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Exj 13

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  • 1. BUMPER U-NUT MOUNTING BRACKET RIVET AIR DEFLECTOR SUPPORT BRACKET END CAPXJ FRAME AND BUMPERS 13 - 1 FRAME AND BUMPERS CONTENTS page pageBUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 BUMPERS INDEX page pageREMOVAL AND INSTALLATION REAR BUMPER END CAP . . . . . . . . . . . . . . . . . 2 FRONT BUMPER END CAP . . . . . . . . . . . . . . . . 1 REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . 3 FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . 2 REAR TOW HOOK . . . . . . . . . . . . . . . . . . . . . . . 4 FRONT TOW HOOK . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL AND INSTALLATION FRONT BUMPER END CAP REMOVAL (1) Remove the bolts attaching the end cap to the bumper (Fig. 1). (2) Pull back the wheelhouse liner and remove the bolts attaching the end cap to the front fender. (3) Lifting the end cap from the bottom, tilt slightly upward and slide it outward to disengage the retainer tab from the bumper (Fig. 1). (4) Separate the end cap from the bumper. Fig. 1 Front Bumper
  • 2. BUMPER GRILLE BUMPER END CAP RETAINER TAB VACUUM RESER- VOIR VACUUM LINE RESERVOIR SCREWS13 - 2 FRAME AND BUMPERS XJREMOVAL AND INSTALLATION (Continued) Fig. 2 Bumper End CapINSTALLATION (1) position the end cap on the bumper and engage TOW TOW HOOK HOOK REINFORCE- MENT MOUNTING BRACKETthe retaining tab. Fig. 3 Vacuum Reservoir (2) Install the bolts attaching the end cap to the (2) Separate tow hook from reinforcement.front fender. (3) If necessary, remove bolt attaching tow hook (3) Install the bolts attaching the end cap to the reinforcement to frame.bumper. Tighten the nut to 9 N·m (7 ft. lbs.) torque.FRONT BUMPERREMOVAL (1) Remove bumper end caps. (2) If equipped, disengage fog lamp wire harnessconnectors. (3) Disconnect vacuum line from reservoir (Fig. 3). (4) Remove Torx-head bolts that attach bumper tomounting brackets (Fig. 1). (5) Remove bumper from vehicle. (6) If necessary, remove bolts attaching bumpermounting brackets to frame.INSTALLATION (1) If removed, install bolts attaching bumpermounting brackets to frame. Tighten bolts to 55 N·m Fig. 4 Front Tow Hook(41 ft. lbs.) torque. INSTALLATION (2) Position bumper on front of vehicle. (1) If removed, install bolt attaching tow hook (3) Install Torx-head bolts that attach bumper to reinforcement to frame. Tighten nut to 30 N·m (22 ft.mounting brackets. Tighten bolts to 55 N·m (41 ft. lbs.) torque.lbs.) torque. (2) Position tow hook on reinforcement. (4) Connect vacuum line to reservoir. (3) Install bolts attaching tow hook to tow hook (5) If equipped, engage fog lamp wire harness con- reinforcement. Tighten nuts to 100 N·m (74 ft. lbs.)nectors. torque. (6) Install bumper end caps. REAR BUMPER END CAPFRONT TOW HOOK REMOVALREMOVAL (1) Remove the bolt attaching the underside of the (1) Remove bolts attaching tow hook to tow hook end cap to the bumper (Fig. 5).reinforcement (Fig. 4).
  • 3. BUMPER SPLASHRIVET PLASTIC BLIND SHIELD U-NUTU-NUT REAR SILL BRACKET UPPER REINFORCEMENT U-NUT END CAP LOWERFORCEMENT REIN- RETAINER RIVETXJ FRAME AND BUMPERS 13 - 3REMOVAL AND INSTALLATION (Continued) (2) Remove the screw attaching the front of the (2) Remove bumper end caps.end cap to the underside of the quarter panel. (3) Remove bolts that attach bumper to bumper (3) Lift the end cap slightly upward and slide it support brackets (Fig. 5).rearward to release it from the retainer. (4) Remove bumper from vehicle. (4) Separate the end cap from the vehicle. (5) If necessary, remove bumper support brackets from the rear sill.INSTALLATION (1) Position the end cap on the rear of the retainer INSTALLATIONand the outer edge of the bumper. (1) If removed, install bumper support brackets on (2) Slide the end cap forward onto the retainer. the rear sill. Tighten bolts to 55 N·m (41 ft. lbs.)Ensure the end cap overlaps the lip of the rear torque.wheelhouse liner. (2) Position bumper on support brackets. (3) Install the screw attaching the front of the end (3) Install bolts that attach bumper to bumpercap to the underside of the quarter panel. support brackets. Tighten bolts to 55 N·m (41 ft. lbs.) (4) Install the bolt attaching the underside of the torque.end cap to the bumper. (4) Install bumper end caps. (5) If removed, install trailer hitch.REAR BUMPERREMOVAL (1) For vehicles equipped with a trailer hitch,remove hitch before removing bumper. If necessary,refer to removal procedure within Group 13, Frameand Bumpers. Fig. 5 Rear Bumper
  • 4. FRAME RAIL BOLT FWD BOLT TOWHOOK BOLT SUPPORT BRACKET NUT FORCEMENTREIN- FRAME BRACKET RIVET13 - 4 FRAME AND BUMPERS XJREMOVAL AND INSTALLATION (Continued)REAR TOW HOOKREMOVAL (1) Remove bolts that attach tow hook bracket andtow hook to frame rail (Fig. 6). (2) Remove bracket and tow hook from frame rail.INSTALLATION (1) Position bracket and tow hook on frame rail. (2) Install bolts that attach tow hook bracket andtow hook to frame rail. Tighten bolts to 94 N·m (70ft. lbs.) torque. Fig. 6 Rear Tow Hook
  • 5. SCREW PUSH NUT NUT STUD SCREW FWD SPLASHSHIELD SKID PLATE CROSSMEMBER SKID PLATE NUT-SERT FWD BOLT FRAME SILL CASE NUT-SERT TRANSFERXJ FRAME AND BUMPERS 13 - 5 FRAME INDEX page pageREMOVAL AND INSTALLATION TRANSFER CASE SKID PLATE . . . . . . . . . . . . . 5 FRONT SKID PLATE . . . . . . . . . . . . . . . . . . . . . 5 SPECIFICATIONS FUEL TANK SKID PLATE . . . . . . . . . . . . . . . . . . 5 FRAME TORQUE SPECIFICATIONS . . . . . . . . 16 TRAILER HITCH . . . . . . . . . . . . . . . . . . . . . . . . 6 VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . 7REMOVAL AND INSTALLATION TRANSFER CASE SKID PLATEFRONT SKID PLATE REMOVAL (1) Support skid plate.REMOVAL (2) Remove bolts that attach skid plate to trans- (1) Remove the screws that attach skid plate to mission support crossmember and frame sill (Fig. 2).side sills. (3) Remove support and skid plate from vehicle. (2) Remove the nuts that attach the skid plate tothe crossmember (Fig. 1). (3) Remove the skid plate from the vehicle. Fig. 2 Transfer Case Skid Plate INSTALLATION (1) Position and support skid plate at frame sill and transmission support crossmember. (2) Attach skid plate to frame sill and crossmem- ber with bolts. Tighten bolts to 260 N·m (192 ft. lbs.) torque. FUEL TANK SKID PLATE Fig. 1 Front Skid PlateINSTALLATION REMOVAL (1) Position the skid plate at front crossmember (1) Position a support under skid plate.and side sills. (2) Remove bolts that attach skid plate to under- (2) Install the nuts to attach the skid plate to body side rails (Fig. 3).crossmember. (3) Remove support and skid plate from vehicle. (3) Install the screws to attach skid plate to side INSTALLATIONsills. (1) Position and support skid plate under fuel tank.
  • 6. FUEL BLIND PLATE TANK RIVET SKID RIVET HOLES REINFORCEMENT13 - 6 FRAME AND BUMPERS XJREMOVAL AND INSTALLATION (Continued) TRAILER HITCH BLIND RIVET RIVET HOLES REINFORCEMENT Fig. 3 Fuel Tank Skid Plate Fig. 4 Trailer Hitch Harness Connector (2) Install bolts to attach skid plate to underbodyrails. Tighten bolts to 74 N·m (55 ft. lbs.) torque. (3) Remove support from under skid plate.TRAILER HITCHREMOVAL (1) If necessary, remove the trailer tow wire har-ness connector from the hitch (Fig. 4). (2) Support the hitch. (3) Remove the bolts that attach the trailer hitchto the frame sills and reinforcement brackets (Fig. 5). (4) If equipped, remove the fuel tank skid plate.NOTE: The reinforcement brackets are held on theframe sills with two blind rivets. Fig. 5 Trailer HitchINSTALLATION (4) Loosely install the bolts to attach the trailer (1) Install frame reinforcement brackets, if hitch (and the skid plate) to frame sills and reinforce-removed. Slide the brackets through the vehicle rear ment brackets.sill openings and attach to the frame sills with blind (5) Tighten all bolts/nuts to 74 N·m (55 ft. lbs.)rivets. torque. (2) Using an adequate lifting device, position hitch (6) Remove the lift/support.at the proper location for installation on vehicle and (7) If removed, attach the trailer wire harness con-support it. nector to the hitch. (3) If equipped, position fuel tank skid plate onvehicle frame sills.
  • 7. XJ FRAME AND BUMPERS 13 - 7SPECIFICATIONSVEHICLE DIMENSIONSWINDSHIELD OPENING • A. & B. Center of radius at bottom to center ofradius at tp
  • 8. 13 - 8 FRAME AND BUMPERS XJSPECIFICATIONS (Continued)FRONT DOOR OPENING 2–DOOR • A. Center of front door lower rear radius to cen-ter of A-pillar radius • B. Center of radius at bottom rear to center ofradius at lower A-pillar • C. Center of radius at bottom front to center ofradius at top rear
  • 9. XJ FRAME AND BUMPERS 13 - 9SPECIFICATIONS (Continued)FRONT DOOR OPENING 4–DOOR • C. Center of front door lower rear radius to cen-ter of A-pillar radius • E. Center of radius at bottom rear to center ofradius at lower A-pillar • F. Center of radius at bottom front to center ofradius at top rear
  • 10. 13 - 10 FRAME AND BUMPERS XJSPECIFICATIONS (Continued)REAR DOOR OPENING • A. Quarter panel to front outer body side upperand lower seam • B. Center of front upper door radius to center ofrear lower door radius • C. Center of front lower door radius to center ofrear upper door radius • D. Rear door hinge mount to rear door strikermount
  • 11. XJ FRAME AND BUMPERS 13 - 11SPECIFICATIONS (Continued)QUARTER WINDOW OPENING 2–DOOR • A. Center of upper and lower rear quarter win-dow opening • B. Center of radius front lower corner to centerof radius rear upper corner • C. Center of radius front upper corner to centerof radius rear lower corner
  • 12. 13 - 12 FRAME AND BUMPERS XJSPECIFICATIONS (Continued)QUARTER WINDOW OPENING 4–DOOR • A. Center of upper and lower rear quarter win-dow opening • B. Center of radius front lower corner to centerof radius rear upper corner • C. Center of radius front upper corner to centerof radius rear lower corner
  • 13. C/LXJ FRAME AND BUMPERS 13 - 13SPECIFICATIONS (Continued)ENGINE COMPARTMENT
  • 14. 13 - 14 FRAME AND BUMPERS XJSPECIFICATIONS (Continued)LIFTGATE OPENING • A. Center of upper liftgate opening to liftgatestriker mount • B. & C. Center of radius upper corner to centerof radius lower corner • D. Distance between outer quarter panel to taillamp mounting panel to inner quarter panel seamsFRAME DIMENSIONS Frame dimensions are listed in millimeter scale.All dimensions are from center to center of PrincipalLocating Point (PLP), or from center to center of PLPand fastener location (Fig. 6).
  • 15. (L.H. ONLY) FRAME DIMENSIONS SHOWN INONLY) (L.H. MILLIMETERS (REF.) (REINF.) (L.H. ONLY) (L.H. ONLY)XJ FRAME AND BUMPERS 13 - 15SPECIFICATIONS (Continued) Fig. 6 Frame Alignment Reference Dimensions
  • 16. 13 - 16 FRAME AND BUMPERS XJSPECIFICATIONS (Continued)FRAME TORQUE SPECIFICATIONSDESCRIPTION TORQUEFront Skid Plate Screw . . . . . . . . 42 N·m (31 ft. lbs.)Front Skid Plate Nut . . . . . . . . 17 N·m (150 in. lbs.)Transfer Case Skid Plate Bolt . . . . . . . . . . . . . . 260 N·m (192 ft. lbs.)Fuel Tank Skid Plate Bolt . . . . . 74 N·m (55 ft. lbs.)Front Bumper End Cap to Mounting Bracket Nut . . . . . . . . 9 N·m (7 ft. lbs.)Front Bumper Mounting Bracket to Frame Bolt . . . . . . . . . . . . . . . 55 N·m (41 ft. lbs.)Front Bumper to Mounting Bracket Bolt . . . . . . . . . . . . . . . . . . . . . 55 N·m (41 ft. lbs.)Front Tow Hook Nut . . . . . . . . . 100 N·m (74 ft. lbs.)Front Tow Hook Reinforcement Nut . . . . . . . . . 30 N·m (22 ft. lbs.)Rear Bumper to Mtg. Bracket Bolt . . . . . . . . . . . . . . 55N·m (41 ft. lbs.)Rear Bumper Mtg. Bracket to Rear Sill Bolt . . . . . . . . . . . . . 55 N·m (41 ft. lbs.)Rear Tow Hook Bolt . . . . . . . . . . 94 N·m (70 ft. lbs.)Trailer Tow Reinforcement Brkt Bolt . . . . . . . . . . . . . . . . . . . . . 74 N·m (55 ft. lbs.)Trailer Tow Plate Bracket Nut . . 52 N·m (40 ft. lbs.)
  • 17. XJ FRAME AND BUMPERS 13 - 1 FRAME AND BUMPERS CONTENTS pageFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FRAME INDEX pageGENERAL INFORMATION EMERGENCY TOW EYES . . . . . . . . . . . . . . . . . 1GENERAL INFORMATIONEMERGENCY TOW EYES If your vehicle is equipped with emergency toweyes, one is mounted in the front and one in the rear. The front tow eye has two holes, the front hole isfor towing use only and the rear angled hole is forshipping use only.CAUTION: Do not use the angled hole for towing.You could damage your vehicle.WARNING: Stand clear of vehicles when pullingwith tow eyes. Tow straps and chains may break,causing serious injury.CAUTION: Tow eyes are for emergency use only, torescue a vehicle stranded off road. Do not use toweyes for tow truck hookup or highway towing. Youcould damage your vehicle. Fig. 1 Emergency Tow Eyes