XJ                                                                                                                        ...
23 - 2      BODY                                                                                                          ...
XJ                                                                                      BODY     23 - 3SPECIFICATIONSAFTER...
23 - 4     BODY                                                                                                           ...
COLD KNIFE                   WINDSHIELDXJ                                                                                 ...
WINDSHIELD TAPE              AND   MOLD- MASKING OFOFINCH                     POSITION PRIMER TO GLASS                    ...
DIVISION BAR                                                                   UPPER SCREW                      GLASS SCRE...
WEATHERSTRIP         SEAL        REVEAL MOUL-                             DING           FRT GLASS     QUARTER CORD       ...
(POSITIONWEATHERSTRIP      1/4-INCH DIAMETER CORD          STRIP GLASS WEATHER-                  IN CHANNEL)XJ            ...
EXTRACTOR6773                                                                      EXTRACTOR                              ...
EXTRACTOR LOCK RELEASE  THUMBWHEEL   TOOL 6773     EXTRACTOR RELEASEBACK BACK                    TOOL 6773 SEAT SEAT      ...
SEAT BACK COVER                                           SEAT   CUSHION                                                  ...
SEAT BACK RING      RECLINEREAT CUSHION      SEAT CUSHION             COVER             S             HOG                 ...
SEAT REMOVER TOOL SEAT COVER                      COVER              CLIPS   REMOVEROOL                                   ...
COVER ZIPPER        SEAT BACKXJ                                                                                         BO...
23 - 16       BODY                                                                                                        ...
XJ                                                                                                                        ...
23 - 18    BODY                                                                                                  XJDIAGNOS...
GRILLE OPENING PANEL     NUT       GRILLE                   FWD                                                           ...
FWD 1. LATCH        13.        12. SPRING        11. SHIM        10. SHOULDER        9. STRIKER        8. GROMMET        7...
DASH PANEL            NUT HOOD              HINGE      HINGE SEAL                                                   BASE  ...
LATCH HOOD SAFETY LATCH     NUT CONNECTING                ROD        HOOD BUMPER                            RIVET         ...
WEATHERSTRIPCOWL           DASH PANEL                  SEAL                    THICK-HEAD RETAINER   FLAT-HEAD RETAINER   ...
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Exj 23

  1. 1. XJ BODY 23 - 1 BODY CONTENTS page pageBODY COMPONENT SERVICE . . . . . . . . . . . . . 16 SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10GENERAL SERVICE INFORMATION . . . . . . . . . . 1 STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . 4PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL SERVICE INFORMATIONGENERAL INFORMATION Do not use harsh alkaline based cleaning sol- vents on painted or upholstered surfaces. DamageSAFETY PRECAUTIONS AND WARNINGS to finish or color can result. Do not hammer or pound on plastic trim panelWARNING: EYE PROTECTION SHOULD BE USED when servicing interior trim. Plastic panels canWHEN SERVICING GLASS COMPONENTS. PER- break.SONAL INJURY CAN RESULT. USE A OSHA APPROVED BREATHING FILTER Chrysler Corporation uses many different types ofWHEN SPRAYING PAINT OR SOLVENTS IN A CON- push-in fasteners to secure the interior and exteriorFINED 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 repairPETROLEUM OR ALCOHOL– BASED CLEANING procedures. At times, a push-in fastener cannot beSOLVENTS. 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 aTHAT IS NOT PROPERLY SUPPORTED ON SAFETY fastener without damaging a component or body, cutSTANDS. 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 aCAUTION: When holes must be drilled or punched suitable fork-type prying device, pry the fastenerin an inner body panel, verify depth of space to the from the retaining hole behind the component beingouter body panel, electrical wiring, or other compo- removed. When installing, verify fastener alignmentnents. 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 pullmaterial 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 inbattery 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 onpainted surfaces. Damage to finish can result.
  2. 2. 23 - 2 BODY XJ PAINT INDEX page pageGENERAL 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 . . . . . . . . . . . . 2GENERAL INFORMATION PAINTED SURFACE TOUCH-UP When a painted metal surface has been scratchedPAINT 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 Topof the dash panel in the engine compartment. Refer Coat. Refer to Introduction group of this manual forto the Introduction section at the front of this man- Body Code Plate information.ual for body code plate description. The paint code isalso identified on the Vehicle Safety Certification TOUCH-UP PROCEDURELabel which is located on the drivers door shut face. (1) Scrape loose paint and corrosion from insideThe 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 Oilmost repair product containers. Remover, and allow to dry. (3) Fill the inside of the scratch or chip with a coatBASE 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 wetcoat/clear coat) is used. Color paint that is applied to enough to puddle-fill the defect without running. Doprimer is called base coat. The clear coat protects the not stroke brush applicator on body surface. Allowbase 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 originalWET 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 strokeclear coat or single-stage finishes can be reduced applicator brush on body surface. Allow touch-upwith 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-upcannot 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 asCAUTION: 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. 3. XJ BODY 23 - 3SPECIFICATIONSAFTERMARKET PAINT REPAIR PRODUCTSEXTERIOR COLOR CHRY S-W ACME AKZO/NOBEL EXTERIOR COLOR PPG BASF DuPONT CODE * M-S SIKKENSFlame Red PR4 4679 23043 B9326 46916 CHA93:PR4Clear CoatMagenta Clear Coat SH1 74171 26079 B9615 51522 CHA96:SH1Citron Pearl Coat SJV 47694 26081 B9672 51524 CHA96:SJVMoss Green RJN 47383 25036 B9533 50277 CHA95:RJNPearl CoatBright Jade SQP 47586 26088 B9636 51533 CHA96:SQPSatin GlowLapis Blue RC4 4935 24098 B9531 50218 CHA95:RC4Clear CoatDark Blue PCJ 4783 24072 B9453 48543 CHA94:PCJPearl CoatBlack Clear Coat DX8 9700 15214 99 34858 CHA85:DX8Gunmetal Pearl Coat TQ7 5248 27035 B9735 52952 CHA97:TQ7Stone White SW1 83542 26089 B9622 51539 CHA96:SW1Clear CoatCLADDING COLOR CLADDING CHRY S-W ACME AKZO/NOBEL PPG BASF DuPONT COLOR CODE * M-S SIKKENSFlame Red PR4 4679 23043 B9326 46916 CHA93:PR4Moss Green RJN 47383 25036 B9533 50277 CHA95:RJNDark Blue PCJ 4783 24072 B9453 48543 CHA94:PCJPear CoatGunmetal TQ7 5248 27035 B9735 52952 CHA:TQ7Pearl CoatBlack DX8 9700 15214 F0204 34858 CHA85:DX8Stone 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 theVehicle Safety Certification label.INTERIOR COLOR INTERIOR S-W ACME CHRY CODE PPG BASF DuPONT COLOR M-SMist Gray C3 35799/2-1576 25065 C9507 50508Saddle T6 27917/2-1594 26121 C9604 51542
  4. 4. 23 - 4 BODY XJ STATIONARY GLASS INDEX page pageDESCRIPTION AND OPERATION REAR DOOR STATIONARY WINDOW GLASS . . 7 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 4 REAR QUARTER WINDOW GLASS . . . . . . . . . . 8REMOVAL AND INSTALLATION WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . . . . . 8DESCRIPTION AND OPERATION structural support for the roof. The urethane bonding used to secure the windshield to the fence is difficultSAFETY PRECAUTIONS to cut or clean from any surface. The moldings are set in urethane, and will be damaged during theWARNING: DO NOT OPERATE THE VEHICLE removal process. Before removing the windshield,WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. check the availability of the windshield and moldingsIT TAKES AT LEAST 24 HOURS FOR URETHANE from the parts supplier.ADHESIVE TO CURE. IF IT IS NOT CURED, THEWINDSHIELD MAY NOT PERFORM PROPERLY INAN ACCIDENT. REMOVAL AND INSTALLATION URETHANE ADHESIVES ARE APPLIED AS A SYS-TEM. USE GLASS CLEANER, GLASS PREP SOL- WINDSHIELDVENT, GLASS PRIMER, PVC (VINYL) PRIMER AND The windshield is positioned in the reveal moldingPINCHWELD (FENCE) PRIMER PROVIDED BY THE and is bonded to the windshield frame with urethaneADHESIVE 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 andFACTURER’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 bodyAFTER 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 longerTHANE 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 surfaceSHOULD 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 theCAUTION: 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 thewindshield. perimeter of the windshield (Fig. 1). (6) Remove the windshield glass from the frame. It is difficult to salvage a windshield during theremoval operation. The windshield is part of the
  5. 5. COLD KNIFE WINDSHIELDXJ BODY 23 - 5REMOVAL 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 primerINSTALLATION—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 spacersCLEANER TO CLEAN WINDSHIELD BEFORE to the bottom of the windshield, 170 mm inboardAPPLYING 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 basedglass 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 adhesive16 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 andto the windshield contact surface to help secure the position the glass on the pinchweld flanges. Ensuremolding to the windshield during the installation that the windshield glass is correctly seated on theprocedure. 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 pressurecenter of each side. (Some stretching of the molding streams of water directly at urethane. If any leaksmay 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 theinspect 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 interioraligned 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 vehiclealignment 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 suitablework surface with two padded, wood 10 cm by 10 cm
  6. 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 PROCEDURE23 - 6 BODY XJREMOVAL 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. 7. DIVISION BAR UPPER SCREW GLASS SCREW LOWERXJ BODY 23 - 7REMOVAL AND INSTALLATION (Continued) • With the molding at room temperature, press (14) Water test the windshield with a water spraythe 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 anycenter 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. Ifand 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 glassedge equally around the perimeter of the opening. REAR DOOR STATIONARY WINDOW GLASS (6) If the pinchweld flanges require repair, removethe windshield glass and straighten, align, or repair REMOVALthe 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 fromence. 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 removearound 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 glassand attach only to the inside of glass. • Thoroughly mix and apply blackout primer tothe 16 mm (5/8 in) surface area around the interiorside 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 spacersto the bottom of the windshield, 170 mm inboardfrom the outer windshield edge (Fig. 5). (10) Cut the urethane applicator nozzle (Fig. 6). (11) Apply a continuous bead of urethane to thesurface area with blackout primer on the interiorside of glass. The bead should be 9-mm (3/8-in) wideby 12.7-mm (1/2-in) deep for best results. Fig. 7 Division Bar/Stationary GlassCAUTION: Be prepared to install the glass immedi- INSTALLATIONately 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. 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 GLASS23 - 8 BODY XJREMOVAL 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 openingREMOVAL 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 revealers. molding. (3) Separate the weatherstrip seal lip from thewindow opening flanges. Use a pry tool and carefullypush the window glass and seal outward. (4) Remove the weatherstrip seal and windowglass from window opening. (5) Remove the weatherstrip seal from the windowglass. Fig. 9 Weatherstrip Seal and Cord Installation Fig. 8 Quarter Window Reveal Molding, Glass and SealINSTALLATION (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 sealantto 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 cordwith a soap and water solution. LIFTGATE GLASS • Ensure that the cord is long enough to go all the REMOVALway 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 betweendiameter bead of sealant at the quarter panel appli- the liftgate glass and the inboard edge of the revealque and liftgate pillar seam. molding. (6) Position the quarter window glass and the (7) Cut around the interior perimeter of the revealweatherstrip 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. 9. (POSITIONWEATHERSTRIP 1/4-INCH DIAMETER CORD STRIP GLASS WEATHER- IN CHANNEL)XJ BODY 23 - 9REMOVAL 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-upCAUTION: 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 holdthane 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 openingand position glass in the center of the openingagainst flange.
  10. 10. EXTRACTOR6773 EXTRACTOR TOOL 6773 TOOL HEAD RESTRAINT RESTRAINT HEAD SLEEVE SLEEVE SEAT BACK FWD FWD BACK SEAT23 - 10 BODY XJ SEATS INDEX page pageREMOVAL 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 . . . . . . . . . . . . . . . 10REMOVAL AND INSTALLATIONHEAD RESTRAINT SLEEVEREMOVALNOTE: When replacing a head restraint sleeve, theretaining tabs on the sleeve will be damaged duringthe removal process. Check the availability ofreplacement parts before servicing. (1) Raise head restraint to the full up position. (2) Turn head restraint lock thumbwheel to releasehead restraint and pull head restraint upward toremove from seat back. (3) Insert head restraint sleeve extractor (specialtool 6773) (Fig. 1) and (Fig. 2) into the seat back. Fig. 1 Head Restraint Sleeve Extractor (4) The retaining tabs are positioned on each sideof the sleeve, when inserting the extractor, ensurethat the flat of the collar is facing the side of theseatback (Fig. 3). (5) Using a small hammer, tap extractor down-ward to release sleeve retaining tab. (6) Remove extractor tool from sleeve, rotate tool180 degrees (Fig. 4) and repeat steps 3 and 4. (7) Remove extractor tool from sleeve and removesleeve 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 InstallationREMOVAL (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. 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 BEZELXJ BODY 23 - 11REMOVAL AND INSTALLATION (Continued) Fig. 3 Head Restraint Sleeve Extractor Positioning Fig. 5 Head Restraint Fig. 4 Head Restraint Sleeve Extractor PositioningINSTALLATION (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 andadjuster 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 throughREMOVAL the access hole in the seat cushion frame, if equipped.NOTE: If the vehicle is equipped with manuallyadjusted bucket seats, the inboard or outboard seat INSTALLATIONtrack 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. 12. SEAT BACK COVER SEAT CUSHION BACK SEAT BACKFAS- LOOP HOOK SEAT CUSH- CUSHION SEAT TENER COVER BACK AND BACK ION HOG RING SUPPORT23 - 12 BODY XJREMOVAL AND INSTALLATION (Continued) (4) Install screws attaching the side shield trimcover to the seat. (5) Install bucket seat.BUCKET SEAT PLATFORM Bucket seat platforms are not repairable. If theseat platform is damaged, replace platform as a unit.BUCKET SEATBACK COVERREMOVAL (1) Remove head restraint, if equipped. (2) Remove screws attaching side shield trim coverto 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 fullrecline position. (6) Remove the seatback cover zipper from thebase 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 seatbackcover to the seatback cushion support wires (Fig. 8). (10) Roll the seatback cover upward and disengagethe hook and loop fastener (Fig. 9). (11) Roll seatback cover up and over the headrestraint sleeves, if equipped and separate from theseatback. 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 theaccess 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. 13. SEAT BACK RING RECLINEREAT CUSHION SEAT CUSHION COVER S HOG SEAT CUSHION RECLINER SEATCUSHION REMOVE BACK RECLINERCUSHION SEAT HAN- DLEXJ BODY 23 - 13REMOVAL 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 COVERREMOVAL (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 sideof the cover to the cushion frame. (6) Turn the cushion over and roll the cover off thecushion. (7) Remove the hog rings attaching the cover tothe 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. 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 BRACKET23 - 14 BODY XJREMOVAL 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 toclips 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 BUMPERREMOVAL (1) Disengage the seat cushion at the rear by pull-ing upward on the release strap. (2) Tilt the seat cushion forward.
  15. 15. COVER ZIPPER SEAT BACKXJ BODY 23 - 15REMOVAL 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 RemovalINSTALLATION (1) Install the cover on the seatback. (2) Attach the cover J-strap to the seatback frame.
  16. 16. 23 - 16 BODY XJ BODY COMPONENT SERVICE INDEX page pageDIAGNOSIS AND TESTING FULL FLOOR CONSOLE . . . . . . . . . . . . . . . . . 51 WATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 17 GRILLE OPENING PANEL (GOP) . . . . . . . . . . . 19 WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 18 GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19SERVICE PROCEDURES HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 BODY LUBRICATION . . . . . . . . . . . . . . . . . . . . 18 HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . . . . 19REMOVAL 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. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . 53DIAGNOSIS AND TESTING • If a leak occurs while driving at highway speeds in a steady rain, test the leak area with a reasonableWATER 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 anporosity, 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 whendrip from a location away from the actual leak point, the leak occurs when the vehicle accelerates, stops ormaking leak detection difficult. All body sealing turns. If the leak occurs on acceleration, hoist thepoints 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 leftthe vehicle should not enter the passenger or luggage turns, hoist the left side of the vehicle. If the leakcompartment. 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 Informationenter the passenger compartment during high pres- section.sure washing or hard driving rain (severe) condi-tions. Overcompensating on door or glass WATER LEAK DETECTIONadjustments to stop a water leak that occurs under To detect a water leak point-of-entry, do a watersevere conditions can cause premature seal wear and test and watch for water tracks or droplets formingexcessive 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 thebefore 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 considerableTESTS 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 ordrains are clear, and body components are properly drop. The highest point usually will show the point ofaligned and sealed. If component alignment or seal- entry. After leak point has been found, repair theing is necessary, refer to the appropriate section of leak and water test to verify that the leak hasthis group for proper procedures. stopped. Locating the entry point of water that is leakingWATER 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 waterOR 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 METHODbeen determined, simulate the conditions as closely When a leak point area is visually obstructed, useas 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 areasteady light rain, flood the leak area with an open- to assist in locating a leak point.ended garden hose.
  18. 18. 23 - 18 BODY XJDIAGNOSIS 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 locationbe 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 mmluggage compartment inspect around seals and body (6 in.) lengths along weatherstrips, weld seams orseams. 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 canPRESSURIZED LEAK TEST METHOD catch wind and whistle. When a water leak into the passenger compart- • Gaps in sealed areas behind overhanging bodyment 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. Ifengine can not be started, connect a charger to thebattery to ensure adequate voltage to the blower. SERVICE PROCEDURESWith interior pressurized, apply dish detergent solu-tion to suspected leak area on the exterior of the BODY LUBRICATIONvehicle. Apply detergent solution with spray device or All mechanisms and linkages should be lubricatedsoft bristle brush. If soap bubbles occur at a body when necessary. This will maintain ease of operationseam, joint, seal or gasket, the leak entry point could and provide protection against rust and excessivebe 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 shouldnent 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 italways 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 componentcrosswinds. Over compensating on door or glass should be wiped clean. After lubrication, any excessadjustments 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, latchexcessive 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 lubricantmoldings 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 itwhistling 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 theappropriate section of this group for proper proce-dures.
  19. 19. GRILLE OPENING PANEL NUT GRILLE FWD BODY GRILLE BRACKET SUPPORT OPENING PANELXJ BODY 23 - 19REMOVAL AND INSTALLATIONGRILLEREMOVAL (1) Remove the headlamp/park lamp bezels. (2) Remove the screws attaching the grille to thegrille 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 HOODINSTALLATION 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 releaseGRILLE 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 marksbracket. 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. 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 FWD23 - 20 BODY XJREMOVAL AND INSTALLATION (Continued) Fig. 3 Hood Components
  21. 21. DASH PANEL NUT HOOD HINGE HINGE SEAL BASE HOOD LATCH ROD SPRING HOOD LATCH CONNECTING RODRETAINER CLIPXJ BODY 23 - 21REMOVAL 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. INSTALLATIONNOTE: 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 CABLEREMOVAL (1) Remove the screw that attaches the latch to REMOVALthe 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 INSTALLATIONREMOVAL (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. 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 GOP23 - 22 BODY XJREMOVAL 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 andinstall 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 tothe 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 LatchINSTALLATION (1) Position the safety latch on the hood. (2) Install the nuts attaching the safety latch tothe inner hood panel. (3) Close hood. Fig. 9 Hood Silencer Pad
  23. 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- RIVETXJ BODY 23 - 23REMOVAL AND INSTALLATION (Continued)INSTALLATION (1) Position the hood silencer pad on the hoodinner panel. (2) Install the retainers attaching the hoodsilencer pad to the inner hood panel. (3) Install the clips attaching the latch connectingrod to the hood inner panel. (4) Install the hood latch release bellcrank. (5) Close hood.COWL WEATHERSTRIPREMOVAL (1) Pry upward along the length of weatherstrip. (2) Detach the weatherstrip retainers from thecowl 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 WeatherstripINSTALLATION (1) Position the weatherstrip on the cowl panel. (2) Press to insert retainers into the cowl panelholes.COWL GRILLEREMOVAL (1) Remove the windshield wiper arms from thepivots. (2) Remove the screws that attach the grille to the Fig. 12 Cowl Grille Screw Tightening Sequencecowl. (3) Remove the windshield washer tubes from the BODY DECALSnozzles. 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 repairand installed so that they are not pinched. and paint refinish be completed first.

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