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XJ                                                                                                                             BODY        23 - 1



                                                                    BODY
                                                                CONTENTS

                                                                  page                                                                       page

BODY COMPONENT SERVICE . . . . . . . . . . . . . 16                         SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL SERVICE INFORMATION . . . . . . . . . . 1                           STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . 4
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2



                                     GENERAL SERVICE INFORMATION

GENERAL INFORMATION                                                           Do not use harsh alkaline based cleaning sol-
                                                                            vents on painted or upholstered surfaces. Damage
SAFETY PRECAUTIONS AND WARNINGS                                             to finish or color can result.
                                                                              Do not hammer or pound on plastic trim panel
WARNING: EYE PROTECTION SHOULD BE USED                                      when servicing interior trim. Plastic panels can
WHEN SERVICING GLASS COMPONENTS. PER-                                       break.
SONAL INJURY CAN RESULT.
  USE A OSHA APPROVED BREATHING FILTER                                         Chrysler Corporation uses many different types of
WHEN SPRAYING PAINT OR SOLVENTS IN A CON-                                   push-in fasteners to secure the interior and exterior
FINED AREA. PERSONAL INJURY CAN RESULT.                                     trim to the body. Most of these fasteners can be
  AVOID PROLONGED SKIN CONTACT WITH                                         reused to assemble the trim during various repair
PETROLEUM OR ALCOHOL– BASED CLEANING                                        procedures. At times, a push-in fastener cannot be
SOLVENTS. PERSONAL INJURY CAN RESULT.                                       removed without damaging the fastener or the com-
  DO NOT STAND UNDER A HOISTED VEHICLE                                      ponent it is holding. If it is not possible to remove a
THAT IS NOT PROPERLY SUPPORTED ON SAFETY                                    fastener without damaging a component or body, cut
STANDS. PERSONAL INJURY CAN RESULT.                                         or break the fastener and use a new one when
                                                                            installing the component. Never pry or pound on a
                                                                            plastic or pressed-board trim component. Using a
CAUTION: When holes must be drilled or punched                              suitable fork-type prying device, pry the fastener
in an inner body panel, verify depth of space to the                        from the retaining hole behind the component being
outer body panel, electrical wiring, or other compo-                        removed. When installing, verify fastener alignment
nents. Damage to vehicle can result.                                        with the retaining hole by hand. Push directly on or
  Do not weld exterior panels unless combustible                            over the fastener until it seats. Apply a low-force pull
material on the interior of vehicle is removed from                         to the panel to verify that it is secure.
the repair area. Fire or hazardous conditions, can                             When it is necessary to remove components to ser-
result.                                                                     vice another, it should not be necessary to apply
  Always have a fire extinguisher ready for use                             excessive force or bend a component to remove it.
when welding.                                                               Before damaging a trim component, verify hidden
  Disconnect the negative (-) cable clamp from the                          fasteners or captured edges holding the component in
battery when servicing electrical components that                           place.
are live when the ignition is OFF. Damage to electri-
cal system can result.
  Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
23 - 2      BODY                                                                                                           XJ


                                                               PAINT

                                                                 INDEX
                                                             page                                                        page

GENERAL INFORMATION                                                    WET SANDING, BUFFING, AND POLISHING . . . 2
 BASE COAT/CLEAR COAT FINISH . . . . . . . . . . . 2                  SPECIFICATIONS
 PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2    AFTERMARKET PAINT REPAIR PRODUCTS . . . 3
 PAINTED SURFACE TOUCH-UP . . . . . . . . . . . . 2


GENERAL INFORMATION                                                   PAINTED SURFACE TOUCH-UP
                                                                        When a painted metal surface has been scratched
PAINT CODE                                                            or chipped, it should be touched-up as soon as possi-
  Exterior vehicle body colors are identified on the                  ble to avoid corrosion. For best results, use Mopar௡
Body Code plate. The plate is located on the left side                Scratch Filler/Primer, Touch-Up Paints and Clear Top
of the dash panel in the engine compartment. Refer                    Coat. Refer to Introduction group of this manual for
to the Introduction section at the front of this man-                 Body Code Plate information.
ual for body code plate description. The paint code is
also identified on the Vehicle Safety Certification                   TOUCH-UP PROCEDURE
Label which is located on the drivers door shut face.                    (1) Scrape loose paint and corrosion from inside
The color names provided in the Paint and Trim                        scratch or chip.
Code Description chart are the color names used on                       (2) Clean affected area with Mopar௡ Tar/Road Oil
most repair product containers.                                       Remover, and allow to dry.
                                                                         (3) Fill the inside of the scratch or chip with a coat
BASE COAT/CLEAR COAT FINISH                                           of filler/primer. Do not overlap primer onto good sur-
  On most vehicles a two-part paint application (base                 face finish. The applicator brush should be wet
coat/clear coat) is used. Color paint that is applied to              enough to puddle-fill the defect without running. Do
primer is called base coat. The clear coat protects the               not stroke brush applicator on body surface. Allow
base coat from ultraviolet light and provides a dura-                 the filler/primer to dry hard.
ble high-gloss finish.                                                   (4) Cover the filler/primer with color touch-up
                                                                      paint. Do not overlap touch-up color onto the original
WET SANDING, BUFFING, AND POLISHING                                   color coat around the scratch or chip. Butt the new
  Minor acid etching, orange peel, or smudging in                     color to the original color, if possible. Do not stroke
clear coat or single-stage finishes can be reduced                    applicator brush on body surface. Allow touch-up
with light wet sanding, hand buffing, and polishing.                  paint to dry hard.
If the finish has been wet sanded in the past, it                        (5) On vehicles without clear coat, the touch-up
cannot be repeated. Wet sanding operation                             color can be lightly wet sanded (1500 grit) and pol-
should be performed by a trained automotive                           ished with rubbing compound.
paint technician.                                                        (6) On vehicles with clear coat, apply clear top coat
                                                                      to touch-up paint with the same technique as
CAUTION: Do not remove clear coat finish, if                          described in Step 4. Allow clear top coat to dry hard.
equipped. Base coat paint must retain clear coat for                  If desired, Step 5 can be performed on clear top coat.
durability.
XJ                                                                                      BODY     23 - 3


SPECIFICATIONS
AFTERMARKET PAINT REPAIR PRODUCTS
EXTERIOR COLOR

                        CHRY                                            S-W ACME      AKZO/NOBEL
 EXTERIOR COLOR                    PPG          BASF       DuPONT
                       CODE *                                              M-S         SIKKENS
Flame Red                PR4       4679         23043       B9326         46916        CHA93:PR4
Clear Coat
Magenta Clear Coat       SH1      74171         26079       B9615         51522        CHA96:SH1
Citron Pearl Coat        SJV      47694         26081       B9672         51524        CHA96:SJV
Moss Green               RJN      47383         25036       B9533         50277        CHA95:RJN
Pearl Coat
Bright Jade             SQP       47586         26088       B9636         51533        CHA96:SQP
Satin Glow
Lapis Blue               RC4       4935         24098       B9531         50218        CHA95:RC4
Clear Coat
Dark Blue                PCJ       4783         24072       B9453         48543        CHA94:PCJ
Pearl Coat
Black Clear Coat         DX8       9700         15214         99          34858        CHA85:DX8
Gunmetal Pearl Coat      TQ7       5248         27035       B9735         52952        CHA97:TQ7
Stone White             SW1       83542         26089       B9622         51539        CHA96:SW1
Clear Coat

CLADDING COLOR

     CLADDING            CHRY                                           S-W ACME      AKZO/NOBEL
                                     PPG           BASF     DuPONT
      COLOR             CODE *                                             M-S         SIKKENS
Flame Red                PR4         4679          23043     B9326         46916       CHA93:PR4
Moss Green               RJN         47383         25036     B9533         50277       CHA95:RJN
Dark Blue                PCJ         4783          24072     B9453         48543       CHA94:PCJ
Pear Coat
Gunmetal                 TQ7         5248          27035     B9735         52952        CHA:TQ7
Pearl Coat
Black                    DX8         9700          15214      F0204        34858       CHA85:DX8
Stone White              SW1         83542         26089     B9622         51539       CHA96:SW1

*Herberts Standox and Spies Hecker use the Chrysler paint code as listed on the Body Code Plate and the
Vehicle Safety Certification label.
INTERIOR COLOR

     INTERIOR                                                                             S-W ACME
                      CHRY CODE              PPG               BASF         DuPONT
      COLOR                                                                                  M-S
Mist Gray                C3               35799/2-1576         25065          C9507         50508
Saddle                   T6               27917/2-1594         26121          C9604         51542
23 - 4     BODY                                                                                                                   XJ


                                             STATIONARY GLASS

                                                             INDEX
                                                         page                                                                   page

DESCRIPTION AND OPERATION                                            REAR DOOR STATIONARY WINDOW GLASS . . 7
 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 4            REAR QUARTER WINDOW GLASS . . . . . . . . . . 8
REMOVAL AND INSTALLATION                                             WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
 LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . . . . . 8

DESCRIPTION AND OPERATION                                         structural support for the roof. The urethane bonding
                                                                  used to secure the windshield to the fence is difficult
SAFETY PRECAUTIONS                                                to cut or clean from any surface. The moldings are
                                                                  set in urethane, and will be damaged during the
WARNING: DO NOT OPERATE THE VEHICLE                               removal process. Before removing the windshield,
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.                       check the availability of the windshield and moldings
IT TAKES AT LEAST 24 HOURS FOR URETHANE                           from the parts supplier.
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.                                                      REMOVAL AND INSTALLATION
  URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-                           WINDSHIELD
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND                          The windshield is positioned in the reveal molding
PINCHWELD (FENCE) PRIMER PROVIDED BY THE                          and is bonded to the windshield frame with urethane
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL                         adhesive.
INTEGRITY COULD BE COMPROMISED.                                     Depending on the circumstances, either one of two
  USE ONLY ADHESIVES, PRIMERS AND CLEAN-                          windshield glass installation methods can be used:
ERS THAT MEET OR EXCEED THE FMVSS 212                               • The short method.
WINDSHIELD RETENTION STANDARD AND THE                               • The extended method.
FMVSS 216 ROOF CRUSH STANDARD.                                      The short method is used when the windshield
  BE SURE TO REFER TO THE URETHANE MANU-                          glass is removed intact, and the body opening and
FACTURER’S DIRECTIONS FOR CURING TIME                             the pinchweld flanges do not require repair.
SPECIFICATIONS, AND DO NOT USE ADHESIVE                             The extended method must be used when the body
AFTER ITS EXPIRATION DATE.                                        opening or a flange is damaged. The extended
  VAPORS THAT ARE EMITTED FROM THE URE-                           method must also be used when urethane no longer
THANE ADHESIVE OR PRIMER COULD CAUSE                              adheres to either the windshield glass or the pinch-
PERSONAL INJURY. USE THEM IN A WELL-VENTI-                        weld flanges.
LATED AREA.
                                                                  REMOVAL
  SKIN CONTACT WITH URETHANE ADHESIVE
                                                                    (1) Cover the interior and exterior body surface
SHOULD BE AVOIDED. PERSONAL INJURY MAY
                                                                  areas with a protective covering.
RESULT.
                                                                    (2) Remove the windshield wiper arms and the
  ALWAYS WEAR EYE AND HAND PROTECTION
                                                                  rearview mirror.
WHEN WORKING WITH GLASS.
                                                                    (3) Using a razor knife, slide the blade between
                                                                  the windshield glass and the inboard edge of the
CAUTION: Protect all painted and trimmed surfaces                 reveal molding.
from coming in contact with urethane or primers.                    (4) Cut around the interior perimeter of the reveal
  Be careful not to damage painted surfaces when                  molding and sever the cap of the reveal molding.
removing moldings or cutting urethane around                        (5) Using a cold knife, cut the urethane around the
windshield.                                                       perimeter of the windshield (Fig. 1).
                                                                    (6) Remove the windshield glass from the frame.
  It is difficult to salvage a windshield during the
removal operation. The windshield is part of the
COLD KNIFE                   WINDSHIELD



XJ                                                                                            BODY      23 - 5
REMOVAL AND INSTALLATION (Continued)
                                                        by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
                                                        allel 75 cm (2.5 ft.) apart (Fig. 2).

                                                        CAUTION: Avoid spilling or dripping primer on
                                                        painted surfaces. Clean spills or drips immediately.
                                                        The primer will damage the paint if it remains on
                                                        the surface for any length of time.

                                                          (10) If the replacement windshield glass does not
                                                        have blackout primer:
                                                          • Attach a 25 mm (1 in) wide masking tape band
                                                        around the interior side of the glass 16 mm (5/8 in)
                                                        from the edge of the glass (Fig. 3).
                                                          • Do not attach tape along the bottom of the glass
                                                        and attach it only to the inside of the glass.
                                                          • Clean the 16-mm (5/8-in) wide surface area
                                                        around the glass with isopropyl alcohol.
Fig. 1 Cutting Urethane Around Windshield—Typical         • Thoroughly mix and apply glass blackout primer
INSTALLATION—SHORT METHOD                               to the 16 mm (5/8 in) surface area around the inte-
  (1) Trim the urethane from the pinchweld flanges.     rior side of the glass (Fig. 4).
Leave a 3 mm (0.1 in.) level base of urethane on the      • Allow the primer to dry for at least 10-12 min-
pinchweld flanges.                                      utes.
                                                          (11) Apply a small amount of adhesive to the bot-
WARNING:   DO NOT USE SOLVENT BASED GLASS               tom support spacers and attach the support spacers
CLEANER     TO CLEAN WINDSHIELD BEFORE                  to the bottom of the windshield, 170 mm inboard
APPLYING   GLASS PREP AND PRIMER. POOR                  from the outer windshield edge (Fig. 5).
ADHESION   CAN RESULT.                                    (12) Cut the urethane adhesive applicator nozzle
                                                        (Fig. 6).
  (2) Clean inside of windshield with ammonia based
glass cleaner and lint-free cloth.                      CAUTION: Be prepared to install the glass immedi-
  (3) Prime outer perimeter of interior side of glass   ately after applying the adhesive, as the adhesive
16 mm (5/8 inch) from edge. Use a wipe-off type ure-    will begin to cure in less than 10 minutes.
thane primer and wipe glass dry after primer appli-
cation.                                                   (13) Apply a continuous, 6-mm (1/4-in) diameter
                                                        bead of urethane adhesive to the surface area.
NOTE: The reveal molding has an adhesive applied          (14) Align the glass with the reference marks and
to the windshield contact surface to help secure the    position the glass on the pinchweld flanges. Ensure
molding to the windshield during the installation       that the windshield glass is correctly seated on the
procedure.                                              support spacers.
                                                          (15) Force the windshield glass inward just enough
  (4) Apply the molding to the windshield:              to wet-out and set the urethane. Use care to avoid
  • With the molding at room temperature, press         excessive squeeze-out of adhesive.
the molding onto the windshield corners.                  (16) Water test the windshield with a water spray
  • From corner to corner, work the molding to the      after installation. Do not direct high pressure
center of each side. (Some stretching of the molding    streams of water directly at urethane. If any leaks
may be required during this procedure.)                 are detected, apply urethane as necessary.
  (5) Place the glass on the pinchweld flanges and        (17) If used, remove the masking tape from the
inspect for gaps in the urethane. Gaps in excess of 3   inner surface of the glass.
mm (1/8 inch) must be filled with urethane.               (18) Install all components and clean the vehicle.
  (6) Adjust windshield glass position until it is        (19) Open the vehicle windows to prevent interior
aligned with the flanges and adhesive.                  pressure while the urethane is curing. If not
  (7) Using a grease pencil or equivalent, make         vented, pressure in the interior of the vehicle
alignment marks on the glass and body.                  may interfere with proper glass bonding.
  (8) Remove replacement windshield from wind-            (20) Install the rearview mirror.
shield opening.
  (9) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
WINDSHIELD TAPE
              AND   MOLD- MASKING OFOFINCH
                     POSITION PRIMER TO GLASS
                     INGS
                       APPLY EDGE WIDE BLACKOUT PRIMER CATOR
                         FROM TAPE TAPE
                         1-INCH AREA GLASS
                                    5/8   THIS  BLOCKS APPLI-       COWL SUPPORT
                                                                    MOLDING   SPACER CUTSUPPORTSHAPE SHAPE
                                                                              FOR EXTENDED PROCE-
                                                                              CUT NOZZLE NOZZLE SPACERS
                                                                                       FORWINDSHIELD
                                                                                          THIS DURE
                                                                                           SHORT THIS
                                                                                                 PROCEDURE



23 - 6     BODY                                                                                                 XJ
REMOVAL AND INSTALLATION (Continued)




                Fig. 2 Work Surface Set up


                                                                    Fig. 5 Windshield Bottom Support Spacers




 Fig. 3 Masking Tape Location For Blackout Primer




                                                                        Fig. 6 Applicator Nozzle Preparation
                                                                INSTALLATION—EXTENDED METHOD
                                                                   (1) Remove the all of urethane from all pinchweld
                                                                flanges.
                                                                   (2) Inspect and repair the windshield opening and
                                                                pinchweld flanges.
                                                                   (3) Prime the pinchweld flanges with a urethane
                                                                base primer. However, if the flange is color-coated
                                                                with paint, prime the flanges with a paint finish
                                                                primer. This is important because urethane
                                                                adhesive will not adhere to all color-coat
                                                                paints. Allow primer sufficient time to dry.

                                                                NOTE: The reveal molding has an adhesive applied
                                                                to the windshield contact surface to help secure the
                                                                molding to the windshield during the installation
                                                                procedure.
           Fig. 4 Blackout Primer Application
                                                                  (4) Apply the reveal molding to the windshield:
DIVISION BAR
                                                                   UPPER SCREW                      GLASS SCREW
                                                                                                     LOWER



XJ                                                                                              BODY      23 - 7
REMOVAL AND INSTALLATION (Continued)
   • With the molding at room temperature, press             (14) Water test the windshield with a water spray
the molding onto the windshield corners.                  after installation. Do not direct high pressure
   • From corner to corner, work the molding to the       streams of water directly at the urethane. If any
center of each side. (Some stretching of the molding      leaks are detected, apply urethane as necessary.
may be required during this procedure).                      (15) If used, remove the masking tape from the
   (5) Install and inspect the fit of the windshield on   inner surface of glass.
the pinchweld flanges as follows:                            (16) Install all components and clean the vehicle.
   • Position windshield until it is aligned within       If necessary, refer to the installation procedures.
windshield opening.                                          (17) Open the vehicle windows to prevent interior
   • Measure the gap between the pinchweld flanges        pressure while the urethane adhesive is curing. If
and glass around perimeter of the glass and flange.       not vented, pressure in the interior of vehicle
   • The reveal molding should equally cover the          will interfere with glass bonding.
A-Pillars on both sides.                                     (18) Install the rearview mirror on the bracket.
   • The flanges should also extend above the glass
edge equally around the perimeter of the opening.         REAR DOOR STATIONARY WINDOW GLASS
   (6) If the pinchweld flanges require repair, remove
the windshield glass and straighten, align, or repair     REMOVAL
the flange(s) as necessary.                                  The rear door stationary window glass is bonded to
   (7) Position the windshield in the opening and         the division bar and is serviced as an assembly.
inspect the windshield fit again. Mark the windshield        (1) Lower the window glass.
final position on the glass and body with a wax pen-         (2) Remove the inner and outer beltline weather-
cil (or use masking tape). The marks (or masking          strip.
tape) will be used for installation alignment refer-         (3) Remove the trim panel and waterdam from
ence.                                                     door inner panel.
   (8) If the replacement windshield does not have           (4) Remove the screws attaching the division bar/
blackout primer:                                          glass to the door (Fig. 7).
   • Attach a 25-mm (1-in) wide masking tape band            (5) Tilt the division bar/glass forward and remove
around the interior side of glass 16 mm (5/8 in) from     it from the door.
edge of glass (Fig. 3).
   • Do not attach tape along the bottom of the glass
and attach only to the inside of glass.
   • Thoroughly mix and apply blackout primer to
the 16 mm (5/8 in) surface area around the interior
side of the glass (Fig. 4).
   • Allow the primer to dry for at least 10-12 min-
utes.
   (9) Apply a small amount of adhesive to the bot-
tom support spacers and attach the support spacers
to the bottom of the windshield, 170 mm inboard
from the outer windshield edge (Fig. 5).
   (10) Cut the urethane applicator nozzle (Fig. 6).
   (11) Apply a continuous bead of urethane to the
surface area with blackout primer on the interior
side of glass. The bead should be 9-mm (3/8-in) wide
by 12.7-mm (1/2-in) deep for best results.                         Fig. 7 Division Bar/Stationary Glass
CAUTION: Be prepared to install the glass immedi-         INSTALLATION
ately after applying the adhesive, as the adhesive          (1) Position the division bar/glass in the door.
will begin to cure in less than 10 minutes.                 (2) Install the screws attaching the division bar/
                                                          glass to the door. Finger tighten the screws.
  (12) Align the windshield with the wax pencil             (3) Tighten the upper screw to 6 N·m (5 ft-lbs)
installation alignment reference marks (or the tape       torque.
strips). Position the windshield on pinchweld flanges       (4) Tighten the lower screw to 6 N·m (5 ft-lbs)
and spacers.                                              torque.
  (13) Force the windshield inward just enough to           (5) Install the beltline weatherstrip.
wet-out and set the urethane. Use care to avoid             (6) Install the door waterdam and trim panel.
excessive squeeze-out of adhesive.
WEATHERSTRIP
         SEAL        REVEAL MOUL-
                             DING           FRT GLASS     QUARTER CORD
                                                          INSTALLATION GLASS
                                                                 WINDOW INSTALLATION CORD
                                                                     WINDOW
                                                                      W/VENTWEATHERSTRIP INSTALLATIONENDWEATHERSTRIP SEAL
                                                                                    SEAL       CORD          WINDOW SEAL
                                                                                                              WEATHER-
                                                                                                                STRIP
                                                                                                                  GLASS



23 - 8     BODY                                                                                                         XJ
REMOVAL AND INSTALLATION (Continued)
REAR QUARTER WINDOW GLASS                                    (7) Pull on each end of the cord to pull the weath-
                                                          erstrip seal channel lip over the window opening
REMOVAL                                                   flanges.
  (1) If equipped, remove the quarter window reveal          (8) Test the vent window for water leaks.
molding (Fig. 8).                                            (9) Install the interior trim cover.
  (2) Remove the quarter window interior trim cov-           (10) If equipped, install the quarter window reveal
ers.                                                      molding.
  (3) Separate the weatherstrip seal lip from the
window opening flanges. Use a pry tool and carefully
push the window glass and seal outward.
  (4) Remove the weatherstrip seal and window
glass from window opening.
  (5) Remove the weatherstrip seal from the window
glass.




                                                             Fig. 9 Weatherstrip Seal and Cord Installation




 Fig. 8 Quarter Window Reveal Molding, Glass and
                       Seal
INSTALLATION
  (1) Clean the original sealant from the weather-
strip channels and window opening flanges.
  (2) Apply a 4-mm (1/6-in) diameter bead of sealant
to the window channel in the weatherstrip seal.
  (3) Install the weatherstrip on the window glass.
Install the seal installation cord in the window open-
ing flange channel (Fig. 9) as follows:                              Fig. 10 Quarter Window With Vent
  • Moisten a length of 6-mm (1/4-in) diameter cord
with a soap and water solution.
                                                          LIFTGATE GLASS
  • Ensure that the cord is long enough to go all the     REMOVAL
way around the perimeter of the weatherstrip.               (1) Open liftgate.
  • Insert the cord into the window opening flange          (2) Remove liftgate trim panel.
channel in the weatherstrip seal.                           (3) Disconnect heated backlite (HBL) connector.
  (4) Apply a 6-mm (1/4-in) diameter bead of sealant        (4) Remove wiper arm.
to the window opening flanges.                              (5) Remove CHMSL lens.
  (5) For two-door vehicles, apply a 3-mm (1/8-in)          (6) Using a razor knife, slide the blade between
diameter bead of sealant at the quarter panel appli-      the liftgate glass and the inboard edge of the reveal
que and liftgate pillar seam.                             molding.
  (6) Position the quarter window glass and the             (7) Cut around the interior perimeter of the reveal
weatherstrip seal in the window opening (Fig. 10)         molding and severe the cap of the reveal molding.
with the free ends of the cord inside the vehicle (Fig.
11).
(POSITIONWEATHERSTRIP
      1/4-INCH DIAMETER CORD
          STRIP GLASS WEATHER-
                  IN CHANNEL)



XJ                                                                                             BODY      23 - 9
REMOVAL AND INSTALLATION (Continued)
                                                           (4) Verify the glass lays evenly against the fence at
                                                         the sides, top and bottom. If not, the flange must be
                                                         formed to the shape of the new glass.
                                                           (5) Using a grease pencil or equivalent, make ref-
                                                         erences marks on the glass and body.
                                                           (6) Remove replacement glass from liftgate open-
                                                         ing.
                                                           (7) Position the glass inside up on a suitable work
                                                         surface.

                                                         WARNING:    DO NOT USE SOLVENT BASED GLASS
                                                         CLEANER      TO CLEAN WINDSHIELD BEFORE
                                                         APPLYING    GLASS PREP AND PRIMER. POOR
                                                         ADHESION    CAN RESULT.

                                                           (8) Clean inside of glass with Mopar Glass Cleaner
                                                         and lint-free cloth.
                                                           (9) Apply PVC (vinyl) primer 25 mm (1 in.) wide
                                                         around edge of glass. Wipe with clean/dry lint-free
                                                         cloth.
                                                           (10) If necessary, apply fence primer around edge
                                                         of fence. Allow at least eighteen minutes drying time.
Fig. 11 Quarter Window Glass and Seal Installation         (11) Apply a 10 mm (0.4 in.) bead of urethane
                                                         around glass border.
  (8) Using a cold knife, cut urethane bonding from        (12) Position glass into liftgate opening and refer-
around liftgate glass. A pneumatic cutting device can    ence marks.
be used if available.                                      (13) Push the glass inward until the reveal mold-
  (9) Separate glass from Liftgate.                      ing is seated onto the liftgate frame. Use care to
                                                         avoid excessive squeeze-out of adhesive.
INSTALLATION
                                                           (14) Open windows to prevent pressure build-up
CAUTION: Open a window before installing glass.          while the urethane is curing.
This will avoid pressurizing the passenger compart-        (15) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
ment. If a door or liftgate is slammed before ure-       masking tape spaced 250 mm (10 in.) apart to hold
thane is cured, water leaks can result.                  glass in place until urethane cures.
                                                           (16) Install the wiper arm.
  (1) Trim the urethane from the liftgate glass open-      (17) Install CHMSL lens.
ing flanges. Leave a 3 mm (0.1 in.) level base of ure-     (18) Connect heated backlite (HBL) connector.
thane on the flanges.                                      (19) After urethane has cured, remove tape strips
  (2) Starting in the corners, press reveal molding      and water test to verify repair.
onto glass.                                                (20) Install liftgate trim panel.
  (3) Place replacement glass into liftgate opening
and position glass in the center of the opening
against flange.
EXTRACTOR6773
                                                                      EXTRACTOR
                                                                       TOOL 6773
                                                                         TOOL                    HEAD RESTRAINT
                                                                                                   RESTRAINT
                                                                                                   HEAD SLEEVE
                                                                                                         SLEEVE      SEAT BACK FWD
                                                                                                                             FWD BACK
                                                                                                                              SEAT



23 - 10     BODY                                                                                                                    XJ


                                                           SEATS

                                                           INDEX
                                                       page                                                                        page

REMOVAL AND INSTALLATION                                         HEAD RESTRAINT SLEEVE . . . . . . . . . .                   . . . . . 10
 BUCKET SEAT CUSHION COVER . . . . . . . . . .             13    REAR SEAT CUSHION COVER . . . . . . .                       . . . . . 13
 BUCKET SEAT PLATFORM . . . . . . . . . . . . . . .        12    REAR SEATBACK COVER . . . . . . . . . . .                   . . . . . 14
 BUCKET SEAT RECLINER . . . . . . . . . . . . . . . .      13    REAR SEATBACK LATCH STRIKER AND
 BUCKET SEAT TRACK . . . . . . . . . . . . . . . . . . .   11      BUMPER . . . . . . . . . . . . . . . . . . . . . . .      . . . . . 14
 BUCKET SEATBACK COVER . . . . . . . . . . . . . .         12   SPECIAL TOOLS
 BUCKET SEATBACK . . . . . . . . . . . . . . . . . . . .   12    SEATS . . . . . . . . . . . . . . . . . . . . . . . . . .   . . . . . 15
 HEAD RESTRAINT COVER . . . . . . . . . . . . . . .        10

REMOVAL AND INSTALLATION
HEAD RESTRAINT SLEEVE
REMOVAL

NOTE: When replacing a head restraint sleeve, the
retaining tabs on the sleeve will be damaged during
the removal process. Check the availability of
replacement parts before servicing.

  (1) Raise head restraint to the full up position.
  (2) Turn head restraint lock thumbwheel to release
head restraint and pull head restraint upward to
remove from seat back.
  (3) Insert head restraint sleeve extractor (special
tool 6773) (Fig. 1) and (Fig. 2) into the seat back.                     Fig. 1 Head Restraint Sleeve Extractor
  (4) The retaining tabs are positioned on each side
of the sleeve, when inserting the extractor, ensure
that the flat of the collar is facing the side of the
seatback (Fig. 3).
  (5) Using a small hammer, tap extractor down-
ward to release sleeve retaining tab.
  (6) Remove extractor tool from sleeve, rotate tool
180 degrees (Fig. 4) and repeat steps 3 and 4.
  (7) Remove extractor tool from sleeve and remove
sleeve from seat back.

INSTALLATION
  (1) Position the sleeve in the seat back.
  (2) Firmly, push sleeve down to snap into place.
  (3) Install head restraint.

HEAD RESTRAINT COVER
                                                                 Fig. 2 Head Restraint Sleeve Extractor Installation
REMOVAL
                                                                  (3) Pull the adjuster bar from the head restraint.
  (1) Remove head restraint from the bucket seat.
                                                                  (4) Roll the cover upward and separate from the
  (2) Remove the screws attaching the bezel and
                                                                head restraint cushion (Fig. 6).
adjuster bar to the head restraint (Fig. 5).
EXTRACTOR
 LOCK RELEASE
  THUMBWHEEL
   TOOL 6773     EXTRACTOR RELEASEBACK BACK
                    TOOL 6773 SEAT SEAT
                     LOCK
                        THUMBWHEEL             FWD        HEAD RESTRAINT CUSHION               HEAD RESTRAINT COVER
                                                                                                      HEAD RESTRAINT
                                                                                                        ADJUSTER BAR
                                                                                                              BEZEL



XJ                                                                                              BODY       23 - 11
REMOVAL AND INSTALLATION (Continued)




 Fig. 3 Head Restraint Sleeve Extractor Positioning




                                                                            Fig. 5 Head Restraint




 Fig. 4 Head Restraint Sleeve Extractor Positioning
INSTALLATION
  (1) Position the cover on the head restraint cush-
ion and roll the cover downward.
  (2) Position the adjuster bar in the head restraint.
  (3) Install the screws attaching the bezel and
adjuster bar to the head restraint.                                     Fig. 6 Head Restraint Cover
  (4) Install head restraint in the bucket seat.           (4) Remove the nuts attaching the seat track to
                                                         the bucket seat platform.
BUCKET SEAT TRACK                                          (5) When separating the seat track from the plat-
                                                         form, route the power seat switch connector through
REMOVAL                                                  the access hole in the seat cushion frame, if
                                                         equipped.
NOTE: If the vehicle is equipped with manually
adjusted bucket seats, the inboard or outboard seat      INSTALLATION
track may be serviced separately.                          (1) While positioning the seat track on the bucket
                                                         seat platform, route the power seat switch connector
  (1) Remove bucket seat from vehicle.                   through the access hole in the seat cushion frame, if
  (2) Remove screws attaching the side shield trim       equipped.
cover from the seat.                                       (2) Install the nuts attaching the seat track to the
  (3) If equipped, disengage the power seat connec-      bucket seat platform.
tor from the power seat switch.                            (3) If equipped, engage the power seat connector to
                                                         the power seat switch.
SEAT BACK COVER
                                           SEAT   CUSHION
                                                     BACK   SEAT BACKFAS-
                                                            LOOP
                                                            HOOK SEAT CUSH- CUSHION
                                                            SEAT   TENER
                                                                    COVER
                                                                     BACK
                                                                     AND
                                                                      BACK
                                                                        ION            HOG RING           SUPPORT



23 - 12    BODY                                                                                              XJ
REMOVAL AND INSTALLATION (Continued)
  (4) Install screws attaching the side shield trim
cover to the seat.
  (5) Install bucket seat.

BUCKET SEAT PLATFORM
  Bucket seat platforms are not repairable. If the
seat platform is damaged, replace platform as a unit.

BUCKET SEATBACK COVER
REMOVAL
  (1) Remove head restraint, if equipped.
  (2) Remove screws attaching side shield trim cover
to bucket seat.
  (3) If equipped, disengage power seat wire connec-
tor from power seat switch.
  (4) Remove the inboard seatback pivot bolt.                                         Fig. 8 Hog Ring
  (5) Position the seatback in the full forward or full
recline position.
  (6) Remove the seatback cover zipper from the
base of the seatback.
  (7) Disengage the cover zipper and route the zip-
per end between the inboard seatback and seat cush-
ion frame.
  (8) Roll the seatback cover upward (Fig. 7).
  (9) Disengage the hogrings attaching the seatback
cover to the seatback cushion support wires (Fig. 8).
  (10) Roll the seatback cover upward and disengage
the hook and loop fastener (Fig. 9).
  (11) Roll seatback cover up and over the head
restraint sleeves, if equipped and separate from the
seatback.


                                                                         Fig. 9 Hook And Loop Fastener
                                                              (3) Continue rolling the cover downward and
                                                            engage the hogrings attaching the seatback cover to
                                                            the seatback cushion support wires.
                                                              (4) Route the zipper end between the inboard seat-
                                                            back and seat cushion frame and engage the cover
                                                            zipper.
                                                              (5) Install the inboard seatback pivot bolt.
                                                              (6) Install the side shield trim cover.
                                                              (7) Install head restraint, if equipped.

                                                            BUCKET SEATBACK
                                                            REMOVAL
                                                              (1) Remove side shield trim cover.
               Fig. 7 Seatback Cover                          (2) Remove inboard seatback pivot bolt.
INSTALLATION                                                  (3) Remove bolts attaching recliner to seat cushion
  (1) Position the seatback cover on the seatback           frame (Fig. 10).
cushion and roll seatback cover down over the head            (4) Separate seatback from vehicle.
restraint sleeves. Route the sleeves through the
access holes in the cover, if equipped.                     INSTALLATION
  (2) Roll the seatback cover downward and engage             (1) Position seatback on seat cushion frame.
the hook and loop fastener.                                   (2) Install inboard seatback pivot bolt.
SEAT BACK RING
      RECLINEREAT CUSHION
      SEAT CUSHION
             COVER
             S
             HOG                           SEAT CUSHION           RECLINER                   SEATCUSHION
                                                                                                 REMOVE
                                                                                                    BACK
                                                                                                    RECLINERCUSHION
                                                                                                       SEAT    HAN-
                                                                                                                DLE



XJ                                                                                             BODY       23 - 13
REMOVAL AND INSTALLATION (Continued)
                                                            (3) With the cushion side down, engage the for-
                                                          ward, rearward and inboard J-straps.
                                                            (4) Engage the clips attaching the outboard side of
                                                          the cover to the cushion frame.
                                                            (5) Install seatback.
                                                            (6) Install side shield trim cover.
                                                            (7) Install seat.

                                                          BUCKET SEAT RECLINER
                                                          REMOVAL
                                                            (1) Remove side shield trim cover.
                                                            (2) Disengage seatback cover zipper.
                                                            (3) Roll outer seatback cover upward.
                                                            (4) Remove bolts attaching recliner to seatback
                Fig. 10 Bucket Seatback                   and seat cushion frames (Fig. 12).
  (3) Install bolts attaching recliner to seat cushion      (5) Separate recliner from seat.
frame.
  (4) Install side shield trim cover.

BUCKET SEAT CUSHION COVER
REMOVAL
  (1) Remove seat from vehicle.
  (2) Remove side shield trim cover.
  (3) Remove seatback.
  (4) With the cushion side down, disengage the for-
ward, rearward and inboard J-straps.
  (5) Disengage the clips attaching the outboard side
of the cover to the cushion frame.
  (6) Turn the cushion over and roll the cover off the
cushion.
  (7) Remove the hog rings attaching the cover to
the cushion support wires (Fig. 11).                                  Fig. 12 Bucket Seat Recliner
  (8) Separate the cover from the cushion.
                                                          INSTALLATION
                                                            (1) Position recliner on seat.
                                                            (2) Install bolts attaching recliner to seatback and
                                                          seat cushion frames (Fig. 12).
                                                            (3) Roll seatback cover downward.
                                                            (4) Engage seatback cover zipper.
                                                            (5) Install side shield trim cover.

                                                          REAR SEAT CUSHION COVER
                                                          REMOVAL
                                                             (1) Remove the seat cushion from the vehicle.
                                                             (2) Remove the cover side, front and rear retaining
                                                          clips from the wire retainers with an appropriate
                                                          removal tool (Fig. 13).
                                                             (3) Remove the serrated retainers from the front
                                                          ends of the cover with a trim panel removal tool (Fig.
       Fig. 11 Seat Cushion Cover Hog Rings               14).
INSTALLATION                                                 (4) Remove the seat cover from the cushion.
  (1) Position the cover on the cushion.
                                                          INSTALLATION
  (2) Install the hog rings attaching the cover to the
                                                            (1) Position the replacement cover on the cushion.
cushion support wires.
SEAT REMOVER TOOL SEAT COVER
                      COVER              CLIPS   REMOVEROOL
                                                 CLIP  T        REAR   WHEEL- FWD
                                                                       HOUSE        STRIKER
                                                                                    LATCH SCREW
                                                                                     TORX-HEAD
                                                                                        BRACKET   SEATBACK
                                                                                                    BRACKET
                                                                                                         STRIKER   SEATBACK
                                                                                                                   BUMPER
                                                                                                                     LATCH
                                                                                                                      BUMPER
                                                                                                                      STRIKER
                                                                                                                        LATCH
                                                                                                                   LATCH
                                                                                                                   STRIKER
                                                                                                                    BRACKET

23 - 14    BODY                                                                                                         XJ
REMOVAL AND INSTALLATION (Continued)
                                                                (3) Release the seatback latch from the striker.
                                                                (4) Tilt the seatback forward for access to the
                                                              striker bracket.
                                                                (5) Remove the retaining screws and the latch
                                                              striker bracket from the trim panel (Fig. 15).




Fig. 13 Seat Cushion Cover Retaining Clip Removal



                                                                Fig. 15 Seatback Latch Striker Bracket Removal/
                                                                                  Installation
                                                              INSTALLATION
                                                                 (1) Position the latch striker bracket on the trim
                                                              panel and install the retaining screws. Tighten the
                                                              screws with 6 N·m (50 in. lbs.) torque.
                                                                 (2) Engage the seatback latch with the striker.
                                                                 (3) Pivot the seat cushion to the horizontal posi-
                                                              tion and lock it in-place by pressing firmly on the
                                                              center of the cushion until the latch engages.

                                                              REAR SEATBACK COVER
                                                              REMOVAL
                                                                (1) Remove the seatback from the vehicle.
                                                                (2) Remove the seatback latch release handle and
                                                              bezel from the seatback.
Fig. 14 Seat Cushion Cover Retaining Clip Removal               (3) Disengage the cover zippers.
   (2) Compress the cover and attach the retaining              (4) Disengage the J-strap attaching the cover to
clips to the front and rear wire retainers.                   the seat back frame (Fig. 16).
   (3) Install the serrated retainers at the ends of the        (5) Remove the cover from the seatback pad.
cover.
   (4) Install the seat cushion in the vehicle. If neces-
sary, refer to the installation procedure.

REAR SEATBACK LATCH STRIKER AND BUMPER
REMOVAL
  (1) Disengage the seat cushion at the rear by pull-
ing upward on the release strap.
  (2) Tilt the seat cushion forward.
COVER ZIPPER        SEAT BACK



XJ                                                                                         BODY        23 - 15
REMOVAL AND INSTALLATION (Continued)
                                                         (3) Engage the cover zippers.
                                                         (4) Install the seat latch release bezel and handle.
                                                         (5) Install the seatback in the vehicle.


                                                        SPECIAL TOOLS
                                                        SEATS




                                                                Extractor Head Restraint Sleeve 6773
          Fig. 16 Seatback Cover Removal
INSTALLATION
  (1) Install the cover on the seatback.
  (2) Attach the cover J-strap to the seatback frame.
23 - 16       BODY                                                                                                                                    XJ


                                         BODY COMPONENT SERVICE

                                                                     INDEX
                                                                 page                                                                             page

DIAGNOSIS AND TESTING                                                        FULL FLOOR CONSOLE . . . . . . . . . . . . . . .                 .   .   51
  WATER LEAKS . . . . . . . . . . . . . . . . . . . . . . .      . 17        GRILLE OPENING PANEL (GOP) . . . . . . . . .                     .   .   19
  WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . .   . 18        GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .   .   .   19
SERVICE PROCEDURES                                                           HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . .      .   .   54
  BODY LUBRICATION . . . . . . . . . . . . . . . . . . .         . 18        HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . .         .   .   19
REMOVAL AND INSTALLATION                                                     HOOD LATCH . . . . . . . . . . . . . . . . . . . . . . .         .   .   21
  A-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . .    .   44      HOOD LATCH STRIKER . . . . . . . . . . . . . . . .               .   .   21
  AIR EXHAUST GRILLE . . . . . . . . . . . . . . . . . .         .   44      HOOD RELEASE CABLE . . . . . . . . . . . . . . .                 .   .   21
  ASSIST HANDLE . . . . . . . . . . . . . . . . . . . . . .      .   45      HOOD SAFETY LATCH . . . . . . . . . . . . . . . .                .   .   22
  B-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . .    .   46      HOOD SILENCER PAD . . . . . . . . . . . . . . . .                .   .   22
  BODY DECALS . . . . . . . . . . . . . . . . . . . . . . .      .   23      HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   .   .   19
  BODY SIDE MOLDING . . . . . . . . . . . . . . . . . .          .   42      LEFT FRONT FENDER . . . . . . . . . . . . . . . .                .   .   26
  BUCKET SEAT . . . . . . . . . . . . . . . . . . . . . . . .    .   50      LIFTGATE HINGE . . . . . . . . . . . . . . . . . . . . .         .   .   56
  C-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . .    .   46      LIFTGATE LATCH STRIKER . . . . . . . . . . . . .                 .   .   57
  COWL GRILLE . . . . . . . . . . . . . . . . . . . . . . . .    .   23      LIFTGATE LATCH . . . . . . . . . . . . . . . . . . . .           .   .   57
  COWL WEATHERSTRIP . . . . . . . . . . . . . . . . .            .   23      LIFTGATE LOCK CYLINDER . . . . . . . . . . . .                   .   .   57
  DOOR SILL SCUFF PLATE . . . . . . . . . . . . . .              .   45      LIFTGATE OPENING UPPER TRIM . . . . . . .                        .   .   48
  DRIP RAIL MOLDING . . . . . . . . . . . . . . . . . . .        .   43      LIFTGATE OUTSIDE HANDLE . . . . . . . . . . .                    .   .   57
  EXTERIOR NAMEPLATES . . . . . . . . . . . . . . .              .   24      LIFTGATE PILLAR TRIM . . . . . . . . . . . . . . .               .   .   47
  FRONT CARPET/MAT . . . . . . . . . . . . . . . . . .           .   52      LIFTGATE SCUFF PLATE . . . . . . . . . . . . . . .               .   .   48
  FRONT DOOR GLASS EXTERIOR MOLDING                              .   34      LIFTGATE SUPPORT ROD BALL STUD . . . .                           .   .   56
  FRONT DOOR GLASS RUN CHANNEL                                               LIFTGATE SUPPORT ROD CYLINDER . . . . .                          .   .   56
    WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . .       .   33      LIFTGATE TRIM PANEL . . . . . . . . . . . . . . . .              .   .   55
  FRONT DOOR GLASS . . . . . . . . . . . . . . . . . .           .   36      LIFTGATE WEATHERSTRIP . . . . . . . . . . . . .                  .   .   58
  FRONT DOOR HINGE PIN . . . . . . . . . . . . . . .             .   29      LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . .     .   .   55
  FRONT DOOR HINGE . . . . . . . . . . . . . . . . . .           .   30      LOWER A-PILLAR COWL TRIM . . . . . . . . . .                     .   .   44
  FRONT DOOR INNER BELT WEATHERSTRIP                             .   32      LUGGAGE RACK . . . . . . . . . . . . . . . . . . . . .           .   .   43
  FRONT DOOR INSIDE HANDLE ACTUATOR .                            .   32      QUARTER PANEL TRIM AND WHEELHOUSE
  FRONT DOOR LATCH STRIKER . . . . . . . . . .                   .   32        COVER . . . . . . . . . . . . . . . . . . . . . . . . . . .    .   .   47
  FRONT DOOR LATCH . . . . . . . . . . . . . . . . . .           .   31      QUARTER PANEL TRIM EXTENSION . . . . .                           .   .   47
  FRONT DOOR LOCK CYLINDER . . . . . . . . . .                   .   31      QUARTER WINDOW APPLIQUE . . . . . . . . .                        .   .   43
  FRONT DOOR LOWER WEATHERSTRIP . . . .                          .   34      REAR CARPET/MAT . . . . . . . . . . . . . . . . . .              .   .   52
  FRONT DOOR OPENING SECONDARY                                               REAR DOOR GLASS EXTERIOR MOLDING                                 .   .   40
    WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . .    . 33           REAR DOOR GLASS RUN CHANNEL
  FRONT DOOR OPENING WEATHERSTRIP . .                         . 33             WEATHERSTRIP . . . . . . . . . . . . . . . . . . . .           .   .   40
  FRONT DOOR OUTER BELT WEATHERSTRIP                           ...           REAR DOOR HINGE PIN . . . . . . . . . . . . . . .                .   .   38
                                                              32             REAR DOOR HINGE . . . . . . . . . . . . . . . . . .              .   .   38
  FRONT DOOR OUTSIDE HANDLE . . . . . . . . . . 31                           REAR DOOR INNER BELT WEATHERSTRIP                                .   .   40
  FRONT DOOR RESTRAINT . . . . . . . . . . . . . . . 30                      REAR DOOR INSIDE HANDLE ACTUATOR .                               .   .   39
  FRONT DOOR SPACER BLOCKS—TWO-DOOR                                          REAR DOOR LATCH STRIKER . . . . . . . . . .                      .   .   39
   VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . 35           REAR DOOR LATCH . . . . . . . . . . . . . . . . . .              .   .   39
  FRONT DOOR TRIM PANEL . . . . . . . . . . . . . . 27                       REAR DOOR OUTER BELT WEATHERSTRIP                                    .   40
  FRONT DOOR WATERDAM . . . . . . . . . . . . . . . 29                       REAR DOOR OUTSIDE HANDLE . . . . . . . . .                       .   .   38
  FRONT DOOR WINDOW REGULATOR . . . . . . 34                                 REAR DOOR RESTRAINT . . . . . . . . . . . . . .                  .   .   38
  FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 29            REAR DOOR TRIM PANEL . . . . . . . . . . . . . .                 .   .   36
  FRONT FENDER FLARE . . . . . . . . . . . . . . . . . 25                    REAR DOOR WATERDAM . . . . . . . . . . . . . .                   .   .   37
  FRONT INNER SCUFF PLATE . . . . . . . . . . . . . 44                       REAR DOOR WEATHERSTRIP . . . . . . . . . .                       .   .   40
  FRONT SHOULDER BELT/BUCKLE . . . . . . . . . 48                            REAR DOOR WINDOW GLASS . . . . . . . . . .                       .   .   41
  FRONT WHEELHOUSE LINER . . . . . . . . . . . . . 26                        REAR DOOR WINDOW REGULATOR . . . . .                             .   .   41
XJ                                                                                                                                      BODY                        23 - 17


 REAR DOOR . . . . . . . . . . . . . . . . . . . . . .   .   .   .   .   37   ADJUSTMENTS
 REAR FENDER FLARE . . . . . . . . . . . . . .           .   .   .   .   42    DOOR LATCH ADJUSTMENT                    .   .   .   .   .   .   .   .   .   .   .   .   .   .   59
 REAR SEAT CUSHION . . . . . . . . . . . . . . .         .   .   .   .   51    DOOR . . . . . . . . . . . . . . . . .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   58
 REAR SEATBACK . . . . . . . . . . . . . . . . . .       .   .   .   .   52    HOOD . . . . . . . . . . . . . . . . .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   58
 REAR SHOULDER/LAP BELT/BUCKLE . .                       .   .   .   .   49    LIFTGATE . . . . . . . . . . . . . .     .   .   .   .   .   .   .   .   .   .   .   .   .   .   59
 REARVIEW MIRROR SUPPORT BRACKET                             .   .   .   53   SPECIFICATIONS
 REARVIEW MIRROR . . . . . . . . . . . . . . . .         .   .   .   .   53    BODY LUBRICANTS . . . . . .              . . . . . . . . . . . . . . 60
 RIGHT FRONT FENDER . . . . . . . . . . . . .            .   .   .   .   26    TORQUE SPECIFICATIONS .                  . . . . . . . . . . . . . . 60
 SAFETY LATCH STRIKER . . . . . . . . . . . .            .   .   .   .   22   SPECIAL TOOLS
 SIDE VIEW MIRROR . . . . . . . . . . . . . . . .        .   .   .   .   25    BODY . . . . . . . . . . . . . . . . .   . . . . . . . . . . . . . . 60
 SUNVISORS . . . . . . . . . . . . . . . . . . . . . .   .   .   .   .   53

DIAGNOSIS AND TESTING                                                           • If a leak occurs while driving at highway speeds
                                                                              in a steady rain, test the leak area with a reasonable
WATER LEAKS                                                                   velocity stream or fan spray of water. Direct the
   Water leaks can be caused by poor sealing,                                 spray in a direction comparable to actual conditions.
improper body component alignment, body seam                                    • If a leak occurs when the vehicle is parked on an
porosity, missing plugs, or blocked drain holes. Cen-                         incline, hoist the end or side of the vehicle to simu-
trifugal and gravitational force can cause water to                           late this condition. This method can be used when
drip from a location away from the actual leak point,                         the leak occurs when the vehicle accelerates, stops or
making leak detection difficult. All body sealing                             turns. If the leak occurs on acceleration, hoist the
points should be water tight in normal wet-driving                            front of the vehicle. If the leak occurs when braking,
conditions. Water flowing downward from the front of                          hoist the back of the vehicle. If the leak occurs on left
the vehicle should not enter the passenger or luggage                         turns, hoist the left side of the vehicle. If the leak
compartment. Moving sealing surfaces will not                                 occurs on right turns, hoist the right side of the vehi-
always seal water tight under all conditions. At                              cle. For hoisting recommendations refer to Group 0,
times, side glass or door seals will allow water to                           Lubrication and Maintenance, General Information
enter the passenger compartment during high pres-                             section.
sure washing or hard driving rain (severe) condi-
tions.   Overcompensating       on    door   or    glass                      WATER LEAK DETECTION
adjustments to stop a water leak that occurs under                              To detect a water leak point-of-entry, do a water
severe conditions can cause premature seal wear and                           test and watch for water tracks or droplets forming
excessive closing or latching effort. After completing                        on the inside of the vehicle. If necessary, remove inte-
a repair, water-test vehicle to verify leak has stopped                       rior trim covers or panels to gain visual access to the
before returning vehicle to use.                                              leak area. If the hose cannot be positioned without
                                                                              being held, have someone help do the water test.
VISUAL INSPECTION BEFORE WATER LEAK                                             Some water leaks must be tested for a considerable
TESTS                                                                         length of time to become apparent. When a leak
  Verify that floor and body plugs are in place, body                         appears, find the highest point of the water track or
drains are clear, and body components are properly                            drop. The highest point usually will show the point of
aligned and sealed. If component alignment or seal-                           entry. After leak point has been found, repair the
ing is necessary, refer to the appropriate section of                         leak and water test to verify that the leak has
this group for proper procedures.                                             stopped.
                                                                                Locating the entry point of water that is leaking
WATER LEAK TESTS                                                              into a cavity between panels can be difficult. The
                                                                              trapped water may splash or run from the cavity,
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS                                      often at a distance from the entry point. Most water
OR TOOLS IN WATER TEST AREA. PERSONAL                                         leaks of this type become apparent after accelerating,
INJURY CAN RESULT.                                                            stopping, turning, or when on an incline.
  When the conditions causing a water leak have                               MIRROR INSPECTION METHOD
been determined, simulate the conditions as closely                             When a leak point area is visually obstructed, use
as possible.                                                                  a suitable mirror to gain visual access. A mirror can
  • If a leak occurs with the vehicle parked in a                             also be used to deflect light to a limited-access area
steady light rain, flood the leak area with an open-                          to assist in locating a leak point.
ended garden hose.
23 - 18    BODY                                                                                                  XJ
DIAGNOSIS AND TESTING (Continued)
BRIGHT LIGHT LEAK TEST METHOD                               ROAD TESTING WIND NOISE
  Some water leaks in the luggage compartment can             (1) Drive the vehicle to verify the general location
be detected without water testing. Position the vehi-       of the wind noise.
cle in a brightly lit area. From inside the darkened          (2) Apply 50 mm (2 in.) masking tape in 150 mm
luggage compartment inspect around seals and body           (6 in.) lengths along weatherstrips, weld seams or
seams. If necessary, have a helper direct a drop light      moldings. After each length is applied, drive the vehi-
over the suspected leak areas around the luggage            cle. If noise goes away after a piece of tape is applied,
compartment. If light is visible through a normally         remove tape, locate, and repair defect.
sealed location, water could enter through the open-
ing.                                                        POSSIBLE CAUSE OF WIND NOISE
                                                               • Moldings standing away from body surface can
PRESSURIZED LEAK TEST METHOD                                catch wind and whistle.
   When a water leak into the passenger compart-               • Gaps in sealed areas behind overhanging body
ment cannot be detected by water testing, pressurize        flanges can cause wind-rushing sounds.
the passenger compartment and soap test exterior of            • Misaligned movable components.
the vehicle. To pressurize the passenger compart-              • Missing or improperly installed plugs in pillars.
ment, close all doors and windows, start engine, and           • Weld burn through holes.
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.           SERVICE PROCEDURES
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the          BODY LUBRICATION
vehicle. Apply detergent solution with spray device or        All mechanisms and linkages should be lubricated
soft bristle brush. If soap bubbles occur at a body         when necessary. This will maintain ease of operation
seam, joint, seal or gasket, the leak entry point could     and provide protection against rust and excessive
be at that location.                                        wear. The weatherstrip seals should be lubricated to
                                                            prolong their life as well as to improve door sealing.
WIND NOISE                                                    All applicable exterior and interior vehicle operat-
  Wind noise is the result of most air leaks. Air leaks     ing mechanisms should be inspected and cleaned.
can be caused by poor sealing, improper body compo-         Pivot/sliding contact areas on the mechanisms should
nent alignment, body seam porosity, or missing plugs        then be lubricated.
in the engine compartment or door hinge pillar areas.         (1) When necessary, lubricate the operating mech-
All body sealing points should be airtight in normal        anisms with the specified lubricants.
driving conditions. Moving sealing surfaces will not          (2) Apply silicone lubricant to a cloth and wipe it
always seal airtight under all conditions. At times,        on door seals to avoid over-spray that can soil pas-
side glass or door seals will allow wind noise to be        senger’s clothing.
noticed in the passenger compartment during high              (3) Before applying lubricant, the component
crosswinds. Over compensating on door or glass              should be wiped clean. After lubrication, any excess
adjustments to stop wind noise that occurs under            lubricant should be removed.
severe conditions can cause premature seal wear and           (4) The hood latch, latch release mechanism, latch
excessive closing or latching effort. After a repair pro-   striker, and safety latch should be lubricated period-
cedure has been performed, test vehicle to verify           ically.
noise has stopped before returning vehicle to use.            (5) The door lock cylinders should be lubricated
  Wind noise can also be caused by improperly fitted        twice each year (preferably autumn and spring):
exterior moldings or body ornamentation. Loose                • Spray a small amount of lock cylinder lubricant
moldings can flutter, creating a buzzing or chattering      directly into the lock cylinder.
noise. An open cavity or protruding edge can create a         • Apply a small amount to the key and insert it
whistling or howling noise. Inspect the exterior of the     into the lock cylinder.
vehicle to verify that these conditions do not exist.         • Rotate it to the locked position and then back to
                                                            the unlocked position several times.
VISUAL INSPECTION BEFORE TESTS                                • Remove the key. Wipe the lubricant from it with
  Verify that floor and body plugs are in place and         a clean cloth to avoid soiling of clothing.
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
GRILLE OPENING PANEL     NUT       GRILLE                   FWD
                                                                          BODY                GRILLE BRACKET
                                                                                                  SUPPORT
                                                                                                      OPENING
                                                                                                        PANEL



XJ                                                                                          BODY      23 - 19


REMOVAL AND INSTALLATION
GRILLE
REMOVAL
  (1) Remove the headlamp/park lamp bezels.
  (2) Remove the screws attaching the grille to the
grille opening panel (GOP) (Fig. 1).
  (3) Separate the grille from the GOP.




                                                                    Fig. 2 Grille Opening Panel
                                                          (5) Install nuts attaching GOP to front fenders.
                                                        Tighten nuts to 4 N·m (38 in-lbs) torque.
                                                          (6) Install headlamps and park/turn signal lamps.
                                                          (7) Install headlamp bezels.
                                                          (8) Install side marker lamps.
                                                          (9) Install grille.
                                                          (10) Adjust headlamp aim, if necessary.

                     Fig. 1 Grille                      HOOD
INSTALLATION
                                                        REMOVAL
  (1) Position the grille in the GOP.
                                                          (1) Raise hood.
  (2) Install the screws.
                                                          (2) Disconnect underhood lamp wire harness con-
  (3) Install the headlamp/park lamp bezels.
                                                        nector, if equipped.
                                                          (3) Disconnect release cable from latch release
GRILLE OPENING PANEL (GOP)
                                                        bellcrank.
REMOVAL                                                   (4) Remove latch release cable clips and remove
  (1) Remove grille.                                    cable from hood (Fig. 3).
  (2) Remove headlamp bezels.                             (5) Mark location of hood, hinges and hinge shims
  (3) Remove side marker lamps.                         for installation.
  (4) Remove headlamps and park/turn signal               (6) Remove bolts that attach hinges to hood.
lamps.                                                    (7) Remove hood from vehicle with aid of a helper.
  (5) Open hood.
                                                        INSTALLATION
  (6) Remove nuts that attach GOP to front fenders
                                                           (1) Position hood on shims and hinges; finger-
(Fig. 2).
                                                        tighten hinge bolts.
  (7) Remove nuts attaching GOP to support
                                                           (2) Align hinges and shims with reference marks
bracket.
                                                        and tighten hinge bolts.
  (8) Pull GOP forward and disconnect harness clips
                                                           (3) Connect latch release cable and latch connect-
and front lamp harness connectors.
                                                        ing rod to bellcrank.
  (9) Remove GOP from vehicle.
                                                           (4) Attach latch release cable to clips.
INSTALLATION                                               (5) Connect underhood lamp wire harness connec-
   (1) Place GOP on bumper and secure all harness       tor.
clips.
   (2) Connect all lamp wire harness connectors.        HOOD HINGE
   (3) Position GOP on vehicle.
                                                        REMOVAL
   (4) Install nuts attaching GOP to support bracket.
                                                         (1) Raise and support hood.
Tighten nuts to 4 N·m (38 in-lbs) torque.
FWD 1. LATCH
        13.
        12. SPRING
        11. SHIM
        10. SHOULDER
        9. STRIKER
        8. GROMMET
        7. CABLE
        6. ROD
        5. BELLCRANK BOLT
        4. CLIP
        3. CATCH
        2. BUMPER                                    FWD



23 - 20    BODY                                            XJ
REMOVAL AND INSTALLATION (Continued)




                            Fig. 3 Hood Components
DASH PANEL
            NUT HOOD              HINGE      HINGE SEAL
                                                   BASE          HOOD LATCH
                                                                      ROD SPRING
                                                                          HOOD          LATCH   CONNECTING
                                                                                                      RODRETAINER CLIP



XJ                                                                                              BODY        23 - 21
REMOVAL AND INSTALLATION (Continued)
   (2) Using a grease pencil or equivalent, mark posi-
tion of hood.
   (3) Remove seal from hinge base (Fig. 4).
   (4) Remove hinge retaining nuts from studs.




                                                                            Fig. 5 Hood Latch
                                                            (4) Remove the headlamp with mounting bucket
                                                          attached from the adjusting screws.
                                                            (5) Remove the upper bolt attaching the striker to
             Fig. 4 Hood Hinge and Seal                   the top of the (GOP).
INSTALLATION                                                (6) Remove the lower bolt attaching the striker to
  (1) Position hinge over studs and align with refer-     the (GOP).
ence marks.                                                 (7) Remove the striker and shims.
  (2) Install nuts.
                                                          INSTALLATION
NOTE: If a replacement hinge seal is being                  (1) Position the shims and striker on the (GOP)
installed, position it around hinge arm, force it         and install the bolts.
against hinge base.                                         (2) Install the headlamp and mounting bucket.
                                                            (3) Install parklamp.
  (3) Position hinge seal around hinge arm and on           (4) Install the headlamp bezel.
hinge base.                                                 (5) Test the striker/hood alignment by opening and
  (4) Adjust hood as necessary.                           closing the hood several times. Adjust the striker, if
                                                          necessary.
HOOD LATCH
                                                          HOOD RELEASE CABLE
REMOVAL
  (1) Remove the screw that attaches the latch to         REMOVAL
the hood inner panel (Fig. 5).                              (1) Drill out bellcrank to hood rivet heads and
  (2) Disconnect the latch connecting rod.                remove rivets (Fig. 6).
  (3) Remove the latch from the hood.                       (2) Disconnect bellcrank from latch rod and hood
                                                          release cable. Remove bellcrank from hood.
INSTALLATION                                                (3) Disconnect hood release cable from clips on
  (1) Connect the latch to the latch connecting rod       hood.
and                                                         (4) Remove left cowl side trim panel.
  (2) Position the latch on the hood inner panel.           (5) Remove cable bracket screws from cowl side
  (3) Install the screw that attaches the latch to the    panel.
hood inner panel.                                           (6) Route cable through dash panel and remove it
                                                          from under instrument panel.
HOOD LATCH STRIKER
                                                          INSTALLATION
REMOVAL                                                     (1) Insert replacement cable end through hole in
 (1) Remove headlamp bezel.                               dash panel into engine compartment.
 (2) Remove parklamp.                                       (2) Route cable forward and seat grommet in dash
 (3) Release the spring attaching the headlamp            panel.
mounting bucket to the grille opening panel (GOP).
LATCH HOOD SAFETY LATCH
     NUT CONNECTING
                ROD        HOOD BUMPER
                            RIVET           HOOD INNER CABLE
                                                  RELEASE
                                                  LATCHSTUD
                                                   BELLCRANK
                                                       HOOD
                                                        PANEL     RADIATOR SUPPORT
                                                                  HOOD HOOD
                                                                       CROSSMEMBER
                                                                         RETAINERSAFETY STRIKER
                                                                                          LATCH               SILENCER PAD
                                                                                                                 RADIATOR
                                                                                                                  SCREW
                                                                                                                   BRACKET
                                                                                                                   GOP



23 - 22      BODY                                                                                                    XJ
REMOVAL AND INSTALLATION (Continued)
                                                                SAFETY LATCH STRIKER
                                                                REMOVAL
                                                                  (1) Remove striker screws from radiator support
                                                                crossmember (Fig. 8).
                                                                  (2) Remove striker from crossmember.




          Fig. 6 Hood Release Cable Bellcrank
  (3) Position cable bracket on cowl side panel and
install screws.
  (4) Install left cowl side trim panel.
  (5) Connect cable and latch rod to bellcrank.
  (6) Position bellcrank on hood and install rivets.
  (7) Attach cable to clips.                                               Fig. 8 Hood Safety Latch Striker
  (8) Test release cable for proper operation.                  INSTALLATION
                                                                  (1) Position striker on radiator support crossmem-
HOOD SAFETY LATCH                                               ber and install screws.
                                                                  (2) Test safety latch operation.
REMOVAL
  (1) Open and support hood.
                                                                HOOD SILENCER PAD
  (2) Remove the nuts attaching the safety latch to
the inner hood panel (Fig. 7).                                  REMOVAL
  (3) Separate the safety latch from the hood.                     (1) Open and support hood.
                                                                   (2) Remove the hood latch release bellcrank.
                                                                   (3) Remove the clips attaching the latch connect-
                                                                ing rod to the hood inner panel.
                                                                   (4) Remove the retainers attaching the hood
                                                                silencer pad to the inner hood panel (Fig. 9).
                                                                   (5) Separate the hood silencer pad from the hood.




                 Fig. 7 Hood Safety Latch
INSTALLATION
  (1) Position the safety latch on the hood.
  (2) Install the nuts attaching the safety latch to
the inner hood panel.
  (3) Close hood.
                                                                                Fig. 9 Hood Silencer Pad
WEATHERSTRIPCOWL
           DASH PANEL
                  SEAL
                    THICK-HEAD RETAINER   FLAT-HEAD RETAINER   COWL
                                                                  PLASTIC
                                                                   PANEL    PUSH-
                                                                            RIVET
                                                                             FWD    GRILLE NOZZLE SCREEN
                                                                                     SCREEN                RIVET      AND SCREW
                                                                                                                      GRILLE
                                                                                                                       NOZZLE
                                                                                                                        SCREEN
                                                                                                                         GRILLE
                                                                                                                   PLASTIC   PUSH-
                                                                                                                             RIVET


XJ                                                                                                     BODY           23 - 23
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
   (1) Position the hood silencer pad on the hood
inner panel.
   (2) Install the retainers attaching the hood
silencer pad to the inner hood panel.
   (3) Install the clips attaching the latch connecting
rod to the hood inner panel.
   (4) Install the hood latch release bellcrank.
   (5) Close hood.

COWL WEATHERSTRIP
REMOVAL
  (1) Pry upward along the length of weatherstrip.
  (2) Detach the weatherstrip retainers from the
cowl panel (Fig. 10).
  (3) Remove the weatherstrip from cowl panel.
                                                                   Fig. 11 Cowl Grille, Screen & Washer Nozzles
                                                                 (1) Position the cowl grille and screen on the cowl.
                                                                 (2) Install the windshield washer tubes on the noz-
                                                               zles.
                                                                 (3) Install the cowl screen and grille screws.
                                                               Tighten in sequence (Fig. 12).

                                                               NOTE: Force the cowl grille rearward while tighten-
                                                               ing the screws.

                                                                 (4) Install the windshield wiper arms on the piv-
                                                               ots.




                 Fig. 10 Cowl Weatherstrip
INSTALLATION
  (1) Position the weatherstrip on the cowl panel.
  (2) Press to insert retainers into the cowl panel
holes.

COWL GRILLE
REMOVAL
  (1) Remove the windshield wiper arms from            the
pivots.
  (2) Remove the screws that attach the grille to      the        Fig. 12 Cowl Grille Screw Tightening Sequence
cowl.
  (3) Remove the windshield washer tubes from          the     BODY DECALS
nozzles.                                                         Small nicks, scratches and other surface marks in
  (4) Remove the cowl grille and screen from           the     a decal can be touched-up with paint.
cowl (Fig. 11).                                                  To eliminate blisters and air bubbles in a decal,
                                                               pierce them with a needle or pin.
INSTALLATION                                                     A heat gun can also be used to remove small wrin-
                                                               kles in a decal.
CAUTION: The washer fluid tubes must be routed                   Decal replacement requires that the metal repair
and installed so that they are not pinched.                    and paint refinish be completed first.
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Exj 23

  • 1. XJ BODY 23 - 1 BODY CONTENTS page page BODY COMPONENT SERVICE . . . . . . . . . . . . . 16 SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 GENERAL SERVICE INFORMATION . . . . . . . . . . 1 STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . 4 PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL SERVICE INFORMATION GENERAL INFORMATION Do not use harsh alkaline based cleaning sol- vents on painted or upholstered surfaces. Damage SAFETY PRECAUTIONS AND WARNINGS to finish or color can result. Do not hammer or pound on plastic trim panel WARNING: EYE PROTECTION SHOULD BE USED when servicing interior trim. Plastic panels can WHEN SERVICING GLASS COMPONENTS. PER- break. SONAL INJURY CAN RESULT. USE A OSHA APPROVED BREATHING FILTER Chrysler Corporation uses many different types of WHEN SPRAYING PAINT OR SOLVENTS IN A CON- push-in fasteners to secure the interior and exterior FINED AREA. PERSONAL INJURY CAN RESULT. trim to the body. Most of these fasteners can be AVOID PROLONGED SKIN CONTACT WITH reused to assemble the trim during various repair PETROLEUM OR ALCOHOL– BASED CLEANING procedures. At times, a push-in fastener cannot be SOLVENTS. PERSONAL INJURY CAN RESULT. removed without damaging the fastener or the com- DO NOT STAND UNDER A HOISTED VEHICLE ponent it is holding. If it is not possible to remove a THAT IS NOT PROPERLY SUPPORTED ON SAFETY fastener without damaging a component or body, cut STANDS. PERSONAL INJURY CAN RESULT. or break the fastener and use a new one when installing the component. Never pry or pound on a plastic or pressed-board trim component. Using a CAUTION: When holes must be drilled or punched suitable fork-type prying device, pry the fastener in an inner body panel, verify depth of space to the from the retaining hole behind the component being outer body panel, electrical wiring, or other compo- removed. When installing, verify fastener alignment nents. Damage to vehicle can result. with the retaining hole by hand. Push directly on or Do not weld exterior panels unless combustible over the fastener until it seats. Apply a low-force pull material on the interior of vehicle is removed from to the panel to verify that it is secure. the repair area. Fire or hazardous conditions, can When it is necessary to remove components to ser- result. vice another, it should not be necessary to apply Always have a fire extinguisher ready for use excessive force or bend a component to remove it. when welding. Before damaging a trim component, verify hidden Disconnect the negative (-) cable clamp from the fasteners or captured edges holding the component in battery when servicing electrical components that place. are live when the ignition is OFF. Damage to electri- cal system can result. Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result.
  • 2. 23 - 2 BODY XJ PAINT INDEX page page GENERAL INFORMATION WET SANDING, BUFFING, AND POLISHING . . . 2 BASE COAT/CLEAR COAT FINISH . . . . . . . . . . . 2 SPECIFICATIONS PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 AFTERMARKET PAINT REPAIR PRODUCTS . . . 3 PAINTED SURFACE TOUCH-UP . . . . . . . . . . . . 2 GENERAL INFORMATION PAINTED SURFACE TOUCH-UP When a painted metal surface has been scratched PAINT CODE or chipped, it should be touched-up as soon as possi- Exterior vehicle body colors are identified on the ble to avoid corrosion. For best results, use Mopar௡ Body Code plate. The plate is located on the left side Scratch Filler/Primer, Touch-Up Paints and Clear Top of the dash panel in the engine compartment. Refer Coat. Refer to Introduction group of this manual for to the Introduction section at the front of this man- Body Code Plate information. ual for body code plate description. The paint code is also identified on the Vehicle Safety Certification TOUCH-UP PROCEDURE Label which is located on the drivers door shut face. (1) Scrape loose paint and corrosion from inside The color names provided in the Paint and Trim scratch or chip. Code Description chart are the color names used on (2) Clean affected area with Mopar௡ Tar/Road Oil most repair product containers. Remover, and allow to dry. (3) Fill the inside of the scratch or chip with a coat BASE COAT/CLEAR COAT FINISH of filler/primer. Do not overlap primer onto good sur- On most vehicles a two-part paint application (base face finish. The applicator brush should be wet coat/clear coat) is used. Color paint that is applied to enough to puddle-fill the defect without running. Do primer is called base coat. The clear coat protects the not stroke brush applicator on body surface. Allow base coat from ultraviolet light and provides a dura- the filler/primer to dry hard. ble high-gloss finish. (4) Cover the filler/primer with color touch-up paint. Do not overlap touch-up color onto the original WET SANDING, BUFFING, AND POLISHING color coat around the scratch or chip. Butt the new Minor acid etching, orange peel, or smudging in color to the original color, if possible. Do not stroke clear coat or single-stage finishes can be reduced applicator brush on body surface. Allow touch-up with light wet sanding, hand buffing, and polishing. paint to dry hard. If the finish has been wet sanded in the past, it (5) On vehicles without clear coat, the touch-up cannot be repeated. Wet sanding operation color can be lightly wet sanded (1500 grit) and pol- should be performed by a trained automotive ished with rubbing compound. paint technician. (6) On vehicles with clear coat, apply clear top coat to touch-up paint with the same technique as CAUTION: Do not remove clear coat finish, if described in Step 4. Allow clear top coat to dry hard. equipped. Base coat paint must retain clear coat for If desired, Step 5 can be performed on clear top coat. durability.
  • 3. XJ BODY 23 - 3 SPECIFICATIONS AFTERMARKET PAINT REPAIR PRODUCTS EXTERIOR COLOR CHRY S-W ACME AKZO/NOBEL EXTERIOR COLOR PPG BASF DuPONT CODE * M-S SIKKENS Flame Red PR4 4679 23043 B9326 46916 CHA93:PR4 Clear Coat Magenta Clear Coat SH1 74171 26079 B9615 51522 CHA96:SH1 Citron Pearl Coat SJV 47694 26081 B9672 51524 CHA96:SJV Moss Green RJN 47383 25036 B9533 50277 CHA95:RJN Pearl Coat Bright Jade SQP 47586 26088 B9636 51533 CHA96:SQP Satin Glow Lapis Blue RC4 4935 24098 B9531 50218 CHA95:RC4 Clear Coat Dark Blue PCJ 4783 24072 B9453 48543 CHA94:PCJ Pearl Coat Black Clear Coat DX8 9700 15214 99 34858 CHA85:DX8 Gunmetal Pearl Coat TQ7 5248 27035 B9735 52952 CHA97:TQ7 Stone White SW1 83542 26089 B9622 51539 CHA96:SW1 Clear Coat CLADDING COLOR CLADDING CHRY S-W ACME AKZO/NOBEL PPG BASF DuPONT COLOR CODE * M-S SIKKENS Flame Red PR4 4679 23043 B9326 46916 CHA93:PR4 Moss Green RJN 47383 25036 B9533 50277 CHA95:RJN Dark Blue PCJ 4783 24072 B9453 48543 CHA94:PCJ Pear Coat Gunmetal TQ7 5248 27035 B9735 52952 CHA:TQ7 Pearl Coat Black DX8 9700 15214 F0204 34858 CHA85:DX8 Stone White SW1 83542 26089 B9622 51539 CHA96:SW1 *Herberts Standox and Spies Hecker use the Chrysler paint code as listed on the Body Code Plate and the Vehicle Safety Certification label. INTERIOR COLOR INTERIOR S-W ACME CHRY CODE PPG BASF DuPONT COLOR M-S Mist Gray C3 35799/2-1576 25065 C9507 50508 Saddle T6 27917/2-1594 26121 C9604 51542
  • 4. 23 - 4 BODY XJ STATIONARY GLASS INDEX page page DESCRIPTION AND OPERATION REAR DOOR STATIONARY WINDOW GLASS . . 7 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 4 REAR QUARTER WINDOW GLASS . . . . . . . . . . 8 REMOVAL AND INSTALLATION WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . . . . . 8 DESCRIPTION AND OPERATION structural support for the roof. The urethane bonding used to secure the windshield to the fence is difficult SAFETY PRECAUTIONS to cut or clean from any surface. The moldings are set in urethane, and will be damaged during the WARNING: DO NOT OPERATE THE VEHICLE removal process. Before removing the windshield, WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. check the availability of the windshield and moldings IT TAKES AT LEAST 24 HOURS FOR URETHANE from the parts supplier. ADHESIVE TO CURE. IF IT IS NOT CURED, THE WINDSHIELD MAY NOT PERFORM PROPERLY IN AN ACCIDENT. REMOVAL AND INSTALLATION URETHANE ADHESIVES ARE APPLIED AS A SYS- TEM. USE GLASS CLEANER, GLASS PREP SOL- WINDSHIELD VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND The windshield is positioned in the reveal molding PINCHWELD (FENCE) PRIMER PROVIDED BY THE and is bonded to the windshield frame with urethane ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL adhesive. INTEGRITY COULD BE COMPROMISED. Depending on the circumstances, either one of two USE ONLY ADHESIVES, PRIMERS AND CLEAN- windshield glass installation methods can be used: ERS THAT MEET OR EXCEED THE FMVSS 212 • The short method. WINDSHIELD RETENTION STANDARD AND THE • The extended method. FMVSS 216 ROOF CRUSH STANDARD. The short method is used when the windshield BE SURE TO REFER TO THE URETHANE MANU- glass is removed intact, and the body opening and FACTURER’S DIRECTIONS FOR CURING TIME the pinchweld flanges do not require repair. SPECIFICATIONS, AND DO NOT USE ADHESIVE The extended method must be used when the body AFTER ITS EXPIRATION DATE. opening or a flange is damaged. The extended VAPORS THAT ARE EMITTED FROM THE URE- method must also be used when urethane no longer THANE ADHESIVE OR PRIMER COULD CAUSE adheres to either the windshield glass or the pinch- PERSONAL INJURY. USE THEM IN A WELL-VENTI- weld flanges. LATED AREA. REMOVAL SKIN CONTACT WITH URETHANE ADHESIVE (1) Cover the interior and exterior body surface SHOULD BE AVOIDED. PERSONAL INJURY MAY areas with a protective covering. RESULT. (2) Remove the windshield wiper arms and the ALWAYS WEAR EYE AND HAND PROTECTION rearview mirror. WHEN WORKING WITH GLASS. (3) Using a razor knife, slide the blade between the windshield glass and the inboard edge of the CAUTION: Protect all painted and trimmed surfaces reveal molding. from coming in contact with urethane or primers. (4) Cut around the interior perimeter of the reveal Be careful not to damage painted surfaces when molding and sever the cap of the reveal molding. removing moldings or cutting urethane around (5) Using a cold knife, cut the urethane around the windshield. perimeter of the windshield (Fig. 1). (6) Remove the windshield glass from the frame. It is difficult to salvage a windshield during the removal operation. The windshield is part of the
  • 5. COLD KNIFE WINDSHIELD XJ BODY 23 - 5 REMOVAL AND INSTALLATION (Continued) by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par- allel 75 cm (2.5 ft.) apart (Fig. 2). CAUTION: Avoid spilling or dripping primer on painted surfaces. Clean spills or drips immediately. The primer will damage the paint if it remains on the surface for any length of time. (10) If the replacement windshield glass does not have blackout primer: • Attach a 25 mm (1 in) wide masking tape band around the interior side of the glass 16 mm (5/8 in) from the edge of the glass (Fig. 3). • Do not attach tape along the bottom of the glass and attach it only to the inside of the glass. • Clean the 16-mm (5/8-in) wide surface area around the glass with isopropyl alcohol. Fig. 1 Cutting Urethane Around Windshield—Typical • Thoroughly mix and apply glass blackout primer INSTALLATION—SHORT METHOD to the 16 mm (5/8 in) surface area around the inte- (1) Trim the urethane from the pinchweld flanges. rior side of the glass (Fig. 4). Leave a 3 mm (0.1 in.) level base of urethane on the • Allow the primer to dry for at least 10-12 min- pinchweld flanges. utes. (11) Apply a small amount of adhesive to the bot- WARNING: DO NOT USE SOLVENT BASED GLASS tom support spacers and attach the support spacers CLEANER TO CLEAN WINDSHIELD BEFORE to the bottom of the windshield, 170 mm inboard APPLYING GLASS PREP AND PRIMER. POOR from the outer windshield edge (Fig. 5). ADHESION CAN RESULT. (12) Cut the urethane adhesive applicator nozzle (Fig. 6). (2) Clean inside of windshield with ammonia based glass cleaner and lint-free cloth. CAUTION: Be prepared to install the glass immedi- (3) Prime outer perimeter of interior side of glass ately after applying the adhesive, as the adhesive 16 mm (5/8 inch) from edge. Use a wipe-off type ure- will begin to cure in less than 10 minutes. thane primer and wipe glass dry after primer appli- cation. (13) Apply a continuous, 6-mm (1/4-in) diameter bead of urethane adhesive to the surface area. NOTE: The reveal molding has an adhesive applied (14) Align the glass with the reference marks and to the windshield contact surface to help secure the position the glass on the pinchweld flanges. Ensure molding to the windshield during the installation that the windshield glass is correctly seated on the procedure. support spacers. (15) Force the windshield glass inward just enough (4) Apply the molding to the windshield: to wet-out and set the urethane. Use care to avoid • With the molding at room temperature, press excessive squeeze-out of adhesive. the molding onto the windshield corners. (16) Water test the windshield with a water spray • From corner to corner, work the molding to the after installation. Do not direct high pressure center of each side. (Some stretching of the molding streams of water directly at urethane. If any leaks may be required during this procedure.) are detected, apply urethane as necessary. (5) Place the glass on the pinchweld flanges and (17) If used, remove the masking tape from the inspect for gaps in the urethane. Gaps in excess of 3 inner surface of the glass. mm (1/8 inch) must be filled with urethane. (18) Install all components and clean the vehicle. (6) Adjust windshield glass position until it is (19) Open the vehicle windows to prevent interior aligned with the flanges and adhesive. pressure while the urethane is curing. If not (7) Using a grease pencil or equivalent, make vented, pressure in the interior of the vehicle alignment marks on the glass and body. may interfere with proper glass bonding. (8) Remove replacement windshield from wind- (20) Install the rearview mirror. shield opening. (9) Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm
  • 6. WINDSHIELD TAPE AND MOLD- MASKING OFOFINCH POSITION PRIMER TO GLASS INGS APPLY EDGE WIDE BLACKOUT PRIMER CATOR FROM TAPE TAPE 1-INCH AREA GLASS 5/8 THIS BLOCKS APPLI- COWL SUPPORT MOLDING SPACER CUTSUPPORTSHAPE SHAPE FOR EXTENDED PROCE- CUT NOZZLE NOZZLE SPACERS FORWINDSHIELD THIS DURE SHORT THIS PROCEDURE 23 - 6 BODY XJ REMOVAL AND INSTALLATION (Continued) Fig. 2 Work Surface Set up Fig. 5 Windshield Bottom Support Spacers Fig. 3 Masking Tape Location For Blackout Primer Fig. 6 Applicator Nozzle Preparation INSTALLATION—EXTENDED METHOD (1) Remove the all of urethane from all pinchweld flanges. (2) Inspect and repair the windshield opening and pinchweld flanges. (3) Prime the pinchweld flanges with a urethane base primer. However, if the flange is color-coated with paint, prime the flanges with a paint finish primer. This is important because urethane adhesive will not adhere to all color-coat paints. Allow primer sufficient time to dry. NOTE: The reveal molding has an adhesive applied to the windshield contact surface to help secure the molding to the windshield during the installation procedure. Fig. 4 Blackout Primer Application (4) Apply the reveal molding to the windshield:
  • 7. DIVISION BAR UPPER SCREW GLASS SCREW LOWER XJ BODY 23 - 7 REMOVAL AND INSTALLATION (Continued) • With the molding at room temperature, press (14) Water test the windshield with a water spray the molding onto the windshield corners. after installation. Do not direct high pressure • From corner to corner, work the molding to the streams of water directly at the urethane. If any center of each side. (Some stretching of the molding leaks are detected, apply urethane as necessary. may be required during this procedure). (15) If used, remove the masking tape from the (5) Install and inspect the fit of the windshield on inner surface of glass. the pinchweld flanges as follows: (16) Install all components and clean the vehicle. • Position windshield until it is aligned within If necessary, refer to the installation procedures. windshield opening. (17) Open the vehicle windows to prevent interior • Measure the gap between the pinchweld flanges pressure while the urethane adhesive is curing. If and glass around perimeter of the glass and flange. not vented, pressure in the interior of vehicle • The reveal molding should equally cover the will interfere with glass bonding. A-Pillars on both sides. (18) Install the rearview mirror on the bracket. • The flanges should also extend above the glass edge equally around the perimeter of the opening. REAR DOOR STATIONARY WINDOW GLASS (6) If the pinchweld flanges require repair, remove the windshield glass and straighten, align, or repair REMOVAL the flange(s) as necessary. The rear door stationary window glass is bonded to (7) Position the windshield in the opening and the division bar and is serviced as an assembly. inspect the windshield fit again. Mark the windshield (1) Lower the window glass. final position on the glass and body with a wax pen- (2) Remove the inner and outer beltline weather- cil (or use masking tape). The marks (or masking strip. tape) will be used for installation alignment refer- (3) Remove the trim panel and waterdam from ence. door inner panel. (8) If the replacement windshield does not have (4) Remove the screws attaching the division bar/ blackout primer: glass to the door (Fig. 7). • Attach a 25-mm (1-in) wide masking tape band (5) Tilt the division bar/glass forward and remove around the interior side of glass 16 mm (5/8 in) from it from the door. edge of glass (Fig. 3). • Do not attach tape along the bottom of the glass and attach only to the inside of glass. • Thoroughly mix and apply blackout primer to the 16 mm (5/8 in) surface area around the interior side of the glass (Fig. 4). • Allow the primer to dry for at least 10-12 min- utes. (9) Apply a small amount of adhesive to the bot- tom support spacers and attach the support spacers to the bottom of the windshield, 170 mm inboard from the outer windshield edge (Fig. 5). (10) Cut the urethane applicator nozzle (Fig. 6). (11) Apply a continuous bead of urethane to the surface area with blackout primer on the interior side of glass. The bead should be 9-mm (3/8-in) wide by 12.7-mm (1/2-in) deep for best results. Fig. 7 Division Bar/Stationary Glass CAUTION: Be prepared to install the glass immedi- INSTALLATION ately after applying the adhesive, as the adhesive (1) Position the division bar/glass in the door. will begin to cure in less than 10 minutes. (2) Install the screws attaching the division bar/ glass to the door. Finger tighten the screws. (12) Align the windshield with the wax pencil (3) Tighten the upper screw to 6 N·m (5 ft-lbs) installation alignment reference marks (or the tape torque. strips). Position the windshield on pinchweld flanges (4) Tighten the lower screw to 6 N·m (5 ft-lbs) and spacers. torque. (13) Force the windshield inward just enough to (5) Install the beltline weatherstrip. wet-out and set the urethane. Use care to avoid (6) Install the door waterdam and trim panel. excessive squeeze-out of adhesive.
  • 8. WEATHERSTRIP SEAL REVEAL MOUL- DING FRT GLASS QUARTER CORD INSTALLATION GLASS WINDOW INSTALLATION CORD WINDOW W/VENTWEATHERSTRIP INSTALLATIONENDWEATHERSTRIP SEAL SEAL CORD WINDOW SEAL WEATHER- STRIP GLASS 23 - 8 BODY XJ REMOVAL AND INSTALLATION (Continued) REAR QUARTER WINDOW GLASS (7) Pull on each end of the cord to pull the weath- erstrip seal channel lip over the window opening REMOVAL flanges. (1) If equipped, remove the quarter window reveal (8) Test the vent window for water leaks. molding (Fig. 8). (9) Install the interior trim cover. (2) Remove the quarter window interior trim cov- (10) If equipped, install the quarter window reveal ers. molding. (3) Separate the weatherstrip seal lip from the window opening flanges. Use a pry tool and carefully push the window glass and seal outward. (4) Remove the weatherstrip seal and window glass from window opening. (5) Remove the weatherstrip seal from the window glass. Fig. 9 Weatherstrip Seal and Cord Installation Fig. 8 Quarter Window Reveal Molding, Glass and Seal INSTALLATION (1) Clean the original sealant from the weather- strip channels and window opening flanges. (2) Apply a 4-mm (1/6-in) diameter bead of sealant to the window channel in the weatherstrip seal. (3) Install the weatherstrip on the window glass. Install the seal installation cord in the window open- ing flange channel (Fig. 9) as follows: Fig. 10 Quarter Window With Vent • Moisten a length of 6-mm (1/4-in) diameter cord with a soap and water solution. LIFTGATE GLASS • Ensure that the cord is long enough to go all the REMOVAL way around the perimeter of the weatherstrip. (1) Open liftgate. • Insert the cord into the window opening flange (2) Remove liftgate trim panel. channel in the weatherstrip seal. (3) Disconnect heated backlite (HBL) connector. (4) Apply a 6-mm (1/4-in) diameter bead of sealant (4) Remove wiper arm. to the window opening flanges. (5) Remove CHMSL lens. (5) For two-door vehicles, apply a 3-mm (1/8-in) (6) Using a razor knife, slide the blade between diameter bead of sealant at the quarter panel appli- the liftgate glass and the inboard edge of the reveal que and liftgate pillar seam. molding. (6) Position the quarter window glass and the (7) Cut around the interior perimeter of the reveal weatherstrip seal in the window opening (Fig. 10) molding and severe the cap of the reveal molding. with the free ends of the cord inside the vehicle (Fig. 11).
  • 9. (POSITIONWEATHERSTRIP 1/4-INCH DIAMETER CORD STRIP GLASS WEATHER- IN CHANNEL) XJ BODY 23 - 9 REMOVAL AND INSTALLATION (Continued) (4) Verify the glass lays evenly against the fence at the sides, top and bottom. If not, the flange must be formed to the shape of the new glass. (5) Using a grease pencil or equivalent, make ref- erences marks on the glass and body. (6) Remove replacement glass from liftgate open- ing. (7) Position the glass inside up on a suitable work surface. WARNING: DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN WINDSHIELD BEFORE APPLYING GLASS PREP AND PRIMER. POOR ADHESION CAN RESULT. (8) Clean inside of glass with Mopar Glass Cleaner and lint-free cloth. (9) Apply PVC (vinyl) primer 25 mm (1 in.) wide around edge of glass. Wipe with clean/dry lint-free cloth. (10) If necessary, apply fence primer around edge of fence. Allow at least eighteen minutes drying time. Fig. 11 Quarter Window Glass and Seal Installation (11) Apply a 10 mm (0.4 in.) bead of urethane around glass border. (8) Using a cold knife, cut urethane bonding from (12) Position glass into liftgate opening and refer- around liftgate glass. A pneumatic cutting device can ence marks. be used if available. (13) Push the glass inward until the reveal mold- (9) Separate glass from Liftgate. ing is seated onto the liftgate frame. Use care to avoid excessive squeeze-out of adhesive. INSTALLATION (14) Open windows to prevent pressure build-up CAUTION: Open a window before installing glass. while the urethane is curing. This will avoid pressurizing the passenger compart- (15) Apply 150 mm (6 in.) lengths of 50 mm (2 in.) ment. If a door or liftgate is slammed before ure- masking tape spaced 250 mm (10 in.) apart to hold thane is cured, water leaks can result. glass in place until urethane cures. (16) Install the wiper arm. (1) Trim the urethane from the liftgate glass open- (17) Install CHMSL lens. ing flanges. Leave a 3 mm (0.1 in.) level base of ure- (18) Connect heated backlite (HBL) connector. thane on the flanges. (19) After urethane has cured, remove tape strips (2) Starting in the corners, press reveal molding and water test to verify repair. onto glass. (20) Install liftgate trim panel. (3) Place replacement glass into liftgate opening and position glass in the center of the opening against flange.
  • 10. EXTRACTOR6773 EXTRACTOR TOOL 6773 TOOL HEAD RESTRAINT RESTRAINT HEAD SLEEVE SLEEVE SEAT BACK FWD FWD BACK SEAT 23 - 10 BODY XJ SEATS INDEX page page REMOVAL AND INSTALLATION HEAD RESTRAINT SLEEVE . . . . . . . . . . . . . . . 10 BUCKET SEAT CUSHION COVER . . . . . . . . . . 13 REAR SEAT CUSHION COVER . . . . . . . . . . . . 13 BUCKET SEAT PLATFORM . . . . . . . . . . . . . . . 12 REAR SEATBACK COVER . . . . . . . . . . . . . . . . 14 BUCKET SEAT RECLINER . . . . . . . . . . . . . . . . 13 REAR SEATBACK LATCH STRIKER AND BUCKET SEAT TRACK . . . . . . . . . . . . . . . . . . . 11 BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 BUCKET SEATBACK COVER . . . . . . . . . . . . . . 12 SPECIAL TOOLS BUCKET SEATBACK . . . . . . . . . . . . . . . . . . . . 12 SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 HEAD RESTRAINT COVER . . . . . . . . . . . . . . . 10 REMOVAL AND INSTALLATION HEAD RESTRAINT SLEEVE REMOVAL NOTE: When replacing a head restraint sleeve, the retaining tabs on the sleeve will be damaged during the removal process. Check the availability of replacement parts before servicing. (1) Raise head restraint to the full up position. (2) Turn head restraint lock thumbwheel to release head restraint and pull head restraint upward to remove from seat back. (3) Insert head restraint sleeve extractor (special tool 6773) (Fig. 1) and (Fig. 2) into the seat back. Fig. 1 Head Restraint Sleeve Extractor (4) The retaining tabs are positioned on each side of the sleeve, when inserting the extractor, ensure that the flat of the collar is facing the side of the seatback (Fig. 3). (5) Using a small hammer, tap extractor down- ward to release sleeve retaining tab. (6) Remove extractor tool from sleeve, rotate tool 180 degrees (Fig. 4) and repeat steps 3 and 4. (7) Remove extractor tool from sleeve and remove sleeve from seat back. INSTALLATION (1) Position the sleeve in the seat back. (2) Firmly, push sleeve down to snap into place. (3) Install head restraint. HEAD RESTRAINT COVER Fig. 2 Head Restraint Sleeve Extractor Installation REMOVAL (3) Pull the adjuster bar from the head restraint. (1) Remove head restraint from the bucket seat. (4) Roll the cover upward and separate from the (2) Remove the screws attaching the bezel and head restraint cushion (Fig. 6). adjuster bar to the head restraint (Fig. 5).
  • 11. EXTRACTOR LOCK RELEASE THUMBWHEEL TOOL 6773 EXTRACTOR RELEASEBACK BACK TOOL 6773 SEAT SEAT LOCK THUMBWHEEL FWD HEAD RESTRAINT CUSHION HEAD RESTRAINT COVER HEAD RESTRAINT ADJUSTER BAR BEZEL XJ BODY 23 - 11 REMOVAL AND INSTALLATION (Continued) Fig. 3 Head Restraint Sleeve Extractor Positioning Fig. 5 Head Restraint Fig. 4 Head Restraint Sleeve Extractor Positioning INSTALLATION (1) Position the cover on the head restraint cush- ion and roll the cover downward. (2) Position the adjuster bar in the head restraint. (3) Install the screws attaching the bezel and adjuster bar to the head restraint. Fig. 6 Head Restraint Cover (4) Install head restraint in the bucket seat. (4) Remove the nuts attaching the seat track to the bucket seat platform. BUCKET SEAT TRACK (5) When separating the seat track from the plat- form, route the power seat switch connector through REMOVAL the access hole in the seat cushion frame, if equipped. NOTE: If the vehicle is equipped with manually adjusted bucket seats, the inboard or outboard seat INSTALLATION track may be serviced separately. (1) While positioning the seat track on the bucket seat platform, route the power seat switch connector (1) Remove bucket seat from vehicle. through the access hole in the seat cushion frame, if (2) Remove screws attaching the side shield trim equipped. cover from the seat. (2) Install the nuts attaching the seat track to the (3) If equipped, disengage the power seat connec- bucket seat platform. tor from the power seat switch. (3) If equipped, engage the power seat connector to the power seat switch.
  • 12. SEAT BACK COVER SEAT CUSHION BACK SEAT BACKFAS- LOOP HOOK SEAT CUSH- CUSHION SEAT TENER COVER BACK AND BACK ION HOG RING SUPPORT 23 - 12 BODY XJ REMOVAL AND INSTALLATION (Continued) (4) Install screws attaching the side shield trim cover to the seat. (5) Install bucket seat. BUCKET SEAT PLATFORM Bucket seat platforms are not repairable. If the seat platform is damaged, replace platform as a unit. BUCKET SEATBACK COVER REMOVAL (1) Remove head restraint, if equipped. (2) Remove screws attaching side shield trim cover to bucket seat. (3) If equipped, disengage power seat wire connec- tor from power seat switch. (4) Remove the inboard seatback pivot bolt. Fig. 8 Hog Ring (5) Position the seatback in the full forward or full recline position. (6) Remove the seatback cover zipper from the base of the seatback. (7) Disengage the cover zipper and route the zip- per end between the inboard seatback and seat cush- ion frame. (8) Roll the seatback cover upward (Fig. 7). (9) Disengage the hogrings attaching the seatback cover to the seatback cushion support wires (Fig. 8). (10) Roll the seatback cover upward and disengage the hook and loop fastener (Fig. 9). (11) Roll seatback cover up and over the head restraint sleeves, if equipped and separate from the seatback. Fig. 9 Hook And Loop Fastener (3) Continue rolling the cover downward and engage the hogrings attaching the seatback cover to the seatback cushion support wires. (4) Route the zipper end between the inboard seat- back and seat cushion frame and engage the cover zipper. (5) Install the inboard seatback pivot bolt. (6) Install the side shield trim cover. (7) Install head restraint, if equipped. BUCKET SEATBACK REMOVAL (1) Remove side shield trim cover. Fig. 7 Seatback Cover (2) Remove inboard seatback pivot bolt. INSTALLATION (3) Remove bolts attaching recliner to seat cushion (1) Position the seatback cover on the seatback frame (Fig. 10). cushion and roll seatback cover down over the head (4) Separate seatback from vehicle. restraint sleeves. Route the sleeves through the access holes in the cover, if equipped. INSTALLATION (2) Roll the seatback cover downward and engage (1) Position seatback on seat cushion frame. the hook and loop fastener. (2) Install inboard seatback pivot bolt.
  • 13. SEAT BACK RING RECLINEREAT CUSHION SEAT CUSHION COVER S HOG SEAT CUSHION RECLINER SEATCUSHION REMOVE BACK RECLINERCUSHION SEAT HAN- DLE XJ BODY 23 - 13 REMOVAL AND INSTALLATION (Continued) (3) With the cushion side down, engage the for- ward, rearward and inboard J-straps. (4) Engage the clips attaching the outboard side of the cover to the cushion frame. (5) Install seatback. (6) Install side shield trim cover. (7) Install seat. BUCKET SEAT RECLINER REMOVAL (1) Remove side shield trim cover. (2) Disengage seatback cover zipper. (3) Roll outer seatback cover upward. (4) Remove bolts attaching recliner to seatback Fig. 10 Bucket Seatback and seat cushion frames (Fig. 12). (3) Install bolts attaching recliner to seat cushion (5) Separate recliner from seat. frame. (4) Install side shield trim cover. BUCKET SEAT CUSHION COVER REMOVAL (1) Remove seat from vehicle. (2) Remove side shield trim cover. (3) Remove seatback. (4) With the cushion side down, disengage the for- ward, rearward and inboard J-straps. (5) Disengage the clips attaching the outboard side of the cover to the cushion frame. (6) Turn the cushion over and roll the cover off the cushion. (7) Remove the hog rings attaching the cover to the cushion support wires (Fig. 11). Fig. 12 Bucket Seat Recliner (8) Separate the cover from the cushion. INSTALLATION (1) Position recliner on seat. (2) Install bolts attaching recliner to seatback and seat cushion frames (Fig. 12). (3) Roll seatback cover downward. (4) Engage seatback cover zipper. (5) Install side shield trim cover. REAR SEAT CUSHION COVER REMOVAL (1) Remove the seat cushion from the vehicle. (2) Remove the cover side, front and rear retaining clips from the wire retainers with an appropriate removal tool (Fig. 13). (3) Remove the serrated retainers from the front ends of the cover with a trim panel removal tool (Fig. Fig. 11 Seat Cushion Cover Hog Rings 14). INSTALLATION (4) Remove the seat cover from the cushion. (1) Position the cover on the cushion. INSTALLATION (2) Install the hog rings attaching the cover to the (1) Position the replacement cover on the cushion. cushion support wires.
  • 14. SEAT REMOVER TOOL SEAT COVER COVER CLIPS REMOVEROOL CLIP T REAR WHEEL- FWD HOUSE STRIKER LATCH SCREW TORX-HEAD BRACKET SEATBACK BRACKET STRIKER SEATBACK BUMPER LATCH BUMPER STRIKER LATCH LATCH STRIKER BRACKET 23 - 14 BODY XJ REMOVAL AND INSTALLATION (Continued) (3) Release the seatback latch from the striker. (4) Tilt the seatback forward for access to the striker bracket. (5) Remove the retaining screws and the latch striker bracket from the trim panel (Fig. 15). Fig. 13 Seat Cushion Cover Retaining Clip Removal Fig. 15 Seatback Latch Striker Bracket Removal/ Installation INSTALLATION (1) Position the latch striker bracket on the trim panel and install the retaining screws. Tighten the screws with 6 N·m (50 in. lbs.) torque. (2) Engage the seatback latch with the striker. (3) Pivot the seat cushion to the horizontal posi- tion and lock it in-place by pressing firmly on the center of the cushion until the latch engages. REAR SEATBACK COVER REMOVAL (1) Remove the seatback from the vehicle. (2) Remove the seatback latch release handle and bezel from the seatback. Fig. 14 Seat Cushion Cover Retaining Clip Removal (3) Disengage the cover zippers. (2) Compress the cover and attach the retaining (4) Disengage the J-strap attaching the cover to clips to the front and rear wire retainers. the seat back frame (Fig. 16). (3) Install the serrated retainers at the ends of the (5) Remove the cover from the seatback pad. cover. (4) Install the seat cushion in the vehicle. If neces- sary, refer to the installation procedure. REAR SEATBACK LATCH STRIKER AND BUMPER REMOVAL (1) Disengage the seat cushion at the rear by pull- ing upward on the release strap. (2) Tilt the seat cushion forward.
  • 15. COVER ZIPPER SEAT BACK XJ BODY 23 - 15 REMOVAL AND INSTALLATION (Continued) (3) Engage the cover zippers. (4) Install the seat latch release bezel and handle. (5) Install the seatback in the vehicle. SPECIAL TOOLS SEATS Extractor Head Restraint Sleeve 6773 Fig. 16 Seatback Cover Removal INSTALLATION (1) Install the cover on the seatback. (2) Attach the cover J-strap to the seatback frame.
  • 16. 23 - 16 BODY XJ BODY COMPONENT SERVICE INDEX page page DIAGNOSIS AND TESTING FULL FLOOR CONSOLE . . . . . . . . . . . . . . . . . 51 WATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 17 GRILLE OPENING PANEL (GOP) . . . . . . . . . . . 19 WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 18 GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SERVICE PROCEDURES HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 BODY LUBRICATION . . . . . . . . . . . . . . . . . . . . 18 HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL AND INSTALLATION HOOD LATCH . . . . . . . . . . . . . . . . . . . . . . . . . 21 A-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . 44 HOOD LATCH STRIKER . . . . . . . . . . . . . . . . . . 21 AIR EXHAUST GRILLE . . . . . . . . . . . . . . . . . . . 44 HOOD RELEASE CABLE . . . . . . . . . . . . . . . . . 21 ASSIST HANDLE . . . . . . . . . . . . . . . . . . . . . . . 45 HOOD SAFETY LATCH . . . . . . . . . . . . . . . . . . 22 B-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . 46 HOOD SILENCER PAD . . . . . . . . . . . . . . . . . . 22 BODY DECALS . . . . . . . . . . . . . . . . . . . . . . . . 23 HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 BODY SIDE MOLDING . . . . . . . . . . . . . . . . . . . 42 LEFT FRONT FENDER . . . . . . . . . . . . . . . . . . 26 BUCKET SEAT . . . . . . . . . . . . . . . . . . . . . . . . . 50 LIFTGATE HINGE . . . . . . . . . . . . . . . . . . . . . . . 56 C-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . 46 LIFTGATE LATCH STRIKER . . . . . . . . . . . . . . . 57 COWL GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . 23 LIFTGATE LATCH . . . . . . . . . . . . . . . . . . . . . . 57 COWL WEATHERSTRIP . . . . . . . . . . . . . . . . . . 23 LIFTGATE LOCK CYLINDER . . . . . . . . . . . . . . 57 DOOR SILL SCUFF PLATE . . . . . . . . . . . . . . . 45 LIFTGATE OPENING UPPER TRIM . . . . . . . . . 48 DRIP RAIL MOLDING . . . . . . . . . . . . . . . . . . . . 43 LIFTGATE OUTSIDE HANDLE . . . . . . . . . . . . . 57 EXTERIOR NAMEPLATES . . . . . . . . . . . . . . . . 24 LIFTGATE PILLAR TRIM . . . . . . . . . . . . . . . . . 47 FRONT CARPET/MAT . . . . . . . . . . . . . . . . . . . 52 LIFTGATE SCUFF PLATE . . . . . . . . . . . . . . . . . 48 FRONT DOOR GLASS EXTERIOR MOLDING . 34 LIFTGATE SUPPORT ROD BALL STUD . . . . . . 56 FRONT DOOR GLASS RUN CHANNEL LIFTGATE SUPPORT ROD CYLINDER . . . . . . . 56 WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . 33 LIFTGATE TRIM PANEL . . . . . . . . . . . . . . . . . . 55 FRONT DOOR GLASS . . . . . . . . . . . . . . . . . . . 36 LIFTGATE WEATHERSTRIP . . . . . . . . . . . . . . . 58 FRONT DOOR HINGE PIN . . . . . . . . . . . . . . . . 29 LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 FRONT DOOR HINGE . . . . . . . . . . . . . . . . . . . 30 LOWER A-PILLAR COWL TRIM . . . . . . . . . . . . 44 FRONT DOOR INNER BELT WEATHERSTRIP . 32 LUGGAGE RACK . . . . . . . . . . . . . . . . . . . . . . . 43 FRONT DOOR INSIDE HANDLE ACTUATOR . . 32 QUARTER PANEL TRIM AND WHEELHOUSE FRONT DOOR LATCH STRIKER . . . . . . . . . . . 32 COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 FRONT DOOR LATCH . . . . . . . . . . . . . . . . . . . 31 QUARTER PANEL TRIM EXTENSION . . . . . . . 47 FRONT DOOR LOCK CYLINDER . . . . . . . . . . . 31 QUARTER WINDOW APPLIQUE . . . . . . . . . . . 43 FRONT DOOR LOWER WEATHERSTRIP . . . . . 34 REAR CARPET/MAT . . . . . . . . . . . . . . . . . . . . 52 FRONT DOOR OPENING SECONDARY REAR DOOR GLASS EXTERIOR MOLDING . . 40 WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . 33 REAR DOOR GLASS RUN CHANNEL FRONT DOOR OPENING WEATHERSTRIP . . . 33 WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . 40 FRONT DOOR OUTER BELT WEATHERSTRIP ... REAR DOOR HINGE PIN . . . . . . . . . . . . . . . . . 38 32 REAR DOOR HINGE . . . . . . . . . . . . . . . . . . . . 38 FRONT DOOR OUTSIDE HANDLE . . . . . . . . . . 31 REAR DOOR INNER BELT WEATHERSTRIP . . 40 FRONT DOOR RESTRAINT . . . . . . . . . . . . . . . 30 REAR DOOR INSIDE HANDLE ACTUATOR . . . 39 FRONT DOOR SPACER BLOCKS—TWO-DOOR REAR DOOR LATCH STRIKER . . . . . . . . . . . . 39 VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . 35 REAR DOOR LATCH . . . . . . . . . . . . . . . . . . . . 39 FRONT DOOR TRIM PANEL . . . . . . . . . . . . . . 27 REAR DOOR OUTER BELT WEATHERSTRIP . 40 FRONT DOOR WATERDAM . . . . . . . . . . . . . . . 29 REAR DOOR OUTSIDE HANDLE . . . . . . . . . . . 38 FRONT DOOR WINDOW REGULATOR . . . . . . 34 REAR DOOR RESTRAINT . . . . . . . . . . . . . . . . 38 FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 29 REAR DOOR TRIM PANEL . . . . . . . . . . . . . . . . 36 FRONT FENDER FLARE . . . . . . . . . . . . . . . . . 25 REAR DOOR WATERDAM . . . . . . . . . . . . . . . . 37 FRONT INNER SCUFF PLATE . . . . . . . . . . . . . 44 REAR DOOR WEATHERSTRIP . . . . . . . . . . . . 40 FRONT SHOULDER BELT/BUCKLE . . . . . . . . . 48 REAR DOOR WINDOW GLASS . . . . . . . . . . . . 41 FRONT WHEELHOUSE LINER . . . . . . . . . . . . . 26 REAR DOOR WINDOW REGULATOR . . . . . . . 41
  • 17. XJ BODY 23 - 17 REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ADJUSTMENTS REAR FENDER FLARE . . . . . . . . . . . . . . . . . . 42 DOOR LATCH ADJUSTMENT . . . . . . . . . . . . . . 59 REAR SEAT CUSHION . . . . . . . . . . . . . . . . . . . 51 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 REAR SEATBACK . . . . . . . . . . . . . . . . . . . . . . 52 HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 REAR SHOULDER/LAP BELT/BUCKLE . . . . . . 49 LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 REARVIEW MIRROR SUPPORT BRACKET . . . 53 SPECIFICATIONS REARVIEW MIRROR . . . . . . . . . . . . . . . . . . . . 53 BODY LUBRICANTS . . . . . . . . . . . . . . . . . . . . 60 RIGHT FRONT FENDER . . . . . . . . . . . . . . . . . 26 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . 60 SAFETY LATCH STRIKER . . . . . . . . . . . . . . . . 22 SPECIAL TOOLS SIDE VIEW MIRROR . . . . . . . . . . . . . . . . . . . . 25 BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 SUNVISORS . . . . . . . . . . . . . . . . . . . . . . . . . . 53 DIAGNOSIS AND TESTING • If a leak occurs while driving at highway speeds in a steady rain, test the leak area with a reasonable WATER LEAKS velocity stream or fan spray of water. Direct the Water leaks can be caused by poor sealing, spray in a direction comparable to actual conditions. improper body component alignment, body seam • If a leak occurs when the vehicle is parked on an porosity, missing plugs, or blocked drain holes. Cen- incline, hoist the end or side of the vehicle to simu- trifugal and gravitational force can cause water to late this condition. This method can be used when drip from a location away from the actual leak point, the leak occurs when the vehicle accelerates, stops or making leak detection difficult. All body sealing turns. If the leak occurs on acceleration, hoist the points should be water tight in normal wet-driving front of the vehicle. If the leak occurs when braking, conditions. Water flowing downward from the front of hoist the back of the vehicle. If the leak occurs on left the vehicle should not enter the passenger or luggage turns, hoist the left side of the vehicle. If the leak compartment. Moving sealing surfaces will not occurs on right turns, hoist the right side of the vehi- always seal water tight under all conditions. At cle. For hoisting recommendations refer to Group 0, times, side glass or door seals will allow water to Lubrication and Maintenance, General Information enter the passenger compartment during high pres- section. sure washing or hard driving rain (severe) condi- tions. Overcompensating on door or glass WATER LEAK DETECTION adjustments to stop a water leak that occurs under To detect a water leak point-of-entry, do a water severe conditions can cause premature seal wear and test and watch for water tracks or droplets forming excessive closing or latching effort. After completing on the inside of the vehicle. If necessary, remove inte- a repair, water-test vehicle to verify leak has stopped rior trim covers or panels to gain visual access to the before returning vehicle to use. leak area. If the hose cannot be positioned without being held, have someone help do the water test. VISUAL INSPECTION BEFORE WATER LEAK Some water leaks must be tested for a considerable TESTS length of time to become apparent. When a leak Verify that floor and body plugs are in place, body appears, find the highest point of the water track or drains are clear, and body components are properly drop. The highest point usually will show the point of aligned and sealed. If component alignment or seal- entry. After leak point has been found, repair the ing is necessary, refer to the appropriate section of leak and water test to verify that the leak has this group for proper procedures. stopped. Locating the entry point of water that is leaking WATER LEAK TESTS into a cavity between panels can be difficult. The trapped water may splash or run from the cavity, WARNING: DO NOT USE ELECTRIC SHOP LIGHTS often at a distance from the entry point. Most water OR TOOLS IN WATER TEST AREA. PERSONAL leaks of this type become apparent after accelerating, INJURY CAN RESULT. stopping, turning, or when on an incline. When the conditions causing a water leak have MIRROR INSPECTION METHOD been determined, simulate the conditions as closely When a leak point area is visually obstructed, use as possible. a suitable mirror to gain visual access. A mirror can • If a leak occurs with the vehicle parked in a also be used to deflect light to a limited-access area steady light rain, flood the leak area with an open- to assist in locating a leak point. ended garden hose.
  • 18. 23 - 18 BODY XJ DIAGNOSIS AND TESTING (Continued) BRIGHT LIGHT LEAK TEST METHOD ROAD TESTING WIND NOISE Some water leaks in the luggage compartment can (1) Drive the vehicle to verify the general location be detected without water testing. Position the vehi- of the wind noise. cle in a brightly lit area. From inside the darkened (2) Apply 50 mm (2 in.) masking tape in 150 mm luggage compartment inspect around seals and body (6 in.) lengths along weatherstrips, weld seams or seams. If necessary, have a helper direct a drop light moldings. After each length is applied, drive the vehi- over the suspected leak areas around the luggage cle. If noise goes away after a piece of tape is applied, compartment. If light is visible through a normally remove tape, locate, and repair defect. sealed location, water could enter through the open- ing. POSSIBLE CAUSE OF WIND NOISE • Moldings standing away from body surface can PRESSURIZED LEAK TEST METHOD catch wind and whistle. When a water leak into the passenger compart- • Gaps in sealed areas behind overhanging body ment cannot be detected by water testing, pressurize flanges can cause wind-rushing sounds. the passenger compartment and soap test exterior of • Misaligned movable components. the vehicle. To pressurize the passenger compart- • Missing or improperly installed plugs in pillars. ment, close all doors and windows, start engine, and • Weld burn through holes. set heater control to high blower in HEAT position. If engine can not be started, connect a charger to the battery to ensure adequate voltage to the blower. SERVICE PROCEDURES With interior pressurized, apply dish detergent solu- tion to suspected leak area on the exterior of the BODY LUBRICATION vehicle. Apply detergent solution with spray device or All mechanisms and linkages should be lubricated soft bristle brush. If soap bubbles occur at a body when necessary. This will maintain ease of operation seam, joint, seal or gasket, the leak entry point could and provide protection against rust and excessive be at that location. wear. The weatherstrip seals should be lubricated to prolong their life as well as to improve door sealing. WIND NOISE All applicable exterior and interior vehicle operat- Wind noise is the result of most air leaks. Air leaks ing mechanisms should be inspected and cleaned. can be caused by poor sealing, improper body compo- Pivot/sliding contact areas on the mechanisms should nent alignment, body seam porosity, or missing plugs then be lubricated. in the engine compartment or door hinge pillar areas. (1) When necessary, lubricate the operating mech- All body sealing points should be airtight in normal anisms with the specified lubricants. driving conditions. Moving sealing surfaces will not (2) Apply silicone lubricant to a cloth and wipe it always seal airtight under all conditions. At times, on door seals to avoid over-spray that can soil pas- side glass or door seals will allow wind noise to be senger’s clothing. noticed in the passenger compartment during high (3) Before applying lubricant, the component crosswinds. Over compensating on door or glass should be wiped clean. After lubrication, any excess adjustments to stop wind noise that occurs under lubricant should be removed. severe conditions can cause premature seal wear and (4) The hood latch, latch release mechanism, latch excessive closing or latching effort. After a repair pro- striker, and safety latch should be lubricated period- cedure has been performed, test vehicle to verify ically. noise has stopped before returning vehicle to use. (5) The door lock cylinders should be lubricated Wind noise can also be caused by improperly fitted twice each year (preferably autumn and spring): exterior moldings or body ornamentation. Loose • Spray a small amount of lock cylinder lubricant moldings can flutter, creating a buzzing or chattering directly into the lock cylinder. noise. An open cavity or protruding edge can create a • Apply a small amount to the key and insert it whistling or howling noise. Inspect the exterior of the into the lock cylinder. vehicle to verify that these conditions do not exist. • Rotate it to the locked position and then back to the unlocked position several times. VISUAL INSPECTION BEFORE TESTS • Remove the key. Wipe the lubricant from it with Verify that floor and body plugs are in place and a clean cloth to avoid soiling of clothing. body components are aligned and sealed. If compo- nent alignment or sealing is necessary, refer to the appropriate section of this group for proper proce- dures.
  • 19. GRILLE OPENING PANEL NUT GRILLE FWD BODY GRILLE BRACKET SUPPORT OPENING PANEL XJ BODY 23 - 19 REMOVAL AND INSTALLATION GRILLE REMOVAL (1) Remove the headlamp/park lamp bezels. (2) Remove the screws attaching the grille to the grille opening panel (GOP) (Fig. 1). (3) Separate the grille from the GOP. Fig. 2 Grille Opening Panel (5) Install nuts attaching GOP to front fenders. Tighten nuts to 4 N·m (38 in-lbs) torque. (6) Install headlamps and park/turn signal lamps. (7) Install headlamp bezels. (8) Install side marker lamps. (9) Install grille. (10) Adjust headlamp aim, if necessary. Fig. 1 Grille HOOD INSTALLATION REMOVAL (1) Position the grille in the GOP. (1) Raise hood. (2) Install the screws. (2) Disconnect underhood lamp wire harness con- (3) Install the headlamp/park lamp bezels. nector, if equipped. (3) Disconnect release cable from latch release GRILLE OPENING PANEL (GOP) bellcrank. REMOVAL (4) Remove latch release cable clips and remove (1) Remove grille. cable from hood (Fig. 3). (2) Remove headlamp bezels. (5) Mark location of hood, hinges and hinge shims (3) Remove side marker lamps. for installation. (4) Remove headlamps and park/turn signal (6) Remove bolts that attach hinges to hood. lamps. (7) Remove hood from vehicle with aid of a helper. (5) Open hood. INSTALLATION (6) Remove nuts that attach GOP to front fenders (1) Position hood on shims and hinges; finger- (Fig. 2). tighten hinge bolts. (7) Remove nuts attaching GOP to support (2) Align hinges and shims with reference marks bracket. and tighten hinge bolts. (8) Pull GOP forward and disconnect harness clips (3) Connect latch release cable and latch connect- and front lamp harness connectors. ing rod to bellcrank. (9) Remove GOP from vehicle. (4) Attach latch release cable to clips. INSTALLATION (5) Connect underhood lamp wire harness connec- (1) Place GOP on bumper and secure all harness tor. clips. (2) Connect all lamp wire harness connectors. HOOD HINGE (3) Position GOP on vehicle. REMOVAL (4) Install nuts attaching GOP to support bracket. (1) Raise and support hood. Tighten nuts to 4 N·m (38 in-lbs) torque.
  • 20. FWD 1. LATCH 13. 12. SPRING 11. SHIM 10. SHOULDER 9. STRIKER 8. GROMMET 7. CABLE 6. ROD 5. BELLCRANK BOLT 4. CLIP 3. CATCH 2. BUMPER FWD 23 - 20 BODY XJ REMOVAL AND INSTALLATION (Continued) Fig. 3 Hood Components
  • 21. DASH PANEL NUT HOOD HINGE HINGE SEAL BASE HOOD LATCH ROD SPRING HOOD LATCH CONNECTING RODRETAINER CLIP XJ BODY 23 - 21 REMOVAL AND INSTALLATION (Continued) (2) Using a grease pencil or equivalent, mark posi- tion of hood. (3) Remove seal from hinge base (Fig. 4). (4) Remove hinge retaining nuts from studs. Fig. 5 Hood Latch (4) Remove the headlamp with mounting bucket attached from the adjusting screws. (5) Remove the upper bolt attaching the striker to Fig. 4 Hood Hinge and Seal the top of the (GOP). INSTALLATION (6) Remove the lower bolt attaching the striker to (1) Position hinge over studs and align with refer- the (GOP). ence marks. (7) Remove the striker and shims. (2) Install nuts. INSTALLATION NOTE: If a replacement hinge seal is being (1) Position the shims and striker on the (GOP) installed, position it around hinge arm, force it and install the bolts. against hinge base. (2) Install the headlamp and mounting bucket. (3) Install parklamp. (3) Position hinge seal around hinge arm and on (4) Install the headlamp bezel. hinge base. (5) Test the striker/hood alignment by opening and (4) Adjust hood as necessary. closing the hood several times. Adjust the striker, if necessary. HOOD LATCH HOOD RELEASE CABLE REMOVAL (1) Remove the screw that attaches the latch to REMOVAL the hood inner panel (Fig. 5). (1) Drill out bellcrank to hood rivet heads and (2) Disconnect the latch connecting rod. remove rivets (Fig. 6). (3) Remove the latch from the hood. (2) Disconnect bellcrank from latch rod and hood release cable. Remove bellcrank from hood. INSTALLATION (3) Disconnect hood release cable from clips on (1) Connect the latch to the latch connecting rod hood. and (4) Remove left cowl side trim panel. (2) Position the latch on the hood inner panel. (5) Remove cable bracket screws from cowl side (3) Install the screw that attaches the latch to the panel. hood inner panel. (6) Route cable through dash panel and remove it from under instrument panel. HOOD LATCH STRIKER INSTALLATION REMOVAL (1) Insert replacement cable end through hole in (1) Remove headlamp bezel. dash panel into engine compartment. (2) Remove parklamp. (2) Route cable forward and seat grommet in dash (3) Release the spring attaching the headlamp panel. mounting bucket to the grille opening panel (GOP).
  • 22. LATCH HOOD SAFETY LATCH NUT CONNECTING ROD HOOD BUMPER RIVET HOOD INNER CABLE RELEASE LATCHSTUD BELLCRANK HOOD PANEL RADIATOR SUPPORT HOOD HOOD CROSSMEMBER RETAINERSAFETY STRIKER LATCH SILENCER PAD RADIATOR SCREW BRACKET GOP 23 - 22 BODY XJ REMOVAL AND INSTALLATION (Continued) SAFETY LATCH STRIKER REMOVAL (1) Remove striker screws from radiator support crossmember (Fig. 8). (2) Remove striker from crossmember. Fig. 6 Hood Release Cable Bellcrank (3) Position cable bracket on cowl side panel and install screws. (4) Install left cowl side trim panel. (5) Connect cable and latch rod to bellcrank. (6) Position bellcrank on hood and install rivets. (7) Attach cable to clips. Fig. 8 Hood Safety Latch Striker (8) Test release cable for proper operation. INSTALLATION (1) Position striker on radiator support crossmem- HOOD SAFETY LATCH ber and install screws. (2) Test safety latch operation. REMOVAL (1) Open and support hood. HOOD SILENCER PAD (2) Remove the nuts attaching the safety latch to the inner hood panel (Fig. 7). REMOVAL (3) Separate the safety latch from the hood. (1) Open and support hood. (2) Remove the hood latch release bellcrank. (3) Remove the clips attaching the latch connect- ing rod to the hood inner panel. (4) Remove the retainers attaching the hood silencer pad to the inner hood panel (Fig. 9). (5) Separate the hood silencer pad from the hood. Fig. 7 Hood Safety Latch INSTALLATION (1) Position the safety latch on the hood. (2) Install the nuts attaching the safety latch to the inner hood panel. (3) Close hood. Fig. 9 Hood Silencer Pad
  • 23. WEATHERSTRIPCOWL DASH PANEL SEAL THICK-HEAD RETAINER FLAT-HEAD RETAINER COWL PLASTIC PANEL PUSH- RIVET FWD GRILLE NOZZLE SCREEN SCREEN RIVET AND SCREW GRILLE NOZZLE SCREEN GRILLE PLASTIC PUSH- RIVET XJ BODY 23 - 23 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position the hood silencer pad on the hood inner panel. (2) Install the retainers attaching the hood silencer pad to the inner hood panel. (3) Install the clips attaching the latch connecting rod to the hood inner panel. (4) Install the hood latch release bellcrank. (5) Close hood. COWL WEATHERSTRIP REMOVAL (1) Pry upward along the length of weatherstrip. (2) Detach the weatherstrip retainers from the cowl panel (Fig. 10). (3) Remove the weatherstrip from cowl panel. Fig. 11 Cowl Grille, Screen & Washer Nozzles (1) Position the cowl grille and screen on the cowl. (2) Install the windshield washer tubes on the noz- zles. (3) Install the cowl screen and grille screws. Tighten in sequence (Fig. 12). NOTE: Force the cowl grille rearward while tighten- ing the screws. (4) Install the windshield wiper arms on the piv- ots. Fig. 10 Cowl Weatherstrip INSTALLATION (1) Position the weatherstrip on the cowl panel. (2) Press to insert retainers into the cowl panel holes. COWL GRILLE REMOVAL (1) Remove the windshield wiper arms from the pivots. (2) Remove the screws that attach the grille to the Fig. 12 Cowl Grille Screw Tightening Sequence cowl. (3) Remove the windshield washer tubes from the BODY DECALS nozzles. Small nicks, scratches and other surface marks in (4) Remove the cowl grille and screen from the a decal can be touched-up with paint. cowl (Fig. 11). To eliminate blisters and air bubbles in a decal, pierce them with a needle or pin. INSTALLATION A heat gun can also be used to remove small wrin- kles in a decal. CAUTION: The washer fluid tubes must be routed Decal replacement requires that the metal repair and installed so that they are not pinched. and paint refinish be completed first.