JEEP XJ 1995 Service And Repair Manual

(2) Ensure that all the retainer clips, screws and
Velcro strips are disengaged before removing the
headliner.
HEADLINER INSTALLATION
(1) When installing a headliner, ensure that the re-
tainer clips and rails are installed (Fig. 4 and 5).
(2) Install the upper trim moldings around the pe-
rimeter of the headliner. Tighten the retaining
screws to 1 Nzm (11 in-lbs) torque.
(3) As applicable, install:
²Assist handles.
²Sunvisors.
²Dome/cargo lamps.
²Overhead console.
²Keyless entry receiver module.
²Sound bar.
²All other attached/overlapping components.
DOME LAMPÐXJ
REMOVAL
(1) Remove the dome lamp lens by squeezing both
sides to release the retaining clips. Pull downward to
remove the lens.
(2) Remove the speed nuts (Fig. 6).
(3) Disconnect the wire harness connector.
(4) Remove the lamp from the headliner.
INSTALLATION
(1) Connect the dome lamp wire harness connector.
(2) Position the dome lamp in the headliner hole
and install the speed nuts.
(3) Install the dome lamp lens.
OVERHEAD CONSOLEÐXJ
Refer to Group 8C, Overhead Console for removal
and installation procedure.
KEYLESS ENTRY RECEIVERÐXJ
Refer to Group 8P, Keyless Entry for removal and
installation procedure.
SUNVISORSÐXJ
REMOVAL
(1) Remove the screws that attach the sunvisor
arm support bracket to the headliner and the roof
panel (Fig. 7).
(2) Detach the sunvisor from the support clip.
(3) Remove the sunvisor from the vehicle.
(4) Remove the retaining screw and support clip.
Fig. 4 Headliner Retainer Clip and Retainer Rail
Fig. 5 Headliner Correctly Installed
Fig. 6 Dome Lamp
JINTERIOR COMPONENTSÐXJ 23 - 93

INSTALLATION
(1) Install the support bracket and the retaining
screw. Tighten the screw to 1 Nzm (9 in-lbs) torque.
(2) Position the sunvisor in the support clip and
align the arm support bracket holes with the head-
liner holes.
(3) Install the screws that attach the sunvisor arm
support bracket to the headliner and the roof panel.
Tighten the screws to 4 Nzm (35 in-lbs) torque.
SOUND BARÐXJ
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove left and right upper trim molding.
(3) Remove sound bar screws.
(4) Separate sound bar from roof.
(5) Disconnect speaker connector.
(6) Disconnect cargo lamp connector.
(7) Remove sound bar from vehicle (Fig. 8).
INSTALLATION
(1) Position sound bar in vehicle.
(2) Connect speaker connecter.
(3) Connect cargo lamp connector.
(4) Position sound bar at roof.
(5) Install sound bar screws.
(6) Install left and right upper trim molding.
(7) Connect battery negative cable.
CARGO LAMPÐXJ
REMOVAL
(1) Remove the cargo lamp lens (Fig. 8) by squeez-
ing both sides to release the retaining clips. Pull
downward to remove the lens.
(2) Remove the push nuts.
(3) Disconnect the wire harness connector.
(4) Remove the lamp from the sound bar.
INSTALLATION
(1) Connect the cargo lamp wire harness connector.
(2) Position the cargo lamp in the sound bar hole
and install the push nuts.
(3) Install the cargo lamp lens.
MINI-FLOOR CONSOLEÐXJ
Mini-consoles are installed in XJ vehicles with and
without a transmission floor shift (Fig. 1).
PARKING BRAKE HANDLE COVERÐXJ
REMOVAL
(1) Detach the rear of the cover from the base and
pivot it upward (Fig.2).
(2) Remove the retaining screws from the cover
base.
(3) Remove the trim cover from the from the floor.
INSTALLATION
(1) Position the cover on the floor and install the
retaining screws.
(2) Pivot the cover to the closed position and en-
gage the locking tab.
MINI-CONSOLE WITH FLOOR SHIFTÐXJ
REMOVAL
(1) Remove the transmission shift lever handle/
knob. For vehicles with an automatic transmission,
pull the handle straight up. For vehicles with a man-
ual transmission, loosen the locknut and un-thread
the shift knob from the shaft.
(2) Remove the automatic transmission and trans-
fer case shift indicator bezel by prying upward to re-
lease them (Fig. 3).
(4) Disconnect the lamp socket from the bezel.
(5) Remove the console retaining screws.
(6) Disconnect the wire harness connector.
Fig. 7 Sunvisor Removal/Installation
Fig. 8 Sound Bar Removal/Installation
23 - 94 INTERIOR COMPONENTSÐXJJ

(7) Remove the mini-console from the transmission
tunnel.
INSTALLATION
(1) Position the mini-console on the transmission
tunnel, connect the wire harness connector and in-
stall the retaining screws. Tighten the screws to 1
Nzm (13 in-lbs) torque.
(2) Position the shift indicator bezel at the console
and connect the lamp socket to the bezel. Install the
bezel in the console.
(3) Install the shift lever handle/knob. For auto-
matic transmissions, push the handle downward un-til it is engaged. For manual transmissions, thread
the knob onto the shaft and tighten the locknut.
FULL FLOOR CONSOLEÐXJ
REMOVAL
(1) Remove the transmission shift lever handle/
knob. For automatic transmissions, pull the handle
straight upward to remove it. For manual transmis-
sions, loosen the locknut and un-thread the shift
knob from the shaft.
Fig. 1 Mini-Console With Floor Shift
Fig. 2 Park Brake Cover With Mini-ConsoleFig. 3 Mini-Console With Floor Shift
JINTERIOR COMPONENTSÐXJ 23 - 95

(2) Remove the automatic transmission shift indi-
cator bezel (Fig. 4). Remove the transfer case shift in-
dicator bezel (if equipped) or cover plate from the
console (Fig. 5).(3) If equipped, insert a thin-blade tool under the
edge of the outside mirror remote control switch and
pry outward to detach it from the console. Disconnect
the wire harness connector from the switch (Fig. 6).
Fig. 4 Full Console
Fig. 5 Transfer Case Shift Indicator Bezel/Cover
PlateFig. 6 Outside Mirror Remote Control Switch
23 - 96 INTERIOR COMPONENTSÐXJJ

(4) Remove the cover retaining screws and remove
the cover from the console (Fig. 7).
(5) Remove the remainder of the console attaching
screws from the brackets and disconnect the wire
harness connector.
(6) Separate the console floor air duct from the air
outlet duct (Fig. 8).
(7) Remove the console and air duct from the floor.
(8) Separate the floor air duct from the console.
(9) Remove the retaining screws and detach the
floor duct from the heater housing, if necessary.
(10) Remove the console support brackets.
The brackets are attached directly to the
floor panel below the carpet.
INSTALLATION
(1) Install the console support brackets, if re-
moved. Tighten the screws to 1 Nzm (11 In-lbs)
torque.
The brackets are attached directly to the
floor panel below the carpet.(2) Attach the floor duct to the heater housing, if
removed. Tighten the screws to 1 Nzm (11 In-lbs)
torque.
(2) Attach the air duct to the console.
(3) Position the console on the floor, attach the air
duct to the air outlet duct, connect the wire harness
connector and install the console retaining screws in
the brackets. Tighten the screws to 1 Nzm (11 In-lbs)
torque.
(4) Install the console cover and shift indicator be-
zels (or cover plate). Tighten the screws to 1 Nzm(11
In-lbs) torque.
(5) If equipped:
²Connect the wire harness connector to the outside
mirror remote control switch.
²Insert the switch into the console hole.
²Push inward to engage the retaining clips.
(6) Install the shift lever handle/knob.
JACK STORAGEÐXJ
The XJ lift jack and related tools are stored under
the rear seat behind the front passenger's seat. The
jack and tools are attached to the floor panel and
seat cushion crossmember with a retainer and hold-
down bolt (Fig. 1).
When necessary, the jack retainer bracket can be
removed from the crossmember by drilling-out the
rivet heads and then removing the rivet bodies with
a punch. Install the retainer bracket with either riv-
ets or bolts and nuts (Fig. 2).
Fig. 7 Full Console Removal/Installation
Fig. 8 Air Outlet and Console Floor Air Ducts
Fig. 1 Jack and Related Tools
JINTERIOR COMPONENTSÐXJ 23 - 97

SPARE TIRE/WHEEL HOLDDOWN AND FLOOR
BRACKETSÐXJ
REMOVAL
(1) Remove the spare tire and wheel (Fig. 3).
(2) Remove the floor bracket retaining screws.
(3) Remove the holddown bolt from the holddown
bracket (Fig. 4 and 5).
(4) Remove the trim panel from the quarter panel.
If necessary, refer to the removal procedure.
(5) Remove the retaining screws and the holddown
bracket from the quarter panel.
INSTALLATION
(1) Position the holddown bracket on the quarter
panel and install the retaining screws. Tighten the
screws to 8 Nzm (71 in-lbs) torque.
(2) Install the quarter trim panel. If necessary, re-
fer to the installation procedure.
(3) Install the holddown bolt in the holddown
bracket.
The length of the holddown bolt is different
for P195 and P225 tires.
(4) Position the floor bracket on the trim panel and
install the retaining screws. Tighten the screws to 1
Nzm (11 in-lbs) torque.
(5) Install the spare tire and wheel.
Fig. 3 Interior Spare Tire/Wheel Holddown and Floor Brackets
Fig. 2 Jack Retainer BracketFig. 4 Spare Tire/Wheel Holddown Bolt and Bracket
(LHD)
23 - 98 INTERIOR COMPONENTSÐXJJ

CARPETS AND FLOOR MATSÐXJ
The carpets/mats are retained around the perime-
ter of the floor panel by the interior trim moldings
and trim panels. To remove a carpet/mat, all of the
retaining trim moldings and panels must be removed
along with all the interfering components (as appli-
cable):
²Seat(s).
²Parking brake lever cover.
²Floor console.
²Transmission and transfer case (if equipped) floor
shift cover/boot.
If necessary, refer to the applicable removal proce-
dure(s) within this manual.
FRONT CARPET/MATÐXJ
REMOVAL
(1) Remove the door sill inner scuff plates.
(2) Remove the front and rear seats (as applicable).
(3) As necessary, remove the trim panels and mold-
ings.
(4) Remove all other interfering components.
(5) Remove the carpet and mat from the floor
panel (Fig. 6).
INSTALLATION
(1) Position the carpet and mat on the floor panel.(2) Install all the components that were removed
to facilitate carpet/mat removal.
(3) Install the trim panels and moldings.
(4) Install the door sill inner scuff plates.
(5) Install the front and rear seats (as applicable).
Fig. 5 Spare Tire/Wheel Holddown Bolt and Bracket (RHD)
Fig. 6 Front Carpet and Mat
JINTERIOR COMPONENTSÐXJ 23 - 99

REAR CARPET/MATÐXJ
REMOVAL
(1) Remove the retaining screws, and the liftgate
latch striker and scuff plate (Fig. 7).
(2) Drill-out the retaining rivet heads and remove
the cargo tie-down footman loops from the carpet.
(3) As necessary, remove the trim panels and mold-
ings.
(4) Remove the all other interfering components.
(5) Remove the carpet and mat from the floor
panel.
(6) If necessary, remove the skid strips from the
carpet (Fig. 8).
(7) If necessary, remove the insulation from the
wheelhouse (Fig. 9).
INSTALLATION
(1) If removed, install the skid strips on the carpet.
(2) If removed, install the insulation on the wheel-
houses.
(3) Position the mat on the floor panel.
(4) Position the carpet on the mat.
(5) Install all the components that were removed
to facilitate carpet and mat removal.
(6) Install the trim panels and moldings.
(7) Install the cargo tie-down footman loops on the
carpet with replacement rivets.
(8) Position the liftgate scuff plate and latch
striker on the carpet and cross sill. Install and
tighten the scuff plate screws to 1 Nzm (11 in-lbs)
torque. Tighten the latch striker screws to 30 Nzm
(22 ft-lbs) torque.
Fig. 7 Liftgate Latch Striker and Scuff Plate
Fig. 8 Rear Carpet Skid Strips
Fig. 9 Wheelhouse Insulation
23 - 100 INTERIOR COMPONENTSÐXJJ

CARGO BARRIERÐXJ
REMOVAL
(1) Tilt both seats forward and raise the storage
compartment lid.
(2) Remove the wing nuts from the front side of
the cargo barrier (Fig. 10).
(3) Remove the fasteners from the lower outer cor-
ners of the cargo barrier.
(4) Remove the cargo barrier.
INSTALLATION
(1) Reverse the removal procedure to install the
cargo barrier.
Fig. 10 Cargo Barrier
JINTERIOR COMPONENTSÐXJ 23 - 101

BODY COMPONENTSÐYJ VEHICLES
CONTENTS
page page
DOORS............................... 134
EXTERIOR COMPONENTS................ 104
GENERAL SERVICE INFORMATION......... 102INTERIOR COMPONENTS................ 151
PAINT................................ 158
STATIONARY GLASS.................... 144
GENERAL SERVICE INFORMATION
LABELS/DECALS/PLATESÐYJ
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.
Fig. 1 YJ Underhood Labels/Decals
Fig. 2 YJ Interior and License Plate Holder
Labels/Decals
23 - 102 GENERAL INFORMATIONÐYJ VEHICLESJ