rear view mirror JEEP CHEROKEE 1994 Service Repair Manual

(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

FIXED WINDOW GLASS
INDEX
page page
Fixed Glass Water Leak Detection and Repair . . 83
Interior Rearview Mirror.................... 74
Interior Rearview Mirror Support Bracket
Replacement.......................... 75
Liftgate Window GlassÐXJ Vehicles.......... 81
Rear Quarter Vent Window GlassÐXJ Vehicles . 80Rear Quarter Window Glass/Rear Quarter
Plastic Insert ÐXJ Vehicles............... 80
Service Information....................... 73
Windshield Glass Replacement.............. 75
Windshield Reveal Moulding................ 73
Windshield Service Information.............. 75
SERVICE INFORMATION
The following service procedures include removal
and installation of the:
²windshield reveal moulding,
²interior rearview mirror,
²windshield glass (using both the short and the ex-
tended installation method),
²rear quarter vent window glass,
²rear quarter window glass,
²liftgate window glass,
²cab rear window, and
²leak detection and repair.
WINDSHIELD REVEAL MOULDING
REMOVAL
(1) Disconnect the reveal mouldings from the clips
around the windshield glass with an appropriate tool
(Fig. 1).
(2) Remove the mouldings from the windshield
frame.
(3) Inspect the reveal moulding retainer clips (Fig.
2). Replace broken, or loose clips (Fig. 3).
Fig. 1 Windshield Reveal Moulding Disengagement
Fig. 2 Windshield Reveal Moulding Retainer Clips
JBODY COMPONENTSÐXJ VEHICLES 23 - 73

INSTALLATION
(1) Position mouldings on the windshield frame
(Fig. 4).
(2) Attach mouldings to the clips by tapping each
moulding with a rubber mallet to seat it on the clips.
INTERIOR REARVIEW MIRROR
MIRROR REMOVAL
(1) Loosen the mirror base-to-bracket setscrew
(Fig. 6).
(2) Slide the mirror base upward and off the sup-
port bracket (Fig. 7).
MIRROR INSTALLATION
(1) Slide the mirror base onto the support bracket
(Fig. 7).
CAUTION: Do not over-tighten setscrew because
glass chipping or breakage could result.
(2) Tighten the setscrew to 1 Nzm (9 in-lbs) torque
(Fig. 6).
Fig. 5 Windshield Reveal Moulding Installation
Fig. 6 Interior Rearview Mirror Setscrew Removal/
Installation
Fig. 7 Interior Rearview Mirror Removal/Installation
Fig. 3 Retainer Clip Removal/Installation
Fig. 4 Windshield Reveal Moulding
23 - 74 BODY COMPONENTSÐXJ VEHICLESJ

INTERIOR REARVIEW MIRROR SUPPORT
BRACKET REPLACEMENT
PREPARATION
(1) Mark reference lines for the mirror support
bracket on the outside of windshield glass with a wax
pencil.
(2) If the vinyl pad remained on the windshield
glass, soften and remove it with a heat gun.
(3) Clean the support bracket surface area on the
glass. Use a mild abrasive cleaning powder on a cloth
saturated with isopropyl (rubbing) alcohol.
(4) Lightly sand the contact surface on the support
bracket with fine grit sandpaper. Wipe bracket con-
tact surface clean with a paper towel and alcohol.
INSTALLATION
(1) Apply adhesive to the act surface on the sup-
port bracket according as follows:
²crush the vial in the plastic housing of the accel-
erator to saturate the felt applicator;
²remove the paper sleeve;
²apply a generous amount of accelerator to the con-
tact surface on the mirror support bracket;
²do not touch the support bracket contact surface
after the accelerator has been applied.
²allow the accelerator to dry for at least five min-
utes; and
(2) Apply accelerator to the support bracket con-
tact surface on the windshield glass. Allow the accel-
erator to dry for one minute.
(3) Install the mirror bracket on the windshield
glass follows:
²apply one drop of adhesive at the center of support
bracket contact surface on windshield glass;
²immediately apply an even coat of adhesive to the
contact surface on the support bracket;
²align the support bracket with the position refer-
ence lines on the windshield glass, then
²press and hold the support bracket in-place for at
least one minute.
Ensure that the mirror support bracket is
correctly aligned because the adhesive will
cure rapidly.
(4) Allow the adhesive to cure for 8-10 minutes,
then remove any residue adhesive with an alcohol-
dampened cloth.
(5) Allow the adhesive to cure for an additional
8-10 minutes before installing the mirror base on the
support bracket.
WINDSHIELD SERVICE INFORMATION
URETHANE ADHESIVE BONDING
The windshield glass is bonded to the body pinch-
weld flanges with urethane adhesive (Fig. 8). Thismethod of windshield installation complies with the
applicable Federal Motor Vehicle Safety Standards
(FMVSS).
WARNING: DO NOT OPERATE THE VEHICLE FOR
AT LEAST 24 HOURS AFTER WINDSHIELD INSTAL-
LATION. THE URETHANE ADHESIVE MAY NOT
PERFORM PROPERLY IN THE EVENT OF A COLLI-
SION IF IT IS NOT SUFFICIENTLY CURED. REFER
TO THE MANUFACTURER OF THE URETHANE BE-
ING USED FOR CURING TIME SPECIFICATIONS.
WHEN INSTALLING THE WINDSHIELD, DO NOT
USE URETHANE ADHESIVE IF THE EXPIRATION
DATE ON THE PRODUCT HAS PASSED. SAFETY
AND QUALITY ON THE REPAIR WOULD BE QUES-
TIONABLE.
REMOVAL/INSTALLATION METHODS
Windshield glass removal is accomplished by the
use of a razor knife and an electric hot knife to cut
through the urethane adhesive. This removal method
applies in all instances.
Depending on the circumstances, either one of two
windshield glass installation methods can be used:
²the short method, and
²the extended method.
The short method is used when the windshield
glass is removed intact, and the body opening and
the pinchweld flanges do not require repair.
The extended method must be used when the body
opening or a flange is damaged. The extended
method must also be used when urethane no longer
adheres to either the windshield glass or the pinch-
weld flanges.
WINDSHIELD GLASS REPLACEMENT
REMOVAL
(1) If the windshield glass short installation
method will be used, ensure that a bead of urethane
remains on the pinchweld flange.
Fig. 8 Windshield Glass Bonding With Urethane
JBODY COMPONENTSÐXJ VEHICLES 23 - 75

(2) Cover the interior and exterior body surface ar-
eas with a protective covering.
(3) Remove the windshield wiper arms, reveal
moulding, interior trim mouldings and rearview mir-
ror.
(4) Make a cut around theperimeterof the wind-
shield glass along the glass edge with a razor knife
(Fig. 9).
(5) Clean the blade of the hot knife with solvent
and a cloth. Sharpen the blade with a fine-tooth file.
CAUTION: When cutting through urethane with a
hot knife, do not allow the knife blade to remain
stationary at any location. Excessive heat will per-
manently soften urethane and cause complete re-
placement of the urethane.
(6) Start the hot knife blade between the glass and
the urethane. Next, cut the adhesive as close to the
glass edge as possible (Fig. 10). Allow as much adhe-
sive to remain on the pinchweld flange as possible.
For best cutting results, clean the knife blade
frequently with steel wool while the blade is
hot.
(7) Remove the windshield glass from the body
opening.
(8) After the hot knife blade has cooled, clean the
blade with solvent and a clean cloth.
INSTALLATIONÐSHORT METHOD
Normally, after a replacement windshield glass is
installed, the rearview mirror bracket also requires
Fig. 9 Cutting Urethane Along the Glass Edge
Fig. 10 Cutting Glass Urethane Adhesive With Hot Knife
23 - 76 BODY COMPONENTSÐXJ VEHICLESJ

CAUTION: Avoid spilling or dripping primer on
painted surfaces. Clean spills or drips immediately.
The primer will damage the paint if it remains on
the surface for any length of time.
²thoroughly mix and apply glass blackout primer to
the 16 mm (5/8 in) surface area around the interior
side of the glass (Fig. 15); then
²allow the primer to dry for at least 10-12 minutes.
(11) Cut the urethane adhesive applicator nozzle
according to the instructions in Figure 16.
(12) Apply a continuous, 6-mm (1/4-in) diameter
bead of urethane adhesive to the surface area.
CAUTION: Be prepared to install glass immediately
after applying the adhesive. The adhesive begins to
cure within 10-15 minutes.(13) Align the glass with the reference marks and po-
sition the glass on the pinchweld flanges. Ensure that
the windshield glass is correctly seated on the support
spacers.
(14) Force the windshield glass inward just enough
to wet-out and set the urethane. Use care to avoid
excessive squeeze-out of adhesive.
(15) Water test the windshield with a water spray
after installation. Do not direct high pressure
streams of water directly at urethane. If any leaks
are detected, apply urethane as necessary.
(16) Install reveal mouldings and (if used) remove
the masking tape from the inner surface of the glass.
(17) Install all components and clean the vehicle.
(18) Open the vehicle windows to prevent interior
pressure while the urethane is curing.If not
vented, pressure in the interior of the vehicle
may interfere with proper glass bonding.
(19) Install the rearview mirror on the bracket and
tighten mirror setscrew to 2 Nzm (15 in-lbs) torque.
INSTALLATIONÐEXTENDED METHOD
Normally, after a windshield is installed, the rear-
view mirror bracket also requires installation.Do not
install the bracket until after the windshield in-
stallation is completed.
(1) Remove the all of urethane from all pinchweld
flanges. Use an electric hot knife and a plow-type
knife blade to remove the adhesive.
(2) Inspect and repair the windshield opening and
pinchweld flanges (Fig. 11).
(3) Inspect and replace any reveal moulding clips if
bent, distorted, broken or loose (Fig. 12).
(4) Prime the pinchweld flanges with a urethane
base primer (Fig. 17). However, if the flange is color-
coated with paint, prime the flanges with a paint fin-
ish primer.This is important because urethane
adhesive will not adhere to all color-coat
paints.Allow primer sufficient time to dry.
Fig. 15 Blackout Primer Application
Fig. 16 Applicator Nozzle Preparation
Fig. 17 Pinchweld Flange Primer
23 - 78 BODY COMPONENTSÐXJ VEHICLESJ

(18) Install the rearview mirror on the bracket and
tighten the mirror setscrew to 2 Nzm (15 in-lbs) torque.
REAR QUARTER VENT WINDOW GLASSÐXJ
VEHICLES
REMOVAL
(1) Remove the vent window handle retaining pin
and nut (Fig. 21).
(2) Remove the hinge-to-glass screws and remove the
window glass. If glass adheres to the hinges, remove 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. 21).
(3) Test the vent window for water leaks.
REAR QUARTER WINDOW GLASS/REAR QUARTER
PLASTIC INSERT ÐXJ VEHICLES
REMOVAL
(1) If equipped, remove the quarter window reveal
moulding (Fig. 22).
(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 (Fig. 23).
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 (Fig. 24) using as follows:
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; and
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.
Fig. 20 Windshield Glass Installation
Fig. 21 Vent Window Handle Removal/Installation
Fig. 22 Quarter Window Reveal Moulding, Glass and Seal
23 - 80 BODY COMPONENTSÐXJ VEHICLESJ

FIXED WINDOW GLASS
INDEX
page page
Fixed Glass Water Leak Detection and Repair . 189
Hard Top Quarter Window Glass............ 188
Rearview Mirror......................... 183
Rearview Mirror Retaining Bracket........... 183
Service Information...................... 183Windshield Frame....................... 184
Windshield Frame Weatherstrip Seal......... 185
Windshield Glass........................ 185
Windshield Reveal Moulding............... 183
SERVICE INFORMATION
The following fixed window service information in-
cludes removal/installation procedures for the:
²windshield reveal moulding,
²rearview mirror,
²windshield frame,
²windshield frame weatherstrip seal,
²windshield glass (using both the short and the ex-
tended installation method), and
²hard top quarter (side) window glass.
WINDSHIELD REVEAL MOULDING
REMOVAL
(1) Disengage the reveal moulding around the pe-
rimeter of the windshield glass with an appropriate
tool.
(2) Remove the mouldings from the windshield
frame.
(3) Inspect the reveal moulding retainers. Replace
the moulding if it has broken, distorted or ineffective
retainers.
INSTALLATION
(1) Position the reveal mouldings on the wind-
shield frame.
(2) Attach the mouldings to the frame by tapping
each moulding with a rubber mallet to seat the re-
tainers.
REARVIEW MIRROR
REMOVAL/INSTALLATION
(1) Loosen the mirror set screw and slide the mir-
ror up and off the retaining bracket (Fig. 1).
(2) To install the mirror, slide the mirror onto the
retaining bracket and install the set screw.
(3) Tighten the mirror setscrew to 1 Nzm (9 in-lbs)
torque.
CAUTION: Do not over-tighten the setscrew be-
cause glass chipping and/or breakage could result.
REARVIEW MIRROR RETAINING BRACKET
REPLACEMENT
(1) Mark reference position lines for the mirror re-
taining bracket on theoutsideof the windshield
glass with a wax pencil. Mark both horizontal and
vertical reference lines for accurate bracket position-
ing.
(2) If the vinyl pad remained on the windshield
glass, soften and remove it with a heat gun. Applica-
tion of low heat will be sufficient to soften the pad.
(3) Thoroughly clean the bracket contact area on
the glass. Use a mild abrasive cleaning powder on a
cloth saturated with isopropyl (rubbing) alcohol. Fi-
nal-clean the glass with a paper dampened with al-
cohol.
(4) Lightly sand the contact surface on the replace-
ment bracket with fine grit sandpaper. Next, wipe
the bracket contact surface clean with a paper towel
and alcohol.
(5) Apply adhesive accelerator to the contact sur-
face on the mirror bracket according to the following
instructions:
²crush the vial in the plastic housing of the accel-
erator to saturate the felt applicator;
²remove the paper sleeve;
²apply a generous amount of accelerator to the con-
tact surface on the mirror retaining bracket;
Fig. 1 Rearview Mirror Removal/Installation
JBODY COMPONENTSÐXJ VEHICLES 23 - 183

When the windshield glass short installation
method is used, an even, uniform bead of ure-
thane adhesive must remain on the frame
pinchweld flanges. This adhesive bead is
needed as a base for the replacement glass.
If the extended installation method is used,
the original windshield interior trim moulding
must be removed and discarded. The adhesive
cannot be removed from the original moulding.
REMOVAL
(1) Cover body surface areas with protective cover-
ing to avoid paint damage and extra clean-up time.
(2) Remove the windshield wiper arms, the reveal
moulding (Fig. 5) and the rearview mirror. If neces-
sary, refer to the applicable removal procedures.
(3) Make a preliminary cut around theperimeter
of the windshield glass along the glass edge with a
razor knife.
CAUTION: When cutting through the urethane with
a hot knife blade, do not allow the knife blade to re-
main stationary at any location.
(4) Cut the adhesive bead with a hot knife and a
straight or hooked knife blade.
(5) Start the hot knife blade between the glass and
the urethane. Next, cut the adhesive as close to the
glass edge as possible. Allow as much adhesive to re-
main on the frame flange as possible.For best cut-
ting results, clean the knife blade frequently
with steel wool while the blade is hot.
(6) Remove the windshield glass from the frame
(Fig. 5).
(7) After the hot knife blade has cooled, clean the
hot knife blade with solvent and a cloth. Sharpen the
blade with a fine-tooth file.
(8) If the extended windshield glass installation
method will be used, remove and discard the interior
trim moulding (Fig. 5).
INSTALLATIONÐSHORT METHOD
Normally, after a windshield is installed, the rear-
view mirror bracket also requires installation. If so,
refer to the rearview mirror bracket replacement pro-
cedure.Do not install bracket until after wind-
shield installation is completed.
(1) Inspect the windshield frame pinchweld flanges
(Fig. 5) Prime any bare spots with urethane primer.
Allow a minimum of 18 minutes for dry time.
(2) Inspect the urethane bead for high spots. Level
the bead by shaving off high spots with a razor knife.
This is necessary for a flush-fit of the windshield
glass.
(3) Inspect the windshield moulding. Replace the
moulding if it has broken, distorted or ineffective re-
tainers.(4) Clean the outer edge of the windshield glass
with naphtha or a similar product.
(5) Prime the outer perimeter of the interior side of
the glass 16 mm (5/8 inch) from the edge. Use a
wipe-off type urethane primer and wipe the glass dry
after primer application.
(6) Place the windshield glass in the frame on the
pinchweld flanges and inspect for gaps in the ure-
thane adhesive. Gaps in excess of 3 mm (1/8 inch)
must be filled with additional urethane adhesive.
(7) Adjust windshield glass position until it is
aligned with the flanges and the adhesive. Next,
make alignment marks on glass and body with a
grease pencil.
(8) Remove the windshield glass and position it on
a flat surface.
(9) If the replacement windshield glass does not
have blackout primer:
²attach a 25-mm (1-in) wide masking tape band
around the interior side of the glass 16 mm (5/8 in)
from the edge of the glass (Fig. 6);
²attach the tape only to the interior side of
the glass;
²thoroughly mix and apply blackout primer to the
16 mm (5/8 in) surface area around the interior side
of the glass (Fig. 6); then
²allow the primer to dry for at least 10-12 minutes.
(10) Cut the urethane adhesive applicator nozzle
according to the instructions in Figure 7.
(11) Apply a 3-mm (1/8-in) diameter bead of ure-
thane to the surface area.
Fig. 6 Blackout Primer Application
23 - 186 BODY COMPONENTSÐXJ VEHICLESJ

CAUTION: Be prepared to install the windshield
glass immediately after applying the adhesive. The
adhesive begins to cure within 10-15 minutes.
(12) Align the windshield with the grease pencil
marks (or the tape strips) and position windshield on
frame flanges.
(13) Force the windshield glass inward just enough
to wet-out and set urethane. Use care to avoid exces-
sive squeeze-out of adhesive.
(14) Water test the windshield with a cold water
spray after installation. Do not direct high pressure
streams of water directly at the urethane. Use a
moderate spray only. If any leaks are detected, apply
urethane as necessary.
(15) Install the windshield reveal moulding and (if
used) remove the masking tape from the inner sur-
face of the glass.
(16) Install all removed components and clean the
vehicle. If necessary, refer to the applicable installa-
tion procedures.
(17) Open windows and liftgate to prevent pres-
sure build-up while the urethane is curing.
(18) Install the rearview mirror on the bracket and
tighten the mirror setscrew with 2 Nzm (15 in-lbs)
torque.
INSTALLATIONÐEXTENDED METHOD
Normally, after a windshield is installed, the rear-
view mirror bracket also requires installation.Do not
install the bracket until after the windshield in-
stallation is completed.
(1) Remove all of the original urethane from all the
frame pinchweld flanges. Use an electric hot knife
and a plow-type knife blade to remove the adhesive.
(2) Inspect and repair the windshield frame and
the pinchweld flanges as necessary.
(3) Inspect and replace the reveal moulding if the
retainers are damaged.(4) Prime the frame pinchweld flanges with a ure-
thane base primer. However, if the flange is top-
coated with paint, prime the flanges with a paint
finish primer.This is important because ure-
thane adhesive will not adhere to all top coat
paints.
(5) Install the replacement interior trim moulding
(Fig. 5) on the frame pinchweld flanges (Fig. 5).
(6) Install and inspect the fit of the windshield
glass on the pinchweld flanges according to the fol-
lowing instructions:
²position the windshield glass on the flanges and
adjust the position until it is correctly aligned within
the windshield frame;
²measure the gap between the frame and the glass
around the entire perimeter of the glass and the
flange;
²the gap should be at least 3 mm (1/8 in) but no
more than 6 mm (1/4 in) at any point around the pe-
rimeter; and
²the flanges should in complete contact with the
glass around the perimeter of the frame.
(7) If the pinchweld flanges require repair, remove
the windshield glass and straighten, align, or repair
the flange(s) as necessary.
(8) Position the windshield on the flanges and in-
spect the windshield fit again. If the fit is acceptable,
mark windshield final position on the glass and the
frame. The marks (or masking tape) will be used for
installation alignment reference.
(9) If the replacement windshield glass does not
have blackout primer:
²attach a 25-mm (1-in) wide masking tape band
around the interior side of the glass 16 mm (5/8 in)
from the edge of the glass (Fig. 6);
²attach the tape only to the interior side of
the glass;
²thoroughly mix and apply blackout primer to the
16 mm (5/8 in) surface area around the interior side
of the glass (Fig. 6); then
²allow the primer to dry for at least 10-12 minutes.
(10) Cut the urethane adhesive applicator nozzle
according to the instructions in Figure 7.
(11) Apply a 3-mm (1/8-in) diameter bead of ure-
thane to the surface area.
CAUTION: Be prepared to install the windshield
glass immediately after applying the adhesive. The
adhesive begins to cure within 10-15 minutes.
(12) Align windshield with reference marks (or the
tape strips) and position it on the frame pinchweld
flanges.
(13) Force the windshield glass inward just enough
to wet-out and set urethane. Use care to avoid exces-
sive squeeze-out of adhesive.
(14) Water test the windshield with a cold water
spray after installation. Do not direct high pressure
Fig. 7 Applicator Nozzle Preparation
JBODY COMPONENTSÐXJ VEHICLES 23 - 187