Jeep XJ. Manual — part 481
FRONT DOOR WATERDAM
REMOVAL
The waterdam is attached to the door inner panel
with a butly adhesive. If cohesive separation of the
butly between the waterdam and door inner panel
occurs during the removal process, cut the strands of
butly with a razor knife or equivalent.
(1) Remove door trim panel.
(2) Disengage clips attaching wire harnesses to the
door inner panel.
(3) Push the harnesses/connectors through the
waterdam and into the door.
(4) Grasp the upper and lower rearward corners of
the waterdam and rapidly peel back the waterdam
from the door inner panel.
(5) Separate the waterdam from the door inner
panel.
INSTALLATION
(1) Route the latch rods through the waterdam.
(2) Position the waterdam on the door, apply adhe-
sive as necessary and press into place.
(3) Route the harnesses/connectors through the
waterdam.
Fig. 21 Window Crank—Typical
1 – WINDOW CRANK REMOVAL TOOL
2 – WINDOW CRANK
Fig. 22 Front Door Trim Panel-Manual Window
1 – U-NUT
2 – DOOR
3 – TRIM PANEL
4 – WINDOW CRANK
5 – SPACER
6 – PUSH-IN FASTENER
Fig. 23 Front Door Trim Panel-Power Window
1 – U-NUT
2 – DOOR
3 – TRIM PANEL
4 – PUSH-IN FASTENER
Fig. 24 Detaching Trim Panel Push-In Fasteners
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BODY
XJ
REMOVAL AND INSTALLATION (Continued)
(4) Engage clips attaching wire harnesses to the
door inner panel.
(5) Install door trim panel.
FRONT DOOR
REMOVAL
(1) Remove door restraint (check) retaining pin.
(2) For vehicles equipped with power windows,
power mirrors and power door locks, remove trim
panel and waterdam. Disconnect all components and
route wire harness out of door.
(3) Remove bolts that attach hinge to door (Fig.
26).
(4) Remove door from vehicle.
INSTALLATION
(1) Position door in body opening.
(2) Align door hinges, plates and shims and install
bolts. Tighten bolts to 3 N·m (2 ft. lbs.) torque.
(3) Install door restraint (check) pin.
(4) If applicable, route and connect wire harness
connectors.
(5) Install door waterdam and trim panel.
FRONT DOOR HINGE
REMOVAL
(1) Remove door restraint (check) retaining pin.
(2) Remove door hinge bolts and shims (Fig. 26).
(3) Retain door hinge shims for correct installa-
tion.
INSTALLATION
(1) Position hinge plates and shims on door face.
(2) Align door hinges and shims with bolt holes
and install hinge bolts. Tighten bolts to 3 N·m (2 ft.
lbs.) torque.
(3) Adjust/align latch striker and latch as neces-
sary.
(4) Install door restraint (check) retaining pin.
FRONT DOOR RESTRAINT
REMOVAL
(1) Remove door trim panel.
(2) Remove door radio speaker from door inner
panel.
(3) Remove door restraint (check) retaining pin
from bracket with a punch.
(4) Remove nuts and remove restraint via speaker
opening. (Fig. 27).
INSTALLATION
(1) Position door restraint in door by way of open-
ing and install nuts.
NOTE: Ensure the spring on the door restraint is
facing outward.
(2) Position door restraint in bracket with holes
aligned and insert retaining pin.
(3) Install radio speaker and door trim panel.
FRONT DOOR OUTSIDE HANDLE
REMOVAL
(1) Remove the door trim panel and waterdam.
Fig. 25 Push-In Fasteners
1 – LOCATING PINS
2 – TRIM PANEL
3 – PUSH-IN FASTENERS
Fig. 26 Front Door Hinge
1 – UPPER HINGE
2 – SHIM
3 – LOWER HINGE
4 – FRONT DOOR
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BODY
23 - 35
REMOVAL AND INSTALLATION (Continued)
(2) Remove the access hole cover and remove the
rearward nut attaching the door handle to the door.
(Fig. 28).
(3) Disconnect the handle-to-latch rod from the
handle latch release lever arm.
(4) Remove the forward nut attaching the handle
to the door.
(5) Separate the handle from the door.
INSTALLATION
(1) Position the handle in the door.
(2) Install the forward nut attaching the handle to
the door.
(3) Connect the latch to handle rod, to the handle
latch release lever arm.
(4) Install the rearward nut attaching the door
handle to the door.
(5) Install the access hole cover.
(6) Install the door waterdam and trim panel.
FRONT DOOR LOCK CYLINDER
REMOVAL
(1) Remove the door trim panel.
(2) Peel back waterdam to access lock cylinder.
(3) Disconnect the door latch-to-lock cylinder rod
at the door latch (Fig. 29).
(4) Remove the lock cylinder retainer clip.
(5) Remove the lock cylinder.
(6) If applicable, remove the door latch-to-lock cyl-
inder rod from the original lock cylinder. Connect it
to the replacement lock cylinder.
INSTALLATION
(1) Position the lock cylinder and in the door open-
ing.
(2) Install the retainer clip.
(3) Connect the door latch-to-lock cylinder rod to
the door latch.
(4) Press the waterdam into position.
(5) Install the door trim panel.
Fig. 27 Door Restraint (Check)
1 – A-PILLAR
2 – RETAINING PIN
3 – NUT
4 – DOOR RESTRAINT
5 – RESTRAINT BRACKET
6 – DOOR INNER PANEL
7 – SPEAKER OPENING
Fig. 28 Front Door Outside Handle
1 – OUTSIDE DOOR HANDLE
2 – OUTSIDE HANDLE TO LATCH ROD
3 – DOOR LATCH
4 – OUTSIDE HANDLE TO LATCH ROD
Fig. 29 Door Lock Cylinder
1 – ACCESS PLUG
2 – RETAINER
3 – LOCK CYLINDER TO LATCH ROD
4 – LATCH
5 – LOCK CYLINDER TO LATCH ROD
6 – LOCK CYLINDER
7 – GASKET
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BODY
XJ
REMOVAL AND INSTALLATION (Continued)
LOCK CYLINDERS
Ignition, door, deck lid, and rear hatch lock cylin-
ders are all codable to the key. Lock barrels, tum-
blers, and tumbler springs are available to allow the
technician to change replacement locks cylinders to
match the customer’s original key set. See the appro-
priate section in this manual for lock cylinder
removal. See the Mopar
t catalogue for part numbers
and lock coding procedures.
FRONT DOOR LATCH
REMOVAL
(1) Remove door trim panel and waterdam.
(2) Remove screws attaching latch to door.
(3) Disconnect all rods from latch (Fig. 30).
(4) Disconnect power lock motor wire connector, if
equipped.
(5) Remove latch from door face.
INSTALLATION
(1) Position latch on door face.
(2) Connect power lock motor wire connector, if
equipped.
(3) Connect all rods to latch.
(4) Install screws attaching latch to door. Tighten
screws to 11 N·m (8 ft. lbs.) torque.
(5) Install waterdam and door trim panel.
FRONT DOOR LATCH STRIKER
REMOVAL
(1) Using a grease pencil or equivalent, mark posi-
tion of striker.
(2) Remove screws attaching striker to B-pillar
(Fig. 31).
(3) Separate striker from B-pillar.
INSTALLATION
(1) Position and align striker on B-pillar.
(2) Install screws attaching striker to B-pillar.
Tighten screws to 28 N·m (20 ft. lbs.) torque.
FRONT DOOR INSIDE HANDLE ACTUATOR
REMOVAL
The front door inside handle actuator is heat
staked to the front door trim panel during the man-
ufacturing process.
(1) Remove the door trim panel.
(2) Using an X-ACTO knife or equivalent, cut the
melted tabs securing the inside handle to the door
trim panel.
(3) Separate the inside handle from the trim
panel.
INSTALLATION
(1) Position the inside handle in the trim panel.
(2) Heat stake the inside handle to the trim panel.
(3) Install the door trim panel.
FRONT DOOR INNER BELT WEATHERSTRIP
REMOVAL
(1) Roll window down.
(2) Remove door trim panel.
(3) Pull up on the rear corner of the weatherstrip
and lift from the door (Fig. 32).
Fig. 30 Door Latch
1 – FRONT DOOR LATCH
2 – LOCK BUTTON TO LATCH ROD
3 – INSIDE HANDLE TO LATCH ROD
4 – OUTSIDE HANDLE TO LATCH ROD
5 – LOCK CYLINDER TO LATCH ROD
Fig. 31 Front Door Latch Striker
1 – SPACER
2 – TAPPING PLATE
3 – STRIKER
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BODY
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REMOVAL AND INSTALLATION (Continued)
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