1994 JEEP CHEROKEE Service Repair Manual

INSTALLATION
(1) Apply weatherstrip adhesive around the perim-
eter of the seal contact surface on the tailgate edge
(Fig. 87).
(2) Position the seal on the tailgate and press it
against the inner panel and flange.
(3) Install the seal retaining rivets (Fig. 87).
CAUTION: Do not apply graphite, brake fluid or wax
to the seal.
HARD TOP LIFTGATE GLASS
REMOVAL
(1) Disconnect the rear defroster/dome lamp wire
harness connectors.
(2) Remove the wiper motor cover. Disconnect the
wiper motor wire harness connector and the washer
fluid hose (Fig. 88).
(3) Remove the wiper arm and blade (Fig. 88).
WARNING: DO NOT REMOVE THE LIFTGATE SUP-
PORT RODS WITH THE LIFTGATE CLOSED. THE
SUPPORT ROD PISTONS ARE OPERATED BY HIGH
PRESSURE GAS AND COULD CAUSE PERSONAL
INJURY AND/OR VEHICLE DAMAGE IF THEY ARE
REMOVED WITH THE PISTONS COMPRESSED
(LIFTGATE CLOSED). ONCE REMOVED, DO NOT
ATTEMPT TO DISASSEMBLE OR REPAIR THE SUP-
PORT RODS.
(4) Open the tailgate (Fig. 89).(5) Remove the support rod cylinder retaining clips
at both ends of each support rod cylinder (Fig. 89)
(6) Pull the support rods off the ball studs (Fig.
89).
(7) Remove the liftgate glass hinge bolts (Fig. 89).
(8) Remove the liftgate glass from the hard top
(Fig. 89).
(9) Remove the weatherstrip seal (Fig. 89), if nec-
essary.
INSTALLATION
(1) Assemble the liftgate components, if necessary
(2) Position the liftgate glass in the hard top open-
ing and install the hinge bolts (Fig. 89). Do not
tighten the bolts.
(3) Adjust the liftgate glass to fit the hard top
opening.
(4) Tighten the hinge bolts to 11 Nzm (95 in-lbs)
torque.
(5) Position the support rod cylinders on the ball
studs (Fig. 89).
(6) Install the support rod cylinder retainer clips
(Fig. 89).
(7) Connect the wiper motor wire harness connec-
tor and the washer fluid hose. Install the wiper mo-
tor cover (Fig. 88).
(8) Install the wiper arm and blade (Fig. 88).
(9) Connect the rear window defroster/dome lamp
wire harness connectors.
DISASSEMBLY
(1) Remove retaining screws and the lower, inner
trim moulding from the latch panel (Fig. 90).
Fig. 87 Tailgate Weatherstrip Seal
Removal/InstallationFig. 88 Liftgate Wiper Motor
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(2) Remove the retaining screws and the latch
panel, inner gasket, outer gasket, and the lower,
outer liftgate moulding from the liftgate (Fig. 90).
(3) Refer to Group 8ÐElectrical for service infor-
mation involving the wiper motor and the defroster.
(4) If necessary, remove the latch strikers and the
ball stud brackets from the hard top inner panel (Fig.
90).
ASSEMBLY
(1) If removed, install the latch strikers and the
ball stud brackets on the hard top inner panel (Fig.
90).
(2) Position the latch panel, and gaskets, and lift-
gate moulding on liftgate and install screws (Fig. 90).
Tighten the screws to 7 Nzm (60 in-lbs) torque.
(3) Position the lower, inner trim moulding on the
latch panel. Install screws (Fig. 90). Tighten the
screws to 2 Nzm (12 in-lbs) torque.
LIFTGATE GLASS WEATHERSTRIP SEAL
REPLACEMENT
REMOVAL
(1) Remove the liftgate glass from the hard top. If
necessary, refer to the removal procedure.
(2) Remove the retaining screws from the liftgate-
to-tailgate weatherstrip seal (Fig. 91).
(3) Carefully separate the seal and retainers from
the bottom of the liftgate glass (Fig. 91).
(4) Remove the hard top weatherstrip seal retain-
ing screws from body rear panels (Fig. 91).
Fig. 91 Liftgate Glass Weatherstrip Seals
Fig. 89 Liftgate Removal/Installation
Fig. 90 Liftgate and Components
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(5) Carefully separate the weatherstrip seal from
the rear panels and the hard top (Fig. 91).
(6) Remove the residual adhesive from the seal
contact areas.
INSTALLATION
(1) Remove the tape cover and position the lift-
gate-to-tailgate weatherstrip seal at the bottom of
the liftgate glass (Fig. 91).
(2) Carefully insert the retainers into the holes
and press the seal against the bottom of the liftgate
glass (Fig. 91).
(3) Install the liftgate-to-tailgate weatherstrip seal
screws (Fig. 91). Tighten the screws securely.
(4) Apply weatherstrip adhesive to the hard top
weatherstrip seal as indicated in Figure 91.
(5) Carefully position the weatherstrip seal on the
rear panels and the hard top (Fig. 91).
(6) Press the seal onto the hard top flange and en-
sure that it is correctly seated on the flange (Fig. 91).
(7) Install the seal retaining screws in the rear
panels and tighten them securely (Fig. 91).
HARD TOP SERVICE INFORMATION
The following service procedures include:
²hard top removal/installation, and
²hard top repair procedures.
The hard top is constructed of compressed molded
fiberglass and painted to a special spatter paint. The
hard top can be removed for service access or for
other purposes.
HARD TOP SERVICE
REMOVAL
CAUTION: When removing the hard top, avoid dam-
aging the foam sealant between the hard top and
body panels.
(1) Remove the screws that attach the hard top to
the windshield frame (Figs. 92 and 93).
Fig. 92 Hard Top Removal/Installation
Fig. 93 Hard Top-To-Windshield Frame Screws
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(2) Remove the screws that attach the hard top to
the rear beltline mouldings, body panels and tapping
plates (Figs. 92 and 94).
(3) Disconnect the wire harness connectors (Fig.
95).
(4) Remove the beltline mouldings and the hard
top from the vehicle (Fig. 92).
INSTALLATION
(1) Inspect the hard top seals for damage and re-
place, if necessary.(2) Carefully position the hard top on the vehicle
(Fig. 92).
CAUTION: When installing the hard top, avoid dam-
aging the foam sealant located between the top and
body panels.
(3) Position the beltline moulding on the hard top
flange and install the screws (Figs. 92 and 94).
Tighten the screws securely.
(4) Connect the wire harness connectors (Fig. 95).
(5) Install the screws to attach the hard top to the
windshield frame (Figs. 92 and 93). Tighten the
screws securely.
HARD TOP ROOF VENT
REMOVAL/INSTALLATION
(1) Remove the roof vent retaining screw from the
spring nut (Fig. 92).
(2) Remove the roof vent from the hard top (Fig.
92).
(3) Position the roof vent on the hard top and in-
stall the retaining screw (Fig. 92).
HARD TOP REPAIR
The hard top fiberglass material can be repaired.
The required repair materials include:
²fiberglass mat or cloth;
²fiberglass resin and hardener;
²structural adhesive (3M brand or an equivalent
product);
²glazing putty;
²aluminum foil; and
²plastic spreader.
HARD TOP HOLE REPAIR
(1) Use a grinder to remove the paint and outline
the damaged area. Use a grade 24 grit disc for paint
removal.
(2) Grind the outlined surface area again to a 50
grit disc to prevent coarse scratches from appearing
in the final finish.
(3) If cracks extend from the hole, it will be neces-
sary to stop-drill the crack(s) with a 3-mm (1/8-in) di-
ameter drill bit.
(4) Position a fiberglass mat or cloth on the repair
surface area. Cut the mat to allow a 2.5-cm (1-in)
overlap of the repair surface area.
(5) Clean the repair surface area.
(6) Place the fiberglass cloth on aluminum foil.
(7) Pour the fiberglass resin into a clean container.
(8) Mix the appropriate amount of hardener and
resin. Follow the manufacturers instructions.
(9) Apply the hardener/resin mixture to both sides
of the fiberglass cloth.
(10) Place the fiberglass cloth over the repair sur-
face area. Next, place the aluminum foil over the
Fig. 94 Hard Top-To-Body Panel Screws
Fig. 95 Wire Harness ConnectionÐTypical
JBODY COMPONENTSÐXJ VEHICLES 23 - 165

cloth. Use a plastic spreader to smooth-out the cloth
and resin. Use firm pressure to remove air bubbles
and to smooth-out the cloth.
(11) Allow the resin to ``cure''.
(12) Smooth-out the surface area to the contour of
the hard top with a 50-grit disc.
(13) Apply plastic filler to complete the repair.
Finish smoothing the surface area with 80-grit pa-
per.
(14) Repeat the previous step on the inside surface
area of the hard top.
(15) ``Featheredge'' the repaired surface area.
(16) Prime the repaired surface area with Ditzler
Epoxy Chromate Primer (DP-40/401), or an equiva-
lent product.
(17) Apply surface primer to the surface area.
(18) Sand the surface area for paint preparation.
After sanding, re-prime the surface area, if neces-
sary.
(19) Prime the surface area for the color coat.
(20) Color coat the repaired surface area.
FRACTURE REPAIR
(1) Use a grinder to remove the paint (from both,
the inner and outer surface areas of the hard top)
and to outline the damaged area.
(2) ``Stop-drill'' the crack(s) with a 3-mm (1/8-in)
diameter drill bit.(3) Bevel the edges of the crack(s) on both sides
with a rotary file.
The edges should be beveled on the inside and
outside of the top to ensure sufficient surface
area for good bonding.
(4) Complete the repairs with fiberglass cloth and
resin as described above in the hard top hole repair
procedure.
TEXTURED PAINT REPAIR
The textured paint applied to hard tops is available
from Mopar Parts sources. The paint supplied will
duplicate the original texture on the hard top.
SOFT TOP SERVICE INFORMATION
The soft top fabric consists of the top cover and the
side and rear curtains (Fig. 96). The top cover is sup-
ported by a tubular bow (frame) and is attached to
the upper side retainers (above the doors) with
snap-on retainers (Fig. 97).
Fig. 96 Soft Top Cover, Curtains and Windows
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SOFT TOP SERVICE
REMOVAL
(1) Detach the snap-on retainers from the upper
side retainers (Figs. 96 and 98).
(2) Slide the upper side retainer lock forward.
Next, disengage the lock from the pin and remove
the retainer from the door flange (Figs. 96, 97 and
99).
(3) Detach the snap-on retainer at the front corner
(Fig. 100, turn the retainers and remove the door
windows (Fig. 101).
Fig. 97 Soft Top Bow, Spreader Bar and Retainers
Fig. 98 Upper Side Retainers
Fig. 99 Upper Side Retainer Removal From Door
Flange
Fig. 100 Door Window Snap-On Retainer
JBODY COMPONENTSÐXJ VEHICLES 23 - 167

(4) Open the side curtain upper and rear zippers
(Figs. 96 and 102).
(5) Detach the interior snap-on retainer and tab,
and pull the bottom edge of each side curtain out of
the lower side retainer channel (Fig. 103).
(6) Slide the front edge of the side curtain down-
ward and remove it from the center bow retainer
channel (Figs. 96 and 104).
(7) Pull downward on the spreader bar to release
the lock and the tension on the center and rear bows
(Figs. 97 and 105).
(8) Open the tailgate.(9) Open the rear curtain upper and side zippers
(Fig. 106).
(10) Roll up the rear curtain and attach it to the
top cover with the elastic straps and snap-on retain-
ers (Fig. 107).
(11) Pull the bottom edge of the rear corners out-
ward and detach from the side (lower) retainer (Fig.
108).
Fig. 101 Door Window Removal/Installation
Fig. 102 Side Curtain Zippers
Fig. 103 Side Curtain and Lower Side Retainer
Fig. 104 Side Curtain Removal/Installation
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(12) Detach the top cover from the upper side retain-
ers located above the doors (Fig. 109). Next, detach the
top cover from the retainer channel located along the
upper edge of the windshield frame (Figs. 96 and 110).
Fig. 105 Releasing Spreader Bar Tension
Fig. 106 Rear Curtain Upper and Side Zippers
Fig. 107 Rear Curtain Upper and Side Zippers
Fig. 108 Detaching Rear Corner Side (Lower) Retainer
Fig. 109 Top Cover Snap-On Retainers At Upper
Side Retainers
Fig. 110 Detaching Top Cover At Windshield
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