1994 JEEP CHEROKEE roof

Fig. 3 Cross-body Splices XJ
Fig. 4 Roof Splices XJ
JSPLICE LOCATIONS 8W - 61

(6) If a complete replacement tape stripe/decal is
not being installed:
²position the replacement tape stripe/decal section
at the center of the repair area,
²align it with the existing tape stripe/decal, and
²allow at least 12 mm (1/2 in) of the tape stripe/de-
cal section to overlap the tape stripe/decal edges.
(7) Apply the wetting solution to the outer side of
the tape stripe/decal.
CAUTION: Avoid unnecessary pulling and stretch-
ing at the ends.
(8) Slide a squeegee from the center to the ends of
the tape stripe/decal. Use firm strokes to remove all
of the air bubbles.(9) If a wrinkle is trapped in the tape stripe/decal
stop immediately. Lift the wrinkled area and re-align
it with the character line to remove the wrinkle.Do
not lift the tape stripe/decal if only a few air
bubbles exist.
(10) Where applicable, allow 12 mm (1/2 in) extra
tape stripe/decal to extend beyond edges.
(11) Fold the excess tape onto the inside flange and
adhere it with finger pressure.
(12) Inspect the tape stripe/decal installation with
the reflected light to find any damage.
(13) Remove all the air and moisture bubbles from
the tape stripe/decal with a needle or pin.
(14) Install any removed components and clean the
vehicle as necessary.
QUARTER WINDOW APPLIQUEÐXJ VEHICLES
REMOVAL/INSTALLATION
(1) Remove nuts from inside vehicle.
(2) Carefully pry the applique the from panel.
(3) Position the replacement applique the on panel
and install the nuts.
DRIP RAIL MOULDINGÐXJ VEHICLES
REMOVAL
(1) Pry the clips from the roof flange.
(2) Remove the clips and moulding from the roof
flange.
(3) Remove the remaining sealant and clean the
roof flange.
Fig. 84 Tailgate Tape StripesÐXJ Vehicles
Fig. 85 Tape Stripes and DecalÐXJ Sport
Fig. 86 Quarter Window Applique and Drip Moulding
JBODY COMPONENTSÐXJ VEHICLES 23 - 29

INSTALLATION
(1) Position the drip rail moulding with clips at
the roof flange and force the clips onto the roof
flange.
(2) Apply sealant to the inner side of the moulding
to seal the roof flange.
AIR EXHAUST GRILLEÐXJ VEHICLES
REMOVAL
(1) Remove the screw that attaches the grille to
door the opening panel (Fig. 87).
(2) Pry the bottom edge of the grille from the door
opening panel.
(3) Pull downward and remove the grille from ex-
haust port in the door opening panel.
INSTALLATION
(1) Position the slot located in the upper end of re-
placement grille at the exhaust port and insert edge
in the slot.
(2) Push inward and seat the grille in the exhaust
port.
(3) Install the screw to attach the grille to the door
opening panel.
EXTERIOR NAMEPLATES
SERVICE INFORMATION
All of nameplates, with the exception of the JEEP
nameplate located on the grille are attached with ad-
hesive.
GRILLE OPENING PANEL NAMEPLATE
REMOVAL
(1) Remove the grille opening panel (GOP) support
bracket.
(2) As applicable, remove the nut(s) from the let-
ter(s) that must be replaced.(3) Remove the nameplate letter(s) from GOP.
INSTALLATION
(1) Clean the panel surface.
(2) Position the replacement letter(s) on the GOP.
(3) Install the nut(s) and tighten.
ADHESIVE-BACKED NAMEPLATES
REMOVAL/INSTALLATION
(1) Pry the nameplate from vehicle panel.
(2) Clean the panel surface.
(3) Position the replacement nameplate on the
panel push inward to seat it.
FUEL FILLER NOZZLE/TUBE
REMOVAL
(1) Remove the fuel filler door from the quarter
panel (Fig. 89).
(2) For XJ vehicles, remove the fuel filler hose
splash shield from the quarter inner panel and frame
rail (Fig. 89).
Fig. 89 Fuel Filler DoorÐTypical
Fig. 87 Door Opening Air Exhaust Grille
Fig. 88 XJ Exterior Nameplates
23 - 30 BODY COMPONENTSÐXJ VEHICLESJ

(3) For power/manual mirrors, remove the inside
trim cover.
(4) For remote control mirrors, loosen the toggle
control setscrew.
(5) For remote control mirrors, remove the inside
trim cover.
(6) Remove the mirror screws.
(7) Remove the mirror from the door. Refer to
Group 8ÐElectrical.
INSTALLATION
(1) Position the mirror adjacent to the vent win-
dow.
(2) Install the mirror screws. Tighten the screws
securely.
(3) For remote mirrors, position the inside trim
cover over the toggle control and tighten the set-
screw.
(4) Install the inside trim cover.
(5) Install the inside trim cover screw.
(6) Install the door trim panel.
LUGGAGE RACKÐXJ VEHICLES
REMOVAL
(1) Remove the slide rail screws.
(2) Remove the luggage rack from the roof.
The skid strips are attached to the roof panel
with adhesive.
(3) Loosen each skid strip with a heat gun.
(4) Lift one edge of each skid strip with a putty
knife and peel it from the roof panel.
(5) Remove the original adhesive from the roof
with an adhesive removal solution.
(6) If the original skid strips are installed, remove
all the original adhesive from them.
INSTALLATION
(1) Install 3M 06379 double-sided tape, or an
equivalent on skid strips.
Fig. 94 Fuel Filler Door-Stop Bumper
Fig. 95 Remote and Power/Manual Mirrors
Fig. 96 Remote Mirror Toggle Control Set Screw
Fig. 97 Trim Covers Without External Mirror
23 - 32 BODY COMPONENTSÐXJ VEHICLESJ

(2) Remove the backing from the double-sided
tape, align each skid strip on the roof, and position it
on the roof panel.
(3) Verify that each skid strip is properly aligned.
(4) Press each skid strip onto the roof panel with a
roller (or use hand pressure).To prevent water leaks, apply 3M Drip-Chek
Sealant, or equivalent.
(5) Position the luggage rack on the roof with the
screw holes aligned.
(6) Install and tighten the slide rail screws to 3
Nzm (28 in-lbs) torque.
Fig. 114 Luggage RackÐXJ VehiclesFig. 115 Skid Strip Installation
JBODY COMPONENTSÐXJ VEHICLES 23 - 33

(5) If necessary, remove the screws and remove the
speaker grilles from the trim panel (Fig. 115).
INSTALLATION
(1) If removed, install the trim panel retainer strip
on the liftgate with replacement rivets.
(2) If removed, install the speaker grilles on trim
panel. Tighten the screws to 1 Nzm (11 in-lbs) torque.
(3) Position the trim panel on liftgate.
(4) Align the trim panel retainers with the holes
in the liftgate inner panel and force the trim panel
inward.
(5) Install the screws to attach the panel upper
sides to the liftgate.
LIFTGATE HINGE
REMOVAL
It is not necessary to remove the liftgate to replace
one or both hinges.
(1) Remove the liftgate (headliner) upper trim
moulding (Fig. 116).
(2) Remove the hinge-to-roof panel nuts (Fig. 117).(3) Remove the hinge-to-liftgate screws and re-
move the hinge from the liftgate (Fig. 118).
INSTALLATION
(1) Position the gaskets, shim and hinge on the
liftgate and the roof panel (Fig. 119).
Fig. 115 Liftgate Trim Panel Speaker Grilles
Fig. 116 Liftgate Upper Trim Moulding
Fig. 117 Liftgate Hinge-To-Roof Panel Nuts
Fig. 118 Liftgate Hinges
Fig. 119 Liftgate Hinge, Gaskets and Shim
JBODY COMPONENTSÐXJ VEHICLES 23 - 67

(2) Install and tighten hinge-to-roof panel nuts to 9
Nzm (7 ft-lbs) torque.
(3) Install the liftgate-to-hinge screws. Tighten
screws to 9 Nzm (7 ft-lbs) torque.
(4) Install the liftgate (headliner) upper trim moul-
ding (Fig. 111).
LIFTGATE LATCH/KEY LOCK CYLINDER/STRIKER
REMOVAL
(1) Raise the liftgate and remove the latch screws
(Fig. 120).
(2) Disconnect the rod from the latch (Fig. 121).(3) Remove the latch from the liftgate (Fig. 122).
(4) Drill-out the rivet heads and remove the lock
solenoid from liftgate (Fig. 123).
(5) Remove the lock cylinder retainer clip (Fig. 124).
Fig. 121 Latch and Key Lock Cylinder
Fig. 122 Liftgate Latch and Solenoid
Fig. 123 Liftgate Lock Solenoid
Fig. 124 Liftgate Key Lock Cylinder
Fig. 120 Liftgate Latch Screws
23 - 68 BODY COMPONENTSÐXJ VEHICLESJ

INSTALLATION
(1) Connect the replacement support rod and cylin-
der to the ball studs.
(2) Secure the support rod and cylinder to the ball
studs with the retainer clips.
(3) Remove the support from the liftgate and test
the operation of the support rod.
LIFTGATE SUPPORT ROD CYLINDER DISPOSAL
WARNING: SAFETY GOGGLES MUST BE WORN
DURING THE DISPOSAL PROCEDURE. THE HIGH
PRESSURE GAS CHARGE IN THE SUPPORT ROD
CYLINDERS WILL BE RELEASED DURING THE
PROCEDURE.
(1) Remove the support rod cylinder(s) from the
liftgate.
(2) Position the support rod cylinder horizontally
in a vise and clamp the cylinder securely.
(3) Wrap the cylinder with 4-5 layers of shop tow-
els.
(4) Measure 1 and 1/2 inches inward from the end
of the cylinder. Mark this location on the towels with
chalk. The cylinder will be punctured at this location
to release the gas charge.
(5) Use a punch and hammer to puncture cylinder.
Force the punch through towels and into the cylinder
with a hammer. Continue striking the punch until
the gas begins to escapebut do not remove the
punch.
(6) Hold the towels and punch in position until all
the gas has escaped. Complete de-pressurization will
require about 4 to 10 seconds. After all the gas has
escaped, slowly remove the punch.
(7) Hold a towel over the hole in cylinder and press
the support rod piston all the way into the cylinder
to purge remaining oil.
(8) Remove the support rod cylinder from the vise
and discard it.
(9) If both support rod cylinders are being re-
placed, repeat this procedure for the remaining cylin-
der.
LIFTGATE SUPPORT ROD BALL STUD
REPLACEMENT
REMOVAL
(1) Open the liftgate.
(2) Support the liftgate in the open position.
(3) Remove the retainer clip that attaches the sup-
port rod and cylinder to the ball stud.
(4) Disconnect the support rod from the ball stud.
(5) Remove the ball stud from the liftgate with a
T-30 Torx-head socket wrench (Fig. 129).
INSTALLATION
(1) Install the replacement ball stud in the liftgate
with a T-30 Torx-head socket wrench. Tighten the
ball stud to 7 Nzm (62 in-lbs) torque.
(2) Connect the support rod to the ball stud.
(3) Secure the support rod to the ball stud with the
clip.
(4) Remove the support from the liftgate and test
the operation of support rod.
LIFTGATE ADJUSTMENT
SERVICE INFORMATION
The position of the liftgate can be adjusted upward
or downward, and inward or outward by the use of
hinge shims. The liftgate stop bumpers must also be
adjusted if liftgate hinges are adjusted. The inward/
outward position of each stop bumper is adjusted by
the use of shims (Fig. 130).
ADJUSTMENT PROCEDURE
(1) To move the position of the liftgate inward or
outward, remove or add shims between the hinge-
halves and liftgate.
(2) To move the position of the liftgate upward or
downward, remove or add shims between the hinge-
halves and roof panel.
(3) To move the position of liftgate stop bumpers
inward or outward, remove or add shims between the
stop bumper screws and anchors (Fig. 131).
LIFTGATE OPENING WEATHERSTRIP SEAL
REMOVAL
(1) Pull the seal away from the flange around the
perimeter of liftgate opening and remove it (Figs. 132
and 133).
(2) Clean the flange as necessary.
Fig. 129 Support Rod Ball Studs
23 - 70 BODY COMPONENTSÐXJ VEHICLESJ