JEEP XJ 1995 Service And Repair Manual

(2) Remove the windshield wiper arms from the
pivots (Fig. 26).
(3) Remove the screws that attach the grille to the
cowl.
(3) Remove the windshield washer tubes from the
nozzles (Fig. 27).
(4) Remove the cowl grille and screen from the
cowl (Fig. 28).(5) If necessary, remove the push-rivets and
washer nozzles from the cowl grille (Fig. 28).
(6) If necessary, remove the cowl grille push-nuts
from the cowl panel (Fig. 29).
(7) If necessary, remove the nuts and cowl grille
support bracket from the dash panel (Fig. 30).
INSTALLATION
(1) If removed, install the cowl grille support
bracket on the dash panel (Fig. 30). Tighten the nuts
to9Nzm (77 in-lbs) torque.
(2) If removed, install the push-nuts in the cowl
panel and the support bracket.
(3) If removed, install the push-rivets and washer
nozzles in the cowl grille.
CAUTION: The washer fluid tubes must be routed
and installed so that they are not pinched.
(4) Position the cowl grille and screen on the cowl.
Install the windshield washer tubes on the nozzles.
(5) Install the cowl screen and grille screws.
Tighten in sequence (Fig. 31).
Fig. 26 Cowl Grille Components
Fig. 27 Washer Fluid Tubes
Fig. 28 Cowl Grille, Screen & Washer Nozzles
Fig. 29 Cowl Grille Push-Nuts
JEXTERIOR COMPONENTSÐXJ 23 - 13

Force the cowl grille rearward while tighten-
ing the screws.
(6) Install the windshield wiper arms on the piv-
ots.
BATTERY TRAYÐXJ
REMOVAL
(1) Remove the screw, nuts, holddown support
bracket and upper holddown bracket from the hold-
down rods (Fig. 32).
(2) Remove the battery from tray.
(3) Remove the nuts that attach battery tray to the
inner fender panel.
(4) Remove the battery tray from the vehicle.
(5) If necessary, remove the retainers and hold-
down rods from the battery tray (Fig. 33).
INSTALLATION
(1) If removed, install side the holddown rods and
retainers on the battery tray.(2) Position the battery tray on the inner fender
panel with the studs inserted in the holes.
(3) Attach the battery tray to the inner fender
panel with the nuts. Tighten the nuts to 30 Nzm (22
ft-lbs) torque.
(4) Install the battery in tray.
(5) Position the upper holddown bracket over the
holddown rods.
(6) Install the holddown support bracket, screw,
and nuts on the holddown rods. Tighten the screw
and nuts.
FRONT FENDERÐXJ
The following information includes procedures for
removal/installation of:
²Fender liner.
²Front fender flare and retainers.
Fig. 30 Cowl Grille Support Bracket
Fig. 31 Cowl Grille Screw Tightening Sequence
Fig. 32 Battery Tray Removal/Installation
Fig. 33 Battery Holddown Rods & Retainers
23 - 14 EXTERIOR COMPONENTSÐXJJ

²Front fender.
REMOVAL
(1) Remove the front bumper.
(2) Right fender only:
²If equipped, remove the radio antenna mast, and
components from the fender (Fig. 34 and 35).
²Remove the battery and tray from the fender inner
panel (Fig. 36, 37 and 38).
Fig. 36 Battery, Speed Servo, PDC & Coolant
Recovery Bottle
Fig. 37 Battery Removal/Installation
Fig. 38 Battery Tray Removal/Installation
Fig. 34 Radio Antenna Removal/Installation
Fig. 35 Power Antenna Wire Harness & Cable
Connectors
JEXTERIOR COMPONENTSÐXJ 23 - 15

²Remove windshield washer reservoir from fender
inner panel (Fig. 39).
²Remove the hood ajar switch, if equipped, from
fender (Fig. 40 and 41).
²Remove the Power Distribution Center (PDC), the
coolant recovery bottle and speed servo from fender
the inner panel (Fig. 42, 43 and 44).
Fig. 41 Hood Ajar Switch Removal/Installation
Fig. 42 Power Distribution Center and Vapor
Canister
Fig. 43 Coolant Recovery Bottle
Fig. 39 Coolant Recovery Bottle, Windshield Washer
Fluid Reservoir & Hood Support Rod
Fig. 40 Hood Ajar Switch, Speed Servo & A/C
Receiver/Drier
23 - 16 EXTERIOR COMPONENTSÐXJJ

²Remove the vapor canister from the fender inner
panel (Fig. 42 and 45).
²Remove the A/C Receiver/Drier from the fender in-
ner panel (Fig. 40).
²If equipped, remove the Daytime Running Light
(DRL) module from the fender inner panel (Fig. 46).
²Support the hood and remove the hood support rod
from the fender inner panel.
(3) Remove the hood bumper from the fender inner
panel (Fig. 47).
(4) Raise and support the vehicle.
(5) Remove the front wheel.
(6) Remove the fender liner, fender flare and re-
tainers (Fig. 48):
²Remove the screws that attach the lower part of
flare to the fender outer panel.²Remove the rivets that attach the flare to the air
deflector.
²Remove the retainers that attach the fender liner
to the fender inner panel.
²Remove the nuts that attach the fender liner to
the fender outer panel and flare retainers.
²Remove the fender liner from between the fender
panels.
²Remove the push-nuts that attach the retainers to
the fender outer panel.
²Remove the retainers and flare from the fender
outer panel.
(7) Remove the grille opening panel (GOP).
(8) Remove the air deflector.
(9) Remove the rocker panel molding from the
fender.
(10) Remove all the fender braces (Fig. 49).
(11) Remove the fender lower screws (Fig. 49).
(12) Remove the fender top, front and the rear
screws. Remove the fender from the inner fender
panel (Fig. 49).
Fig. 44 Speed Servo
Fig. 45 Vapor Canister
Fig. 46 Daytime Running Light (DRL) Module
Fig. 47 Hood Bumper
JEXTERIOR COMPONENTSÐXJ 23 - 17

INSTALLATION
(1) Position the fender on the inner fender panel.
(2) Install all of the fender screws finger-tight.
(3) Install the fender braces.
(4) Align the fender with the body panels and
tighten the fender screws to 8.5 Nzm (76 in-lbs)
torque.
(5) Install the grille opening panel (GOP).
(6) Install the air deflector.(7) Install the fender flare and retainers (Fig. 50).
Then install the fender liner.
²Position the retainers and the flare on the fender.
²Install the push-nuts to attach the retainers to the
fender.
²Position the fender liner between the fender and
fender inner panel (Fig. 51).
²Install the nuts to attach the fender liner to the
fender and flare retainers (Fig. 48).
Fig. 48 Fender Flare & Liner Removal/Installation
Fig. 49 Fender Removal/Installation
23 - 18 EXTERIOR COMPONENTSÐXJJ

²Install the retainers to attach the fender liner to
the fender inner panel.
²Install the rivets to attach the flare to the air de-
flector (Figs. 48 and 50). and
²Install the screws to attach the flare to the fender.
Tighten the screws to 1 Nzm (13 in-lbs) torque.
(8) Connect the front lamp wire harness connectors
to the engine wire harness connectors (Fig. 52).
(9) Install the front lamps.
(10) Install the front bumper.
(11) Install the wheel, remove the support and
lower the vehicle.
(12) Right fender only: install the hood support rod
on the fender inner panel.
(13) Install the hood bumper on the fender inner
panel.(14) Right fender only: install the Daytime Run-
ning Light (DRL) module on fender inner panel.
(15) Right fender only: install the A/C Receiver/
Drier on the fender inner panel.
(16) Right fender only: install the vapor canister
on the fender inner panel. Tighten the vapor canister
screws to 5 Nzm (45 in-lbs) torque.
(17) Right fender only: install the PDC, coolant re-
covery bottle and speed servo on the fender inner
panel.
(18) Right fender only: install the hood ajar switch,
if equipped. Tighten the screws to 2 Nzm (15 in-lbs)
torque.
(19) Right fender only: install the windshield
washer fluid reservoir on the inner panel.
(20) Right fender only: install the battery tray and
battery on the inner panel.
(21) Right fender only: if equipped, install the ra-
dio antenna. Tighten the nut/escutcheon to 4.5 Nzm
(40 in-lbs) torque. Tighten the power antenna bracket
screws to 2 Nzm (20 in-lbs) torque.
REAR WHEELHOUSE FLARES AND LINERSÐXJ
REMOVAL
(1) Remove the flare and liner lower screws (Fig.
53 and 54).
(2) Remove the nuts that attach the liner to the
wheelhouse.
(3) Remove the liner from the wheelhouse.
(4) Remove the push-nuts that attach the flare re-
tainers to the wheelhouse (Fig. 55).
(5) Remove the flare and retainers from the wheel-
house.
INSTALLATION
(1) Position the flare and retainers at the wheel-
house.
(2) Install the push-nuts to attach the flare retain-
ers to the wheelhouse.
(3) Position the liner in the wheelhouse.
Fig. 50 Fender Flare & Retainers
Fig. 51 Fender Liner and Retainers
Fig. 52 Front Lamp Wire Harness Connectors
JEXTERIOR COMPONENTSÐXJ 23 - 19

(4) Install the nuts to attach the liner to the
wheelhouse and flare retainers.
(5) Install the flare and liner lower screws. Tighten
the screws to 1 Nzm (13 in-lbs) torque.
BODY SIDE MOLDING/CLADDINGÐXJ
REMOVAL
(1) Loosen the vinyl body side molding (Fig. 56 and
57) with a heat gun.
(2) Lift edge of molding with a putty knife and peel
molding from body panel. Apply heat to any location
where the molding remains adhered to a panel.
(3) Remove the adhesive from the body panel with
3M All Purpose Cleaner, or an equivalent cleaner.
Fig. 53 Rear Wheelhouse Flare, Retainers and Liner
Fig. 54 Rear Wheelhouse Liner
Fig. 55 Rear Wheel Opening Flare
Fig. 56 Body Side MoldingÐ2-Door XJ Vehicles
Fig. 57 Body Side Molding/CladdingÐ4-Door XJ
Vehicles
23 - 20 EXTERIOR COMPONENTSÐXJJ

(4) If the original molding will be installed, also re-
move all adhesive from it.
INSTALLATION
(1) Install 3M 06379 double-sided tape on the
molding.
(2) For vertical alignment, use masking tape or a
string as reference.
(3) Remove the backing from the tape, align the
molding and position it on the body panel.
(4) Press the molding onto the body panel with a
roller or hand pressure.
BODY STRIPES/DECALSÐXJ
SERVICE INFORMATION
XJ body stripes and decals are weather resistant
tape with a adhesive backing.
REPAIR
Small nicks, scratches and other surface marks in
a body stripe/decal can be touched-up with paint.
To eliminate blisters and air bubbles in a body
stripe/decal, pierce them with a needle or pin.
A heat gun can also be used to remove small wrin-
kles in a stripe/decal.
REQUIREMENTS
Body stripe/decal replacement requires that the
metal repair and paint refinish be completed first.
The work area temperature should be between
18ÉC (65ÉF) and 32ÉC (90ÉF).A tape stripe/decal
should not be replaced if the work area temper-
ature is less than 18ÉC (65ÉF).
The following equipment and material are neces-
sary for removal and installation:
²Commercial tape stripe/decal removal solution.
²Commercial adhesive removal solution.
²Liquid dish detergent (for the wetting solution).
²Mixture of wetting solution.
²Commercial wax and silicone removal solution.
²Isopropyl (rubbing) alcohol.
²Small squeegee (plastic or hard rubber).
²Water bucket and sponge.
²Clean wiping rags or paper towels.
²Heat gun (or infra-red heat bulb).
²Wax pencil.
²
Sharp knife, single edge razor blade or X-acto knife.
²Pair of scissors.
²Needle or pin.
The use of a wetting solution aids the installation of a
tape stripe/decal on a painted panel. Prepare the wet-
ting solution by mixing two or three teaspoons of dish
detergent with 1 gallon of water.Do not use soap.
Too much detergent will reduce the effective-
ness of the mixture.
REMOVAL
(1) Clean the repaired surface, adjacent panels and
door the openings as necessary.
(2) Start at one end of the tape stripe/decal and
apply heat with a heat gun. Slowly peel the stripe/
decal from the panel by pulling it back.Do not pull
the tape stripe/decal outward from panel.
WARNING: USE TAPE STRIPE/DECAL REMOVAL
SOLUTION IN A WELL-VENTILATED AREA ONLY.
(3) A tape stripe/decal removal solution can be used
for removal at areas where a heat gun is ineffective:
²Mask-off the body panel area surrounding the tape
stripe/decal (Fig. 1).
²Move solution spray across the complete length of
stripe/decal with a steady motion.
²Ensure that the complete stripe/decal is covered
with solution.
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 (Fig. 2).
Fig. 1 Stripe/Decal Removal Solution Application
Fig. 2 Body Stripe/Decal Removal
JEXTERIOR COMPONENTSÐXJ 23 - 21

²If there is difficulty with peeling the stripe/decal
away from the body panel, use a squeegee (Fig. 3).
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. 4).
(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.
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. 5).
If applicable, the body panel character line
can be used as the tape stripe/decal alignment
reference.
(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. 6).
(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 (Fig. 7).
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.
Fig. 3 Body Stripe/Decal Removal With A Squeegee
Fig. 4 Adhesive Removal With A Squeegee
Fig. 5 Stripe/Decal Alignment Reference Mark
23 - 22 EXTERIOR COMPONENTSÐXJJ