1994 JEEP CHEROKEE Service Repair Manual

KEY LOCK CYLINDERS
The ignition switch, glove box door, front doors and
liftgate all have key lock cylinders (Fig. 6). When
lock cylinder access or replacement is necessary, re-
fer to the applicable service information source:
²Ignition SwitchÐGroup 8D,
²Instrument Panel,
²Front Doors, and
²Liftgate.
Fig. 4 XJ VIN PlateFig. 5 XJ Jack Usage & Storage Instruction Labels
Fig. 6 Ignition Switch & Glove Box Door Key Lock
Cylinders
23 - 2 BODY COMPONENTSÐXJ VEHICLESJ

EXTERIOR COMPONENTS
BRUSH GUARD
REMOVAL
(1) Remove the bolts and washers that attach the
brush guard (Fig. 1) to the side sills.
(32 Remove the nuts and washers that the attach
brush guard to the bumper. Remove the brush guard
from the bumper.
INSTALLATION
(1) Position and support the brush guard on the
bumper. Install the attaching washers and nuts.
Do not tighten the nuts until the brush guard is
properly positioned on the vehicle and aligned.
(2) Install the bolts and washers to attach the
brush guard to side sills.
(3) Align the brush guard and tighten the bolts.
GRILLE AND GRILLE OPENING PANEL (GOP)
REMOVAL
(1) Remove the screws and grille (Fig. 2) from the
grille opening panel (GOP).
(2) Remove the screws, side marker lenses and the
headlamp bezels from the grille opening panel (GOP)
(Fig. 3).
(3) Remove the headlamps and park/turn signal
lamps from the GOP (Fig. 4).
(4) Open the hood.
(5) Remove the nuts that attach the grille opening
panel (GOP) to the bracket on radiator support cross-
member.
(6) Remove the nuts that attach the grille opening
panel (GOP) to the front fenders (Fig.5).
Fig. 2 Grille & GOP
Fig. 1 Brush Guard Removal/Installation
JBODY COMPONENTSÐXJ VEHICLES 23 - 3

(7) Remove the screws that attach the grille open-
ing panel (GOP) support bracket to the front sill
crossmember (Fig. 6).
(8) Pull the grille opening panel (GOP) forward
and disconnect the clips and all the front lamp har-
ness connectors (Fig. 7).(9) Remove the grille opening panel (GOP) from
the vehicle.
(10) If necessary, remove the air inlet baffles from
GOP (Fig. 8).
Fig. 3 Side Marker Lamp Removal/Installation
Fig. 4 Headlamp & Park/Turn Signal Lamp Removal/
Installation
Fig. 5 GOP Attaching Nuts At Front Fender
Fig. 6 Crossmember-to-GOP Support Bracket
Fig. 7 Front Lamp Wire Harness Connectors
Fig. 8 GOP Air Inlet Baffles
23 - 4 BODY COMPONENTSÐXJ VEHICLESJ

INSTALLATION
(1) Place the grille opening panel (GOP) on bumper
and connect all front lamp wire harness connectors.
(2) Position the grille opening panel (GOP) on the
vehicle and install the side and upper nuts. Tighten
nuts to 7 Nzm (58 in-lbs) torque.
(3) Install the screw to attach grille opening panel
(GOP) to the crossmember support bracket. Tighten
the screw to 1 Nzm (11 in-lbs) torque.
(4) Install headlamps and park/turn signal lamps
in GOP.(5) Install the headlamp bezels on the GOP.
Tighten the screws to 1 Nzm (13 in-lbs) torque.
(6) Install the side marker lenses and screws on
the grille opening panel (GOP). Tighten the screws to
1Nzm (13 in-lbs) torque.
(7) Install the grille on the GOP. Tighten screws to
1Nzm (13 in-lbs) torque.
(8) Adjust the headlamp aim, if necessary. Refer to
the headlamp beam adjustment procedure within
Group 8L.
RADIATOR SUPPORT CROSSMEMBER
REMOVAL
(1) Remove the grille opening panel (GOP) (Fig. 2).
(2) For 2.5L engines, remove the power steering
pump reservoir from the left filler panel (Fig. 9).
(3) Remove the radiator support crossmember and
radiator from the front of vehicle (Fig. 10).
(4) If additional disassembly is required, remove
the horns, baffle braces and the wire harnesses from
the baffles (Fig. 11).
INSTALLATION
(1) If removed, install the horns, baffle braces and
the wire harnesses on the baffles (Fig. 11).
(2) Position the radiator and the radiator support
Fig. 9 P/S Pump Reservoir Removal/Installation
Fig. 10 Radiator Support Crossmember & Modular Radiator
JBODY COMPONENTSÐXJ VEHICLES 23 - 5

crossmember at the front of vehicle (Fig. 10). Install
and tighten screws to 9 Nzm (76 in-lbs) torque.
(3) For 2.5L engines, install the power steering
pump reservoir on the left filler panel (Fig. 9).
(4) Install the grille opening panel (GOP).
HOOD
The hood service procedures included in this sec-
tion include:
²hood removal and installation;
²hood adjustment;
²hingeÐlatchÐstriker service; and
²latch release cable service.
Refer to Figures 12Ð16 for the hood component
reference.
Fig. 11 Horns, Baffle Braces & Wire Harnesses
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Fig. 12 Hood Latches, Rod, Release Cable, Striker & Safety Latch
JBODY COMPONENTSÐXJ VEHICLES 23 - 7

HOOD REMOVAL
(1) Raise hood.
(2) Disconnect the underhood lamp wire harness
connector, if equipped (Fig. 13).
(3) Drill out and remove the rivets that attach the
hood release cable bellcrank to the hood (Fig. 14).
(4) Disconnect the bellcrank from the latch con-
necting rod and the release cable. Remove the bell-
crank from the hood.
(5) Remove the latch release cable clips and re-
move the cable from the hood (Fig. 12).
(6) Remove the screws that attach the latches to
the hood (Fig. 15).
(7) Disconnect the latches from the hood and latch
connecting rod. Remove the latches from the hood.
(8) Remove the nuts that attach the safety latch to
the hood. Remove the safety latch from the hood.
(9) Remove the clips and latch connecting rod from
the hood.
(10) Mark the location of hood, the hinges and the
hinge shims for installation (Fig. 16).(11) Remove the screws that attach the hinges to
the hood. Remove the hood from the vehicle with the
aid of a helper.
(12) Remove the insulation panel from the hood
(Fig. 17).
HOOD INSTALLATION
(1) Install the insulation panel on the hood.
(2) Position the hood on the shims and hinges; fin-
ger-tighten the hinge bolts.
(3) Align the hinges and shims with the reference
marks. Tighten the hinge bolts to 30 Nzm (22 ft-lbs)
torque.
(4) Connect the latch release cable and latch con-
necting rod to the bellcrank.
(5) Position the bellcrank on the hood and install
the rivets.
Fig. 13 Underhood Lamp
Fig. 14 Hood Release Cable Bellcrank
Fig. 15 Hood Latch & Safety Latch
Fig. 16 Hood Hinges and Support Rod
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(6) Attach the latch release cable to the clips.
(7) Connect the latches to the latch rod and posi-
tion them on the hood.
(8) Install the screws to attach the latches to the
hood.
Tighten the screws to 9 Nzm (77 in-lbs) torque.
(9) Position the safety latch on the hood and install
the attaching nuts. Tighten the screws to 13 Nzm
(115 in-lbs) torque.
(10) Test latch release cable and latches for proper
operation.
(11) Connect the underhood lamp wire harness
connector.
(12) Inspect the hood for proper alignment and ad-
just as necessary.
HOOD ADJUSTMENT
The hood bolt holes are elongated for fore and aft
and side-to-side adjustment.
(1) If hood is low to the cowl panel, insert shims
between the hinge and hood at the rear hinge bolts.
(2) Adjust the hood bumper (Fig. 18) in or out to
provide proper hood-to-fender height alignment.(3) Adjust the hood strikers (Fig. 19) with shims as
necessary. Tighten the screws to 22 Nzm (16 ft-lbs)
torque after adjustment.
(4) Align each latch and striker so that the striker
enters latch squarely.
HOOD HINGE REPLACEMENT
REMOVAL
(1) Remove the hood from the vehicle.
(2) Remove the seal from the hinge base (Fig. 20).
(3) Remove the hinge retaining nuts from the
studs.
(4) Remove the restraint cable and hinge from the
cowl panel.
INSTALLATION
(1) Position the hinge over the studs and place the
restraint cable on the right side, lower stud.
Fig. 17 Hood Insulation Panel
Fig. 18 Hood Bumper
Fig. 19 Hood Latch Striker
Fig. 20 Hood Hinge and Seal
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