JEEP XJ 1995 Service And Repair Manual

Fig. 3 YJ Jack Storage and Usage Labels
Fig. 4 YJ Sunvisor Labels
Fig. 5 YJ VIN Plate
JGENERAL INFORMATIONÐYJ VEHICLES 23 - 103

EXTERIOR COMPONENTS
INDEX
page page
Battery TrayÐYJ......................... 110
Body Side Step MoldingÐYJ................ 115
Body Stripes/DecalsÐYJ................... 116
Cowl Grille and ScreenÐYJ................ 109
Cowl Weatherstrip SealÐYJ................ 109
Exterior Nameplates (Adhesive-Backed)ÐYJ.... 120
External Spare/Wheel Tire CarrierÐYJ........ 133
Fender FlareÐYJ........................ 114
Fender Inner Splash ShieldsÐYJ............. 116
Fender Splash ApronsÐYJ................. 115
FendersÐYJ............................ 110
Fuel Filler Protector/NozzleÐYJ............. 121
Half Metal Door Mirror (External)ÐYJ......... 121
Hard Top Liftgate GlassÐYJ................ 124
Hard Top RepairÐYJ..................... 127
Hard Top Roof VentÐYJ................... 127
Hard TopÐYJ........................... 126Hood AlignmentÐYJ...................... 107
Hood Insulator PanelÐYJ.................. 107
Hood Safety LatchÐYJ.................... 109
HoodÐYJ.............................. 107
Liftgate Glass Weatherstrip Seal ReplacementÐYJ. 125
Radiator Grille AppliqueÐYJ................ 104
Soft Top Service InformationÐYJ............. 127
Soft Top ServiceÐYJ..................... 129
Sport BarÐYJ........................... 132
Tailgate AdjustmentÐYJ................... 121
Tailgate HingeÐYJ....................... 121
Tailgate Latch and Release HandleÐYJ........ 122
Tailgate Latch StrikerÐYJ.................. 123
Tailgate Lock CylinderÐYJ................. 122
Tailgate Weatherstrip SealÐYJ.............. 123
TailgateÐYJ............................ 121
Wheelhouse Splash LinersÐYJ.............. 115
RADIATOR GRILLE APPLIQUEÐYJ
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).
Fig. 1 Grille Applique, Headlamp Bezel and Grille Panel
23 - 104 EXTERIOR COMPONENTSÐYJJ

(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.
(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.
RADIATOR GRILLE PANEL
REMOVAL
(1) Remove the front crossmember cover.
(2) Remove the screws and washers, and separate
the radiator and shroud from the grille panel (Fig. 3).(3) If equipped, remove the retaining bolts and
separate the A/C condenser from the grille panel
(Fig. 4).
(4) Remove the retaining screws and the P/S fluid
reservoir from the grille panel (Fig. 5).
Fig. 2 Front LampsFig. 3 Radiator and Shroud
Fig. 4 Radiator and Shroud
Fig. 5 P/S Fluid Reservoir
JEXTERIOR COMPONENTSÐYJ 23 - 105

(5) Remove the retaining screws and the air intake
adapters from the grille panel (Fig. 6).
(6) Remove the bolts and washers that attach the
grille panel to the fenders (Fig. 7).
(7) Remove the bolts, washers and spacers that at-
tach the grille panel to the front crossmember (Fig.
8).
(8) Remove the nuts that attach the radiator sup-
port rods to the front brackets (Fig. 9). Remove the
rods from the brackets.
(9) Tilt the grille panel forward and disconnect the
head lamp, turn signal and marker lamp wire har-
ness connectors.
(10) For vehicles equipped with A/C, discharge the
A/C system. Disconnect the high pressure hose at the
sight glass connection and at the compressor. Cap thehose and fittings to prevent foreign material entry. If
necessary, refer to Group 24ÐHeating And Air Con-
ditioning.
(11) Remove the grille panel from the vehicle (Fig.
8).
(12) If a replacement radiator grille panel will be
installed, remove the grille applique (Fig. 8) and
transfer the lamps, the headlamp buckets and the re-
taining brackets.
Fig. 7 Grille Panel Front Bolt
Fig. 8 Radiator Grille Applique and Grille Panel
Fig. 6 Air Intake and Radiator Baffle Adapters
23 - 106 EXTERIOR COMPONENTSÐYJJ

INSTALLATION
(1) Position the grille panel on the vehicle.
(2) Connect the marker, park and headlamp wire
harness connectors.
(3) Connect the radiator support rods with the re-
taining brackets (Fig. 9).
(4) Attach the grille panel to the front crossmem-
ber.
(5) Install the grille panel-to-front fender bolts
(Fig. 7). Tighten the retaining screws to 27 Nzm (20
ft-lbs) torque.
(6) Install the air intake adapters on the grille
panel (Fig. 6). Tighten the retaining screws to 3 Nzm
(25 in-lbs) torque.
(7) Install the P/S fluid reservoir on the grille
panel (Fig. 5). Tighten the retaining screws to 8 Nzm
(72 in-lbs) torque.
(8) If equipped, install the A/C condenser on the
grille panel (Fig. 4). Tighten the retaining screws to 2
Nzm (20 in-lbs) torque. Connect the high pressure
hose at the sight glass connection and at the com-
pressor.
(9) Install the radiator and shroud on the grille
panel (Fig. 3). Tighten the retaining screws to 15
Nzm (132 in-lbs) torque.
(10) Install the front crossmember cover.
(11) If removed, install the grille applique (Fig. 8).
(12) Evacuate and charge the A/C system.
HOODÐYJ
REMOVAL
(1) Raise and support the hood.
(2) Disconnect the underhood lamp wire harness
connector (Fig. 10).(3) Mark the position of the hinges on the hood for
installation alignment reference (Fig. 11).
(4) Remove the hinge attaching screws and remove
the hood (Fig. 11).
(5) If the hood must be replaced, remove and
transfer the insulator panel, hinges, latches,
bumpers, brackets, footman loop, hood lamp, support
rod, and safety latch to the replacement hood (Fig.
12).
INSTALLATION
(1) Position the hood on the vehicle and install the
hinge attaching screws.
(2) Align the hinges with the installation reference
marks on the hood and tighten the hinge screws se-
curely.
(3) Connect the underhood lamp wire harness con-
nector (Fig. 10).
(4) Close the hood.
HOOD ALIGNMENTÐYJ
The hood hinge attaching screw holes are oversized
to facilitate hood adjustment movement.
(1) Loosen the hinge attaching screws.
(2) Move the hood in the direction(s) required for
correct alignment.
(3) Tighten the hinge attaching screws.
HOOD INSULATOR PANELÐYJ
REMOVAL
(1) Raise and support the hood.
(2) Remove the insulator panel retainers (Fig. 13).
(3) Remove the insulator panel from the hood.
INSTALLATION
(1) Position the insulator panel on the hood.
(2) Install the insulator panel retainers.
(3) Remove the support rod and close the hood.
Fig. 9 Radiator Support Rods
Fig. 10 Underhood Lamp
JEXTERIOR COMPONENTSÐYJ 23 - 107

Fig. 11 Hood and Components
Fig. 12 Safety Latch and Support Rod
Fig. 13 Hood Insulator Panel
23 - 108 EXTERIOR COMPONENTSÐYJJ

HOOD SAFETY LATCHÐYJ
REMOVAL
(1) Raise and support the hood.
(2) Remove the latch retaining screws from the
grille panel (Fig. 14).
(3) Remove the latch from the grille panel.
INSTALLATION
(1) Position the latch on the grille panel (Fig. 14).
(2) Install the latch retaining screws.
(3) Remove the support rod and close the hood.
COWL WEATHERSTRIP SEALÐYJ
REMOVAL/INSTALLATION
(1) Carefully separate the seal from the cowl/dash
panel flange (Fig. 15).
(2) Position the seal on the cowl/dash panel flange
(Fig. 15) and press it against the panel edge.
COWL GRILLE AND SCREENÐYJ
REMOVAL
(1) Remove the screws that attach the cowl air in-
take grille to the cowl and to the air intake duct (Fig.
16).(2) Remove the grille and screen from the cowl
(Fig. 16).INSTALLATION
(1) Position the cowl screen and grille on the cowl.
(2) Attach the grille and screen to the cowl and the
air intake duct with the screws (Fig. 16).
Fig. 14 Hood Safety Latch Removal/Installation
Fig. 15 Cowl Weatherstrip Seal
Fig. 16 Cowl Grille Removal/Installation
JEXTERIOR COMPONENTSÐYJ 23 - 109

BATTERY TRAYÐYJ
REMOVAL
(1) Remove the cables from the battery and power
distribution center (Fig. 1).
(2) Remove the retaining nuts and the battery
holddown bracket from the holddown J-bolts (Fig. 2).
(3) Remove the battery from the tray.
(4) Remove the retaining screws, the support
bracket and the PDC from the battery tray (Fig. 3).
(5) Remove the nuts that attach the battery tray to
the cowl panel (Fig. 2).
(6) Remove the screws that attach the support
brackets to the fender inner panel.
(7) Remove the screw that attaches the brace to
the battery tray (Fig. 2).
(8) Remove the battery tray from the vehicle (Fig.
2).
INSTALLATION
(1) If removed, install the J-bolts on the battery
tray.
(2) Position the battery tray on the cowl panel with
the studs inserted in the holes.
(3) Attach the battery tray to the cowl panel studs
with the attaching nuts.Tighten the nuts on the
studs to 4 Nzm (35 in-lbs) torque.
(4) Install the screw that attaches the brace to the
battery tray. Tighten the screw to 18 Nzm (156 in-lbs)
torque.
(5) Install the screws that attach the support
brackets to the fender inner panel. Tighten the
screws to 18 Nzm (156 in-lbs) torque.(6) Install the support bracket and PDC on the
battery tray. Tighten the screws to 18 Nzm (156 in-
lbs) torque.
(7) Install the battery in the tray.
(8) Position the holddown bracket over the J-bolts.
(9) Install the retaining nuts on the J-bolts.
Tighten the nuts to 4 Nzm (35 in-lbs) torque.
(10) Remove the cables from the battery and power
distribution center.
FENDERSÐYJ
SERVICE INFORMATION
YJ fenders are comprised of the fender outer panel,
the fender inner panel, the front and rear support
brackets, and the splash shields (Fig. 4).
Fig. 1 Battery and PDC Cables
Fig. 2 Battery Tray Removal/Installation
Fig. 3 PDC and Bracket Removal/Installation
23 - 110 EXTERIOR COMPONENTSÐYJJ

REMOVAL
(1) As applicable, remove or disconnect all compo-
nents attached to the fender inner panel.
(2) Left fender:
²Remove the air cleaner housing and support
bracket from the fender inner panel (Fig. 5 and 6).
Fig. 4 Fender Components
Fig. 5 Air Cleaner Housing and Radiator Baffle
Adapter Fender
Fig. 6 Air Cleaner Housing and Support Bracket
JEXTERIOR COMPONENTSÐYJ 23 - 111

²Remove the horn from the fender inner panel (Fig.
7).
²Remove the windshield washer fluid reservoir and
coolant reserve bottle from the fender inner panel
(Fig. 8 and 9).(4) Right fender:
²Remove the jack and related tools from the jack
storage tray (Fig. 10).
²Remove the jack storage tray and A/C receiver/
drier from the fender inner panel (Fig. 11).
Fig. 7 Horn Removal/Installation
Fig. 8 Windshield Washer Fluid Reservoir
Fig. 9 Coolant Reserve Bottle
Fig. 10 Jack and Related Tools
Fig. 11 Jack Storage Tray and A/C Receiver/Drier
23 - 112 EXTERIOR COMPONENTSÐYJJ