1995 JEEP YJ Service And Repair Manual

fog light seats lumbar support maintenance reset height fuel filter

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JEEP YJ 1995 Service And Repair Manual TORQUE SPECIFICATIONS
11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLDJ

Page 1386 of 2158

JEEP YJ 1995 Service And Repair Manual FRAME AND BUMPERS
CONTENTS
page page
BUMPERS.............................. 5
BUMPERS............................. 16FRAME................................. 1
FRAME................................ 10
FR

FRAME AND BUMPERS
CONTENTS
page page
BUMPERS.............................. 5
BUMPERS............................. 16FRAME................................. 1
FRAME................................ 10
FRAME
INDEX
page page
Frame Dimensions......................... 1
Front Skid Plate........................... 1
Fuel Filler Hose Splash ShieldÐXJ Vehicles...... 4
Fuel Tank Skid Plate........................ 3Fuel Tank Support Strap..................... 4
General Information........................ 1
Transfer Case Skid Plate.................... 3
GENERAL INFORMATION
Jeep XJ Vehicles (Fig. 1) and the cab section of
Jeep are constructed as a unitized body and frame.
Jeep XJ unibodies are constructed from special
high-strength steel and coated metals. These types of
metals reduce weight and provide strength.
A vehicle constructed as a unibody reacts differ-
ently to the impact of a collision. While the damage
at the immediate point of impact is easily recogniz-
able, the damage must be diagnosed to expose it.
With unibody construction, there are five logical ar-
eas to examine to expose damage:
²Damage at the immediate point of impactÐpri-
mary damage.²The other (lessor) body damageÐsecondary dam-
age.
²Damage to the exterior trim and other surface-at-
tached components.
²Damage to the mechanical components.
²The interior trim and accessory damage.
When there is damage to a vehicle, the alignment
points must be returned too specifications.
FRAME DIMENSIONS
Frame dimensions are listed in millimeter scale.
All dimensions are from center to center of Principal
Locating Point (PLP), or from center to center of PLP
and fastener location (Fig. 2).
FRONT SKID PLATE
REMOVAL
(1) Remove the screws that attach skid plate to
side sills (Fig. 3).
(2) Remove the nuts that attach the skid plate to
the crossmember (Fig. 3).
(3) Remove the skid plate from the vehicle (Fig. 3).
INSTALLATION
(1) Position the skid plate at front crossmember
and side sills (Fig. 3).
(2) Install the nuts to attach the skid plate to
crossmember.
(3) Install the screws to attach skid plate to side
sills.
Fig. 1 JeepÐXJ
JFRAME AND BUMPERS 13 - 1

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JEEP YJ 1995 Service And Repair Manual Fig. 2 Frame Alignment Reference DimensionsÐXJ Vehicles
13 - 2 XJÐFRAMEJ

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JEEP YJ 1995 Service And Repair Manual 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. 4).
(3) Remove the support and

Page 1389 of 2158

JEEP YJ 1995 Service And Repair Manual FUEL FILLER HOSE SPLASH SHIELDÐXJ
VEHICLES
REMOVAL
(1) Remove the screws that attach fuel filler hose
splash shield to wheelhouse panel and frame rail
(Fig. 7).
(2) Remove the hose splash shield from

Page 1390 of 2158

JEEP YJ 1995 Service And Repair Manual BUMPERS
INDEX
page page
Front Bumper............................. 5
Front Tow Hooks........................... 7Rear Bumper............................. 8
Rear Tow Hook............................ 9
F

Page 1391 of 2158

JEEP YJ 1995 Service And Repair Manual The retaining screws and the steering gear
skid plate must be removed before the left
strap can be removed from the sillmember.
(5) Detach the tow hook straps from the sillmem-
ber.
(6) Support the bu

Page 1392 of 2158

JEEP YJ 1995 Service And Repair Manual (12) Remove the fog lamps (Fig. 10) from the
bumper rail.
(13) If necessary, remove the vacuum reservoir(s)
from the bumper rail.
(14) If necessary, remove the sill crossmember re-
inforcement bracket

(12) Remove the fog lamps (Fig. 10) from the
bumper rail.
(13) If necessary, remove the vacuum reservoir(s)
from the bumper rail.
(14) If necessary, remove the sill crossmember re-
inforcement brackets from the sillmembers.
ASSEMBLY/INSTALLATION
(1) If removed, install the sill crossmember rein-
forcement brackets on the sillmembers (Fig. 11).
Tighten bolts to 56 Nzm (41 ft. lbs.) torque.
(2) If equipped, install the bumper support brack-
ets and bumper guards on the bumper rail. Tighten
hardware in the sequence indicated in (Fig. 6).
Tighten the locknuts with 20 Nzm (15 ft. lbs.) torque.
Tighten bolts to 56 Nzm (41 ft. lbs.) torque.
(3) If not equipped with bumper guards, install the
bumper support brackets on the bumper rail. Tighten
bolts to 56 Nzm (41 ft. lbs.) torque.
(4) Install tow hooks. Tighten nuts with 100 Nzm
(74 ft. lbs.) torque.
(5) Install the bumper end caps on the bumper
rail. Tighten nuts with 8 Nzm (72 in. lbs.) torque.(6) Install the license plate bracket on the bumper
rail. Tighten the nuts securely.
(7) Install the fog lamps on the bumper rail.
Tighten the nuts to 20 Nzm (15 ft. lbs.) torque.
(8) If removed, install the vacuum reservoir(s) on
the bumper rail. Tighten the retaining screws and
bolts to 8 Nzm (72 in. lbs.) torque.
(9) Position and support the bumper at the front of
the vehicle.
(10) Attach the bumper support brackets to the
right and left sillmembers and reinforcement brack-
ets. Tighten screws and bolts to 56 Nzm (41 ft. lbs.)
torque.
(11) Install the Torx-head bolts and locknuts that
attach the tow hook straps to the underbody sillmem-
ber. Tighten locknuts with 30 Nzm (22 ft. lbs.) torque.
Install the steering gear skid plate and screws
after the left tow hook strap has been installed.
(12) Connect the fog lamp wire harness connectors.
(13) Connect the vacuum reservoir tube harness
connectors.
(14) Remove the bumper support.
FRONT TOW HOOKS
If a tow hook must be replaced or removed only for
service access, remove the nuts and bolts that attach
it to the bumper support bracket. When installing a
tow hook, tighten nuts with 100 Nzm (74 ft. lbs.)
torque.
If a tow hook/bumper support bracket must be re-
placed, refer to the following removal and installation
procedures.
REMOVAL
If equipped with a brush guard, refer to the Brush
Guard Removal within Group 23, Body Components.
(1) Disconnect the fog lamp wire harness connec-
tors, if equipped.
(2) Disconnect the vacuum reservoir tube harness
connectors.
(3) Support the bumper.
(4) Remove the bolts that attach the bumper sup-
port brackets to the right and left sillmembers.
(5) Remove the locknuts and Torx-head bolts that
attach the tow hook straps to the underbody sillmem-
ber.
The retaining screws and the steering gear
skid plate must be removed before the left
strap can be removed from the sillmember.
(6) Detach the tow hook straps from the sillmem-
ber.
(7) Remove the support and the bumper from the
vehicle.
(8) Remove the nuts and bolts that attach the tow
hooks to the bumper support brackets.
(9) Remove the tow hook from the bumper support
bracket.
Fig. 10 Fog Lamp
Fig. 11 Reinforcement Brackets
JXJÐBUMPERS 13 - 7

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