1995 JEEP YJ Service And Repair Manual

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Page 1937 of 2158

JEEP YJ 1995 Service And Repair Manual ²Install the retainers to attach the fender liner to
the fender inner panel.
²Install the rivets to attach the flare to the air de-
flector (Figs. 48 and 50). and
²Install the screws to attach the

²Install the retainers to attach the fender liner to
the fender inner panel.
²Install the rivets to attach the flare to the air de-
flector (Figs. 48 and 50). and
²Install the screws to attach the flare to the fender.
Tighten the screws to 1 Nzm (13 in-lbs) torque.
(8) Connect the front lamp wire harness connectors
to the engine wire harness connectors (Fig. 52).
(9) Install the front lamps.
(10) Install the front bumper.
(11) Install the wheel, remove the support and
lower the vehicle.
(12) Right fender only: install the hood support rod
on the fender inner panel.
(13) Install the hood bumper on the fender inner
panel.(14) Right fender only: install the Daytime Run-
ning Light (DRL) module on fender inner panel.
(15) Right fender only: install the A/C Receiver/
Drier on the fender inner panel.
(16) Right fender only: install the vapor canister
on the fender inner panel. Tighten the vapor canister
screws to 5 Nzm (45 in-lbs) torque.
(17) Right fender only: install the PDC, coolant re-
covery bottle and speed servo on the fender inner
panel.
(18) Right fender only: install the hood ajar switch,
if equipped. Tighten the screws to 2 Nzm (15 in-lbs)
torque.
(19) Right fender only: install the windshield
washer fluid reservoir on the inner panel.
(20) Right fender only: install the battery tray and
battery on the inner panel.
(21) Right fender only: if equipped, install the ra-
dio antenna. Tighten the nut/escutcheon to 4.5 Nzm
(40 in-lbs) torque. Tighten the power antenna bracket
screws to 2 Nzm (20 in-lbs) torque.
REAR WHEELHOUSE FLARES AND LINERSÐXJ
REMOVAL
(1) Remove the flare and liner lower screws (Fig.
53 and 54).
(2) Remove the nuts that attach the liner to the
wheelhouse.
(3) Remove the liner from the wheelhouse.
(4) Remove the push-nuts that attach the flare re-
tainers to the wheelhouse (Fig. 55).
(5) Remove the flare and retainers from the wheel-
house.
INSTALLATION
(1) Position the flare and retainers at the wheel-
house.
(2) Install the push-nuts to attach the flare retain-
ers to the wheelhouse.
(3) Position the liner in the wheelhouse.
Fig. 50 Fender Flare & Retainers
Fig. 51 Fender Liner and Retainers
Fig. 52 Front Lamp Wire Harness Connectors
JEXTERIOR COMPONENTSÐXJ 23 - 19

Page 1938 of 2158

JEEP YJ 1995 Service And Repair Manual (4) Install the nuts to attach the liner to the
wheelhouse and flare retainers.
(5) Install the flare and liner lower screws. Tighten
the screws to 1 Nzm (13 in-lbs) torque.
BODY SIDE MOLDING/CLADDING

Page 1939 of 2158

JEEP YJ 1995 Service And Repair Manual (4) If the original molding will be installed, also re-
move all adhesive from it.
INSTALLATION
(1) Install 3M 06379 double-sided tape on the
molding.
(2) For vertical alignment, use masking tape or a

(4) If the original molding will be installed, also re-
move all adhesive from it.
INSTALLATION
(1) Install 3M 06379 double-sided tape on the
molding.
(2) For vertical alignment, use masking tape or a
string as reference.
(3) Remove the backing from the tape, align the
molding and position it on the body panel.
(4) Press the molding onto the body panel with a
roller or hand pressure.
BODY STRIPES/DECALSÐXJ
SERVICE INFORMATION
XJ body stripes and decals are weather resistant
tape with a adhesive backing.
REPAIR
Small nicks, scratches and other surface marks in
a body stripe/decal can be touched-up with paint.
To eliminate blisters and air bubbles in a body
stripe/decal, pierce them with a needle or pin.
A heat gun can also be used to remove small wrin-
kles in a stripe/decal.
REQUIREMENTS
Body stripe/decal replacement requires that the
metal repair and paint refinish be completed first.
The work area temperature should be between
18ÉC (65ÉF) and 32ÉC (90ÉF).A tape stripe/decal
should not be replaced if the work area temper-
ature is less than 18ÉC (65ÉF).
The following equipment and material are neces-
sary for removal and installation:
²Commercial tape stripe/decal removal solution.
²Commercial adhesive removal solution.
²Liquid dish detergent (for the wetting solution).
²Mixture of wetting solution.
²Commercial wax and silicone removal solution.
²Isopropyl (rubbing) alcohol.
²Small squeegee (plastic or hard rubber).
²Water bucket and sponge.
²Clean wiping rags or paper towels.
²Heat gun (or infra-red heat bulb).
²Wax pencil.
²
Sharp knife, single edge razor blade or X-acto knife.
²Pair of scissors.
²Needle or pin.
The use of a wetting solution aids the installation of a
tape stripe/decal on a painted panel. Prepare the wet-
ting solution by mixing two or three teaspoons of dish
detergent with 1 gallon of water.Do not use soap.
Too much detergent will reduce the effective-
ness of the mixture.
REMOVAL
(1) Clean the repaired surface, adjacent panels and
door the openings as necessary.
(2) Start at one end of the tape stripe/decal and
apply heat with a heat gun. Slowly peel the stripe/
decal from the panel by pulling it back.Do not pull
the tape stripe/decal outward from panel.
WARNING: USE TAPE STRIPE/DECAL REMOVAL
SOLUTION IN A WELL-VENTILATED AREA ONLY.
(3) A tape stripe/decal removal solution can be used
for removal at areas where a heat gun is ineffective:
²Mask-off the body panel area surrounding the tape
stripe/decal (Fig. 1).
²Move solution spray across the complete length of
stripe/decal with a steady motion.
²Ensure that the complete stripe/decal is covered
with solution.
²Allow stripe/decal removal solution to remain on
the stripe/decal for 20 minutes.
²After 20 minutes, peel the stripe/decal away from
flange area (Fig. 2).
Fig. 1 Stripe/Decal Removal Solution Application
Fig. 2 Body Stripe/Decal Removal
JEXTERIOR COMPONENTSÐXJ 23 - 21

Page 1940 of 2158

JEEP YJ 1995 Service And Repair Manual ²If there is difficulty with peeling the stripe/decal
away from the body panel, use a squeegee (Fig. 3).
²With the stripe/decal removed, scrape all the
stripe/decal solution from the panel surface b

²If there is difficulty with peeling the stripe/decal
away from the body panel, use a squeegee (Fig. 3).
²With the stripe/decal removed, scrape all the
stripe/decal solution from the panel surface before
proceeding.
WARNING: USE THE ADHESIVE REMOVAL SOLU-
TION IN A WELL-VENTILATED AREA ONLY.
(4) After the stripe/decal is removed, remove any
adhesive remaining with a removal solution.
Allow the adhesive removal solution to re-
main on the panel for 3 to 5 minutes only.
(5) After 3 to 5 minutes, use a squeegee to remove
the adhesive (Fig. 4).
(6) Remove the masking tape and mask from the
panel.
(7) Wipe the panel with a cloth saturated with an
adhesive cleaning solution.BODY PANEL SURFACE PREPARATION
(1) The area that will be covered by the tape
stripe/decal must be cleaned with cleaning solution.
(2) Freshly painted surfaces must be thoroughly
dry.
(3) Clean the painted surface with a commercial
wax and silicone removal solution. Wipe the surface
with a clean cloth and allow it to dry.
REPLACEMENT ON ONE PANEL
For tape stripes/decals, use a clean sponge and ap-
ply the wetting solution:
²To the adhesive side of the tape stripe/decal.
²To the painted panel surface.
The wetting solution will permit ease of tape
stripe/decal movement when positioning it.
(1) Align a straight edge with the existing tape
stripe/decal ends (Fig. 5).
If applicable, the body panel character line
can be used as the tape stripe/decal alignment
reference.
(2) Position the tape stripe/decal and carrier on the
body panel and the mark length with a wax pencil.
(3) Cut the stripe/decal and carrier at the required
length with scissors.
(4) Position the stripe/decal and carrier on the
body panel and hold it in-place with masking tape
(Fig. 6).
(5) Lift the bottom edge of tape stripe/decal and
carrier. Use the tape sections as hinges, and reverse
the position of stripe/decal and carrier (Fig. 7).
CAUTION: Always remove the carrier from the tape
stripe/decal, never remove the tape stripe/decal
from carrier
(6) Bend a corner of carrier outward and then,
with a flick of the finger, separate the corner of car-
rier from the decal.
Fig. 3 Body Stripe/Decal Removal With A Squeegee
Fig. 4 Adhesive Removal With A Squeegee
Fig. 5 Stripe/Decal Alignment Reference Mark
23 - 22 EXTERIOR COMPONENTSÐXJJ

Page 1941 of 2158

JEEP YJ 1995 Service And Repair Manual (7) Separate approximately 15 cm (6 in) of the car-
rier from one end of the tape stripe/decal.(8) Return the tape stripe/decal back to its original
position. If a solution is being used, position adh

Page 1942 of 2158

JEEP YJ 1995 Service And Repair Manual COMPLETE REPLACEMENT
The following procedure will simplify the installa-
tion of a complete or very large section (Fig. 11, 12,
13, 14 and 15).
(1) Place the tape stripe/decal on a clean, flat sur-
fa

Page 1943 of 2158

JEEP YJ 1995 Service And Repair Manual (3) Retain the tape stripe/decal firmly against flat
surface and separate the carrier from tape stripe/de-
cal.
(4) Use a sponge and apply solution to the tape
stripe/decal adhesive and to panel surfa

(3) Retain the tape stripe/decal firmly against flat
surface and separate the carrier from tape stripe/de-
cal.
(4) Use a sponge and apply solution to the tape
stripe/decal adhesive and to panel surface.
(5) Position the adhesive side of tape stripe/decal
on the panel with the bottom aligned with the char-
acter line.
²Align the end of the replacement tape stripe/decal
with the end of existing tape stripe/decal.
²Correctly align the index darts and index notches.
(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.
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
REMOVAL/INSTALLATION
(1) Remove nuts from inside vehicle (Fig. 16).
(2) Carefully pry the applique the from panel.
(3) Position the replacement applique the on panel
and install the nuts.
DRIP RAIL MOLDINGÐXJ
REMOVAL
(1) Pry the clips from the roof flange.
(2) Remove the clips and molding from the roof
flange.(3) Remove the remaining sealant and clean the
roof flange.
INSTALLATION
(1) Position the drip rail molding with clips at the
roof flange and force the clips onto the roof flange.
(2) Apply sealant to the inner side of the molding
to seal the roof flange.
AIR EXHAUST GRILLEÐXJ
REMOVAL
(1) Remove the screw that attaches the grille to
door the opening panel (Fig. 17).
(2) Pry the bottom edge of the grille from the door
opening panel.
Fig. 16 Quarter Window Applique and Drip Molding
Fig. 17 Door Opening Air Exhaust Grille
JEXTERIOR COMPONENTSÐXJ 23 - 25

Page 1944 of 2158

JEEP YJ 1995 Service And Repair Manual (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 inser

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