1994 JEEP CHEROKEE Service Repair Manual

(4) Remove the glass and weatherstrip seal from
the liftgate (Fig. 30).
(5) Remove the weatherstrip seal from the window glass.
(6) Clean the weatherstrip channels and window
opening flanges.
INSTALLATION
(1) Apply a 4-mm (1/6-in) diameter bead of sealant
to liftgate glass channel in the weatherstrip seal
(Fig. 30).
(2) Install weatherstrip seal on the glass (Fig. 31).
Install the seal installation cord in the window open-
ing channel as follows:
²moisten a length of 6-mm (1/4-in) diameter cord
with a soap and water solution;
²insert the cord into the window opening flange
channel in the weatherstrip seal.
Fig. 29 Quarter Window Glass With Vent Installed
Fig. 30 Liftgate Window Glass Reveal Moulding, Glass and Seal
Fig. 28 Quarter Window Glass and Seal Installed
23 - 82 BODY COMPONENTSÐXJ VEHICLESJ

(3) Apply a 6-mm (1/4-in) diameter bead of sealant
around the perimeter of the window opening flange
in the liftgate (Fig. 30).
(4) Install the window glass and the weatherstrip
seal in the window opening with the cord according
to the following instructions:
²position the window glass and the weatherstrip
seal in the window opening with the free ends of the
cord inside the vehicle (Fig. 32); and
²
pull on each end of the cord to pull the weatherstrip seal
channel lip over the window opening flange (Fig. 33).
(5) Test the liftgate window for water leaks.
(6) Install the interior trim covers.
(7) If equipped, install the liftgate window reveal
moulding (Fig. 30).
FIXED GLASS WATER LEAK DETECTION AND REPAIR
SERVICE INFORMATION
Water leaks around the windshield or a fixed window
glass can be sealed without removing the glass. If thewindshield/window glass is bonded and only has a small
leak, seal it with a liquid butyl sealant. If the weather-
strip seal or urethane adhesive has a large break, a ure-
thane adhesive must be used to seal the leak.
LEAK TEST
Water test the windshield/window with a spray only.
Do not use hard streams of water.Work from the
bottom to the top of windshield/window glass.
If a water leak exists between the glass and weath-
erstrip seal (or between the seal and a body flange):
²push the glass outward at the leak area, and
²determine the extent of the gap.
Push the glass outward while a helper sprays the
windshield/window with water.
SEALING MINOR LEAK AREAS
(1) Thoroughly clean and remove all foreign material
from the leak area. Dry area with compressed air.
(2) Seal the leak area with butyl sealant. Allow the
sealant to cure for at least 1/2 hour. Next, water test
the glass to ensure that the leak is sealed.
SEALING MAJOR LEAK AREAS
(1) Thoroughly clean the leak area.
(2) As applicable, apply primer to either the wind-
shield/window or weatherstrip seal leak area. Use
blackout primer on the windshield/window and ure-
thane primer on the weatherstrip seal.
(3) Apply urethane adhesive to the leak area. Use
an adhesive cartridge with a pointed nozzle.
(4) Water test the windshield/window immediately
with cold water spray. Allow water to spill over the
edge of the windshield/window and weatherstrip seal.
Do not direct a hard stream of water on re-
cently applied urethane.
(5) Apply additional urethane adhesive, if necessary.
(6) Remove any excess urethane adhesive.
Fig. 31 Weatherstrip Seal and Cord Installation
Fig. 32 Liftgate Window Glass Installation With Cord
Fig. 33 Liftgate Window Glass and Weatherstrip Seal
JBODY COMPONENTSÐXJ VEHICLES 23 - 83

UNDERBODY COMPONENTS
INDEX
page page
Catalytic Converter/Muffler/Tailpipe Support
Brackets............................. 85
Front Skid Plate......................... 84
Fuel and Brake Fluid Tube Retainer Clip....... 86
Fuel Filler Hose Splash ShieldÐXJ Vehicles.... 86
Fuel Filter Bracket........................ 86Fuel Tank Skid Plate...................... 84
Fuel Tank Support Strap................... 86
Rear Tow HookÐXJ Vehicles............... 87
Service Information....................... 84
Trailer Hitches........................... 88
Transfer Case Skid Plate.................. 84
SERVICE INFORMATION
In some cases, components in the following proce-
dures either support, or are concealed by other com-
ponents. When necessary, refer to component
removal procedure for service access.
FRONT SKID PLATE
REMOVAL
(1) Remove the screws that attach skid plate to
side sills (Fig. 1).
(2) Remove the nuts that attach the skid plate to
the crossmember (Fig. 1).
(3) Remove the skid plate from the vehicle (Fig. 1).
INSTALLATION
(1) Position the skid plate at front crossmember
and side sills (Fig. 1).
(2) Install the nuts to attach the skid plate to
crossmember.(3) Install the screws to attach skid plate to side
sills.
TRANSFER CASE SKID PLATE
REMOVAL
(1) Support the skid plate.
(2) Remove the bolts that attach the skid plate to
the transmission support crossmember and frame sill
(Fig. 2).
(3) Remove the support and skid plate from the ve-
hicle.
INSTALLATION
(1) Position and support the skid plate at the
frame sill and transmission support crossmember
(Fig. 2).
(2) Attach the skid plate to the frame sill and
crossmember with bolts. Tighten bolts to 22 Nzm (16
ft-lbs) torque.
FUEL TANK SKID PLATE
REMOVALÐXJ VEHICLES
(1) Position a support under skid plate.
(2) Remove the bolts that attach skid plate to un-
derbody side rails (Figs. 3 and 4).
Fig. 1 Front Skid Plate Removal/Installation
Fig. 2 Transfer Case Skid Plate
23 - 84 BODY COMPONENTSÐXJ VEHICLESJ

(3) Remove the support and the skid plate from
the vehicle.
INSTALLATIONÐXJ VEHICLES
(1) Position and support skid plate under fuel
tank.
(2) Install bolts to attach the skid plate to under-
body rails. Tighten the bolts to 50 Nzm (37 ft-lbs)
torque.
(3) Remove the support from under skid plate.
CATALYTIC CONVERTER/MUFFLER/TAILPIPE
SUPPORT BRACKETS
REMOVAL
(1) As applicable, detach the catalytic converter,
muffler or tailpipe support bracket from insulator.
Remove the insulator from bracket.
(1) As applicable, install nuts and bolts, or screws
that attach bracket to frame. Tighten nuts/screws to
21 Nzm (16 ft-lbs) torque.(2) Install insulator on support bracket.
Fig. 1 Catalytic Converter Support Bracket
Fig. 2 Muffler/Tailpipe Support BracketÐXJ Vehicles
Fig. 3 Tailpipe Support BracketÐXJ Vehicles
Fig. 3 Fuel Tank Skid Plate W/O Trailer Hitch Or Tow
Hook
Fig. 4 Fuel Tank Skid Plate With Trailer Hitch Or
Tow Hook
JBODY COMPONENTSÐXJ VEHICLES 23 - 85

(3) Attach catalytic converter, muffler or tailpipe
insulator to support hanger to insulator.
FUEL AND BRAKE FLUID TUBE RETAINER CLIP
REMOVAL
(1) Remove the fuel/brake fluid tubes from clip
grooves.
(2) As applicable, pry serrated clip outward and re-
move it from frame rail hole, or remove stand-off
bracket screw.
INSTALLATION
(1) Position clip at the frame/panel hole.
(2) As applicable, force serrated clip inward and
seat it against the frame/panel, or install the stand-
off bracket screw.
(3) Insert fuel/brake fluid tubes in clip grooves and
press inward to seat them.
FUEL FILTER BRACKET
REMOVAL
(1) Remove screws that attach fuel filter bracket to
frame rail.
(2) Remove the screw from fuel filter bracket
clamp.
(3) Remove the clamp and fuel filter from bracket.
(4) Remove the bracket from filter.
INSTALLATION
(1) Position fuel filter bracket on filter.
(2) Position clamp on bracket and install screw.
Tighten screw to 8 Nzm (74 in-lbs) torque.(3) Position fuel filter bracket on frame rail.
(4) Install the screws that attach bracket to frame
rail. Tighten screws to 42 Nzm (31 ft-lbs) torque.
FUEL FILLER HOSE SPLASH SHIELDÐXJ
VEHICLES
REMOVAL
(1) Remove the screws that attach fuel filler hose
splash shield to wheelhouse panel and frame rail.
(2) Remove the hose splash shield from wheelhouse
panel and frame rail (Fig. 7).
INSTALLATION
(1) Position fuel filler hose splash shield at wheel-
house panel and frame rail.
(2) Install screws to attach splash shield to wheel-
house panel and frame rail.
FUEL TANK SUPPORT STRAP
SERVICE INFORMATION
XJ fuel tank support straps are attached to the un-
Fig. 4 Fuel and Brake Tube Serrated/Bracket-Type
Retainer ClipsÐXJ Vehicles
Fig. 5 Fuel Filter Bracket Removal/Installation
Fig. 6 Fuel Filter Bracket Clamp
Removal/Installation
23 - 86 BODY COMPONENTSÐXJ VEHICLESJ

derside of the vehicle via T-slots and hole-slots in the
frame members.
REMOVAL
(1) If equipped, position a support under skid plate.
(2) If equipped, remove the bolts that attach skid
plate to underbody side rails.
(3) If applicable, remove the support and skid plate
from fuel tank.
(4) Support fuel tank.
(5) Loosen nut from fuel tank support strap bolt to
allow bolt head to be removed from hole-slot in frame
member.
(6) Remove the strap T-end from frame member
T-slot.
(7) Separate support strap from fuel tank and re-
move it from vehicle.
INSTALLATION
(1) Position support strap around fuel tank.
(2) Insert strap T-end in frame member T-slot.(3) Insert bolt in hole-slot in frame member.
Tighten nut on the bolt until bolt-head and T-end are
seat and strap is tight against the bottom of fuel
tank.
(4) Remove the support from the fuel tank.
(5) If removed, position and support and the fuel
tank skid plate under the fuel tank.
(6) If applicable, install the bolts that attach the
skid plate to the underbody side rails. Tighten the
bolts to 50 Nzm (37 ft-lbs) torque.
(7) Remove the support from under the skid plate.
REAR TOW HOOKÐXJ VEHICLES
REMOVAL
(1) Remove the bolts that attach tow hook bracket
to the frame rail and reinforcement bracket.
Fig. 7 Fuel Filler Hose Splash ShieldÐXJ Vehicles
Fig. 8 Fuel Tank Support StrapÐXJ Vehicles
Fig. 9 Fuel Tank Support StrapsÐXJ Vehicles
Fig. 10 Rear Tow HookÐXJ Vehicles
JBODY COMPONENTSÐXJ VEHICLES 23 - 87

The reinforcement bracket is held on the
frame rail with two blind rivets.
(2) Remove the bracket and tow hook from frame
rail.
INSTALLATION
(1) Position bracket and tow hook on the frame
rail.
(2) Install bolts that attach tow hook bracket to
frame rail and reinforcement bracket. Tighten bolts
to 75 Nzm (55 ft-lbs) torque.
TRAILER HITCHES
CLASS III HITCHÐXJ VEHICLES
A class III weight-distributing/equalizer type hitch
can be used to tow a trailer:
²having a maximum gross weight of 5,000 lbs/2250
kg, and
²having a maximum tongue weight of 750 lbs/332
kg).
The following vehicle basic equipment is required
for class III trailer towing:
²P205/75R15 or larger tires;
²full size spare tire;
²trailer sway control;
²trailer tow wire harness and connector;
²heavy duty turn signal flasher element;
²heavy duty axle (with synthetic lubricant);²heavy duty cooling system;
²heavy duty generator/battery;
²auxiliary automatic transmission fluid cooler; and
²I-6, 4.0L engine.
Wide-angle type door mirrors are recommended but
not required.
WIRE HARNESS CONNECTORS
CLASS I HITCH CONNECTOR
The trailer tow wire harness connector for class I
trailer hitches is a 5-terminal, in-line type connector.
Terminal 5 is the source for vehicle ground.
CLASS III HITCH CONNECTOR
The trailer tow wire harness connector for class III
trailer-tow hitches is a 7-terminal, circular type con-
nector.
The 12-volt circuit for the trailer is protected
from overloads. A auto-reset type circuit
breaker is located in the trailer tow wire har-
ness near the plug-in relays.
CAUTION: The trailer tow wire harness package
does not include a vehicle battery isolator unit. Be-
cause of this, the trailer battery can totally dis-
charge the vehicle battery if the engine is not
operated for an extended period of time.
Fig. 11 Trailer Tow Wire Harness Connectors
23 - 88 BODY COMPONENTSÐXJ VEHICLESJ

A blue wire (without a connector) located under in-
strument panel near fuse panel is available for
trailer electric brake control unit.
The stop lamp and turn signal plug-in relays are
located behind left quarter trim panel.
HITCH REMOVALÐXJ VEHICLES
An XJ class III, weight-distributing/equalizer type
hitch is comprised of:
²a towing tube with a ball mount receptacle, and²various reinforcement/support brackets that are at-
tached to the vehicle frame sills and rear crossmem-
ber with bolts.
(1) If necessary, remove the trailer tow wire har-
ness connector from the hitch.
(2) Support the hitch.
(3) Remove the bolts that attach the towing tube
to the frame sills and reinforcement bracket. If
equipped, remove the fuel tank skid plate.
Fig. 14 Equalizer Type HitchÐXJ Vehicles
Fig. 12 Class III Trailer Tow Wire Harness and
ConnectorsFig. 13 Class III Trailer Tow Wire Harness Plug-In
Relays
JBODY COMPONENTSÐXJ VEHICLES 23 - 89