door lock JEEP CHEROKEE 1994 Service Service Manual

(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

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

BODY COMPONENTSÐYJ VEHICLES
CONTENTS
page page
ADD-A-TRUNK........................ 198
DOORS.............................. 172
EXTERIOR COMPONENTS............... 134FIXED WINDOW GLASS................ 181
GENERAL SERVICE INFORMATION........ 132
INTERIOR COMPONENTS............... 188
GENERAL SERVICE INFORMATION
LABELS/DECALS/PLATES
Most of the labels, decals and metal plates that are
affixed to YJ vehicles (Figs. 1, 2, 3, 4 and 5) contain
either safety or otherwise essential information.
Refer to the Introduction of this manual for addi-
tional information involving labels and metal plates.
INSTALLATION
Follow the instructions included with each replace-
ment label/decal/plate to affix it to a panel, compo-
nent or window glass.
KEY LOCK CYLINDERS
The ignition switch, glove box door, floor console,
metal front doors and the tailgate all have key lock
cylinders. When lock cylinder service is necessary,
refer to the applicable service information source:
²Ignition SwitchÐGroup 8D,
²Instrument Panel,
²Floor Consoles,
²Front Doors, and
²Tailgate.
Fig. 1 YJ Underhood Labels/DecalsFig. 2 YJ Interior and License Plate Holder Labels/
Decals
23 - 132 BODY COMPONENTSÐXJ VEHICLESJ

EXTERIOR COMPONENTS
INDEX
page page
Battery Tray........................... 140
Body Extension Panels and FasciasÐYJ
Renegade Vehicles..................... 147
Body Side Step Moulding................. 145
Body Stripes/Decals..................... 153
Cowl Grille and Screen................... 139
Cowl Weatherstrip Seal................... 139
Exterior Nameplates (Adhesive-Backed)....... 158
External Spare/Wheel Tire Carrier........... 172
Fender Flare........................... 144
Fender Inner Splash Shields............... 147
Fender Splash Aprons.................... 147
Fenders............................... 141
Fog LampÐYJ Renegade Vehicles.......... 150
Front Fascia and Skid PlateÐYJ Renegade
Vehicles............................. 148
Front Fender Extension PanelÐYJ Renegade
Vehicles............................. 149
Fuel Filler Protector/Nozzle................ 158
Half Metal Door Mirror (External)............ 158
Hard Top Liftgate Glass.................. 162
Hard Top Repair........................ 165
Hard Top Roof Vent..................... 165
Hard Top Service....................... 164
Hard Top Service Information.............. 164Hood................................. 137
Hood Alignment......................... 138
Hood Insulator Panel..................... 138
Hood Safety Latch....................... 139
Liftgate Glass Weatherstrip Seal Replacement . . 163
Radiator Grille Applique................... 134
Rear Fascia and Skid PlateÐYJ Renegade
Vehicles............................. 152
Rear Quarter Extension PanelÐYJ Renegade
Vehicles............................. 151
Rocker Extension PanelÐYJ Renegade
Vehicles............................. 150
Soft Top Service........................ 167
Soft Top Service Information............... 166
Sport Bar............................. 171
Tailgate Adjustment...................... 160
Tailgate Hinge.......................... 159
Tailgate Latch and Release Handle.......... 160
Tailgate Latch Striker..................... 161
Tailgate Lock Cylinder.................... 160
Tailgate Service......................... 159
Tailgate Service Information................ 159
Tailgate Weatherstrip Seal................. 161
Wheelhouse Splash Liners................ 146
RADIATOR GRILLE APPLIQUE
REMOVAL
(1) Raise the hood.
(2) Remove the headlamp bezels (Fig. 1).
(3) Remove the headlamp bulb retainer screws
(Fig. 2).
(4) Disconnect and remove the headlamps and
buckets as a unit (Fig. 2).
(5) Remove the parking lamp retaining screws
(Fig. 2).
(6) Disconnect the wire harness connectors and re-
move the parking lamps (Fig. 2).
(7) Remove the front crossmember cover.
(8) Remove the retaining screws and the bumper
inserts at the top of the grille panel (Fig. 1).
(9) Detach the grille applique from the grille panel
(Fig. 1).
(10) Remove the double faced foam adhesive tape
at the bottom of the grille applique (Fig. 1).
INSTALLATION
(1) Install double faced foam tape at the bottom,
interior side of the grille applique (Fig. 1).
(2) Position the grille applique over the grille
panel and press inward along the bottom where the
tape is located (Fig. 1).
(3) Install the grille applique retaining screws and
the bumper inserts (Fig. 1).(4) Connect the wire harness connectors and posi-
tion the headlamp buckets and headlamps in the
grille panel (Fig. 2).
(5) Install the headlamp bulb retainer and the
screws (Fig. 1). Tighten the screws to 2 Nzm (18 in-
lbs) torque.
(6) Install the headlamp bezels and the retaining
screws (Fig. 1). Tighten the screws securely.
(7) Connect the wire harness connectors and in-
stall the parking lamps (Fig. 2).
(8) Install the parking lamp retaining screws.
Tighten the screws to 2 Nzm (18 in-lbs) torque.
(9) Close the hood.
(10) Install the front crossmember cover.
23 - 134 BODY COMPONENTSÐXJ VEHICLESJ

(2) Remove the mirror from the door hinge (Fig.
78).
INSTALLATION
(1) Clean the door hinge-mirror base contact sur-
face.
(2) Position the mirror base at the door hinge (Fig.
78).
(3) Install the mirror base attaching screws in the
door hinge (Fig. 78). Tighten the attaching screws to
11 Nzm (96 in-lbs) torque.
TAILGATE SERVICE INFORMATION
The following tailgate service procedures include:
²tailgate removal/installation,
²tailgate hinge replacement,
²tailgate adjustment,
²tailgate latch removal/installation,
²tailgate lock cylinder removal/installation,
²tailgate latch striker removal/installation, and
²tailgate seal replacement.
TAILGATE SERVICE
REMOVAL
(1) For YJ Renegade vehicles:
²open the tailgate;
²remove the tailgate check rod cover by removing
the screws located at the outer edge of the cover (Fig.
80);
²use a small pry bar to pry out the rod spacer that
retains the check rod in the bracket (Fig. 81);²apply inward pressure on the rod to release it from
the bracket (Fig. 81);
²remove the check rod from the tailgate;
²remove the plastic shield from the tailgate (Fig.
81); and
²close the tailgate.
(2) For all vehicles, remove the tailgate hinge
screws with a Torx bit (Fig. 82).
(3) Disengage the latch and remove the tailgate
from the vehicle.
INSTALLATION
(1) Position and align the tailgate in the body
opening and engage the latch.
(2) Install the hinge retaining screws (Fig. 82).
Tighten the screws to 18 Nzm (156 in-lbs) torque.
(3) For YJ Renegade vehicles, install the shield,
check rod and spacer (Figs. 81 and 82). Tighten the
slide pin to 75 Nzm (55 ft-lbs) torque.
(4) For YJ Renegade vehicles, install the check rod
cover (Figs. 80 and 82). Tighten the screws to 3 Nzm
(24 in-lbs) torque.
TAILGATE HINGE
REPLACEMENT
(1) Remove the hinge retaining screws and remove
the hinge (Fig. 82).
(2) Prepare and paint the replacement hinge to
match the body paint color.
(3) Lubricate the hinge with spray lubricant.
(4) Position the hinge on the body and install the
retaining screws (Fig. 82). Tighten the screws to 18
Nzm (156 in-lbs) torque.
Fig. 80 Check Rod Cover
Removal/InstallationÐRenegade Vehicles
Fig. 81 Check Rod Spacer RemovalÐRenegade
Vehicles
JBODY COMPONENTSÐXJ VEHICLES 23 - 159

SOFT TOP SERVICE
REMOVAL
(1) Detach the snap-on retainers from the upper
side retainers (Figs. 96 and 98).
(2) Slide the upper side retainer lock forward.
Next, disengage the lock from the pin and remove
the retainer from the door flange (Figs. 96, 97 and
99).
(3) Detach the snap-on retainer at the front corner
(Fig. 100, turn the retainers and remove the door
windows (Fig. 101).
Fig. 97 Soft Top Bow, Spreader Bar and Retainers
Fig. 98 Upper Side Retainers
Fig. 99 Upper Side Retainer Removal From Door
Flange
Fig. 100 Door Window Snap-On Retainer
JBODY COMPONENTSÐXJ VEHICLES 23 - 167

(4) Open the side curtain upper and rear zippers
(Figs. 96 and 102).
(5) Detach the interior snap-on retainer and tab,
and pull the bottom edge of each side curtain out of
the lower side retainer channel (Fig. 103).
(6) Slide the front edge of the side curtain down-
ward and remove it from the center bow retainer
channel (Figs. 96 and 104).
(7) Pull downward on the spreader bar to release
the lock and the tension on the center and rear bows
(Figs. 97 and 105).
(8) Open the tailgate.(9) Open the rear curtain upper and side zippers
(Fig. 106).
(10) Roll up the rear curtain and attach it to the
top cover with the elastic straps and snap-on retain-
ers (Fig. 107).
(11) Pull the bottom edge of the rear corners out-
ward and detach from the side (lower) retainer (Fig.
108).
Fig. 101 Door Window Removal/Installation
Fig. 102 Side Curtain Zippers
Fig. 103 Side Curtain and Lower Side Retainer
Fig. 104 Side Curtain Removal/Installation
23 - 168 BODY COMPONENTSÐXJ VEHICLESJ

(4) Position front of the upper side snap retainers
at the door flanges and lock pin at each side of the
vehicle (Fig. 116). Engage the locks with the pins
and then slide the locks rearward.
(5) Insert the front edge of the top cover into the
retainer channel on the windshield frame (Figs. 110
and 117).
(6) Ensure that the center bow leg is positioned all
the way forward in the receptacle.
(7) Ensure that the rear corners of the top cover
are inserted in the retainer channels (Fig. 117).
(8) Pull the rear bow legs rearward until they en-
gage with the notch in the lower side retainers. En-
sure that the side curtain rear zippers are not
entrapped or folded behind the rear bow.(9) Force the spreader bars (Fig. 118) upward until
the lock engages.
(10) Slide the front edge of each side curtain up-
ward into the retainer channel on the center bow
(Figs. 104 and 117).
(11) Close top zipper on each side curtain5-8cm
(2 - 3 in). Next, close the rear zipper at the bottom
corner of the curtain5-8cm(2-3in).
(12) Attach the side curtain front and rear tab
snap-on retainers to the lower side retainer (Fig.
103).
(13) Completely close both side curtain zippers.
(14) Pull downward firmly on the side curtains.
Start at one end and move toward the opposite end.
The bottom edge of the curtains must be completely
inserted in the lower side retainer channels (Fig.
103).
(15) Release the rear window curtain straps and
insert the bottom edge into the tailgate retainer
channel (Fig. 117). Close the rear window curtain
zippers and attach the side snap-on retainers.
(16) Attach all the top cover snap-on retainers to
the upper side retainers located above both doors
(Fig. 109). As necessary, slide the mating half of the
snap-on retainers so that they will align with the
snap-on retainers on the top cover. Tuck the edge of
the top cover inside the side retainer.
(17) Install the door windows by inserting the re-
tainers into the door grommets. Attach the snap-on
retainers located along the bottom edge of the win-
dow to the door retainer (Fig. 100).
SPORT BAR
REMOVAL
(1) Remove the screws that attach the sport bar
base plates to the floor and wheelhouse panels (Fig.
119).
Fig. 116 Upper Side Retainer Lock Engagement
Fig. 117 Soft Top Installation
Fig. 118 Engaging Spreader Bar Lock
JBODY COMPONENTSÐXJ VEHICLES 23 - 171

DOORS
INDEX
page page
Full-Metal Door Assist Handle.............. 175
Full-Metal Door Hinges................... 179
Full-Metal Door Key Lock Cylinder........... 178
Full-Metal Door Latch.................... 179
Full-Metal Door Latch External Release Handle . 178
Full-Metal Door Latch Inside Release and
Lock Handle.......................... 175
Full-Metal Door Service................... 181
Full-Metal Door Trim Panel................ 175Full-Metal Door Vent Window Glass......... 177
Full-Metal Door Waterdam................. 176
Full-Metal Door Weatherstrip Seals.......... 180
Full-Metal Door Window Glass.............. 178
Full-Metal Door Window Glass Regulator...... 177
Full-Metal Door Window Glass Regulator Handle. 175
Half-Metal Door Latch Striker............... 175
Half-Metal Soft Top Door.................. 173
HALF-METAL SOFT TOP DOOR
REMOVAL/DISASSEMBLY
(1) Open the door.
(2) Disconnect the door restraint strap from the
pin (Fig. 1).
(3) Turn the window retaining sleeves 1/4 turn to
the left and pull them up and out of the door (Fig. 2).
(4) Remove the window from the door by detaching
the soft top-to-door snap fasteners and pulling the
window up and out of the door (Fig. 3).
(5) Remove the latch interior release handle (Fig.
4).
(6) Remove the assist handle (Fig. 4).
(7) Remove the trim panel by detaching the retain-
ers around the perimeter of the trim panel (Fig. 4).
Fig. 2 Window Retaining Sleeves
Fig. 3 Window Removal/Installation
Fig. 1 Half-Metal Soft Top Door
JBODY COMPONENTSÐXJ VEHICLES 23 - 173