. 3).
(2) As applicable, remove the instrument cluster or
other I/P component screws.
(3) Disconnect wire harness connector(s) from cluster
or other I/P component. Refer to Group 8ÐElectrical.
(4) Remove the cluster or other I/P component
from the upper section of instrument panel (Fig. 9).
Fig. 1 Instrument Cluster Bezel Removal/Installation
Fig. 2 Instrument Cluster Bezel Removal/Installation
JBODY COMPONENTSÐXJ VEHICLES 23 - 91

INSTALLATION
(1) Position the cluster or other I/P component at
the upper section of the instrument panel and con-
nect the wire harness connectors.
(2) Install the cluster or other I/P component re-
taining screws. Tighten the screws with 1 Nzm (11 in-
lbs) torque.
(3) Install the instrument cluster bezel on the in-
strument panel with the retaining screws.
I/P ASH RECEIVER TRAY LAMP
REMOVAL
(1) Remove the ash receiver tray from instrument
panel (Fig. 10).
(2) Remove the lamp retaining screw from the ash
receiver tray cavity (Fig. 11).(3) Disconnect the lamp wire harness connector
and remove the lamp from the instrument panel.
Fig. 5 Switch Housings and Lenses
Fig. 6 Cigarette Lighter
Fig. 7 Radio
Fig. 3 Instrument Cluster Bezel
Fig. 4 Instrument Cluster
23 - 92 BODY COMPONENTSÐXJ VEHICLESJ

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.
INSTRUMENT PANEL
REMOVAL
(1) Remove the defroster duct bezel from the in-
strument panel.
(2) Remove the steering column cover insert from
the instrument panel (Fig. 13).
(3) Remove the park brake screw from the lower
section of the instrument panel (Fig. 14).(4) Remove the screws from the lower section of
the instrument panel (Fig. 15).
(5) Remove the lower section of the instrument
panel from the upper section.
Fig. 8 Heater/AC and Heater Control Panels
Fig. 9 Instrument Cluster and Other I/P Components
Fig. 10 Ash Receiver Tray
Fig. 11 Ash Receiver Tray Lamp
Fig. 12 Defroster Duct Bezel Removal/Installation
JBODY COMPONENTSÐXJ VEHICLES 23 - 93

(6) Remove the screw and the ground wire from
the upper section of the instrument panel (Fig. 16).
(7) Loosen the I/P-to-cowl side panel screws (Fig.
17).
(8) Pull the instrument panel outward from thedash panel for clearance, tilt it rearward and discon-
nect:
²the wire harness connectors,
²the side window defogger tubes,
²the heat/vent tube, and
²the temperature control cable from the upper sec-
tion of instrument panel (Fig. 17).
(9) Remove the upper section of instrument panel
from dash panel (Fig. 18).
INSTALLATION
(1) Position upper section of instrument panel at
dash panel and supported by the I/P-to-cowl side
panel screws.
(2) Connect wire harness connectors, side window
defog tubes, heat/vent tube, and temperature control
cable to the upper instrument panel.
Fig. 13 Steering Column Cover Insert
Fig. 14 Park Brake Release Handle
Fig. 15 Lower Section Of Instrument Panel Removal/
Installation
Fig. 16 Instrument Panel Ground Wire
Fig. 17 Instrument Panel Tilted Rearward
23 - 94 BODY COMPONENTSÐXJ VEHICLESJ

(3) Tilt instrument panel forward and tighten the
I/P-to-side cowl panel screws and ground wire.
(4) Position lower section of the instrument panel
at upper section.
(5) Install screws in lower section of the instru-
ment panel. Tighten screws securely.
(6) Install the park brake and screw in lower sec-
tion of the instrument panel. Tighten screw securely.
(7) Install steering column cover insert on instru-
ment panel.
(8) Install the defroster duct bezel on the instru-
ment panel.
(9) Install the defroster duct bezel on the instru-
ment panel.
I/P TWEETER SPEAKER/COURTESY LAMP
SUPPORT BRACKET
REMOVAL
(1) Remove the park brake retaining screw from
the lower section of the instrument panel.
(2) Remove the retaining screws from the lower
section of the instrument panel.
(3) Remove the lower section of the instrument
panel from the upper section.
(4) Disconnect the wire harness connector and re-
move the speaker screws from lower section of in-
strument panel (Fig. 19).(5) Disconnect the wire harness connector and re-
move the courtesy lamp support bracket screw (Fig.
20).
DASH PANEL INSULATION PANEL
REMOVAL
(1) Remove the instrument panel from the dash
panel. Remove the defroster tubes from the ducts
(Fig. 21).
Fig. 18 Instrument Panel Disassembled
Fig. 19 Tweeter Speaker Removal/Installation
JBODY COMPONENTSÐXJ VEHICLES 23 - 95