Jeep Wrangler TJ. Manual — part 547
(3) Position the front end lighting wire harness
into the retainers on the fender. Engage the retainers
to secure.
(4) Install the bolts attaching the fender to the
HCU tray reinforcement bracket.
(5) Install the bolts attaching the fender to the
cowl.
(6) If equipped, install the body side molding.
(7) Route the fog lamp (if equipped), park lamp
and side marker wire harness through the access
hole in the fender well. Seat the grommet.
(8) Engage the headlamp wire connector.
(9) Install the HCU tray.
(10) Position the HCU on the support tray and
install the bolts.
(11) Install EVAP canister.
(12) Install horns. (Refer to 8 - ELECTRICAL/
HORN/HORN - INSTALLATION)
(13) Engage horn wire connectors.
(14) Install the windshield washer reservoir.
(15) Connect the negative terminal on the battery.
(Refer to 8 - ELECTRICAL/BATTERY SYSTEM/CA-
BLES - INSTALLATION)
RADIATOR GRILLE PANEL
REMOVAL
(1) Remove the front crossmember cover.
(2) Remove the crossmember valence cover.
(3) Remove the radiator overflow bottle.
(4) Remove the bolts that attach the radiator and
shroud from the grille panel.
(5) If A/C equipped:
(a) Evacuate the system.
(b) Disconnect the high and low pressure lines
at the quick disconnect couplings.
(c) Cover (cap) the lines to prevent contamina-
tion.
(6) Remove the bolts attaching the radiator sup-
port rods to the grille panel.
(7) Disconnect the head lamp, turn signal, marker
lamp and horn wire harness connectors.
(8) Remove the bolts attaching the fenders to the
grille panel.
(9) Remove the bolt attaching the grille to the
frame mount.
(10) Separate the grille from the vehicle.
Fig. 3 FRONT FENDER
1 - REINFORCEMENT
2 - BATTERY TRAY
3 - BODY
4 - REINFORCEMENT
5 - FENDER
6 - TRAY
7 - RADIATOR GRILLE PANEL
23 - 30
EXTERIOR
TJ
LEFT FRONT FENDER (Continued)
INSTALLATION
Transfer all related components.
(1) Position the grille panel on the vehicle. Ensure
the rubber support bumpers are aligned (Fig. 4).
(2) Install the bolt attaching the grille to the frame
mount.
(3) Install the bolts attaching the fenders to the
grille panel.
(4) Connect the head lamp, turn signal, marker
lamp and horn wire harness connectors.
(5) Install the bolts attaching the radiator support
rods to the grille panel.
(6) If A/C equipped:
(a) Connect the high and low pressure lines at
the quick disconnect couplings.
(b) Evacuate and charge the system.
(7) Install the radiator and shroud to the grille
panel.
(8) Install the radiator overflow bottle.
(9) Install the crossmember valence cover.
(10) Install the front crossmember cover.
WHEELHOUSE SPLASH
SHIELD
REMOVAL
(1) Remove the plastic push pins that attach the
splash shield to the wheelhouse (Fig. 5).
(2) Remove the push-in fasteners attaching the
splash shield to the wheelhouse. (The push-in fasten-
ers are molded into the splash shield.)
(3) Remove the splash shield from the wheelhouse.
INSTALLATION
(1) Position the splash shield in the wheelhouse.
(2) Press the splash shield push-in fasteners into
place.
(3) Attach the splash shield to the wheelhouse
with push pins.
Fig. 4 GRILLE BUMPERS
1 - GRILLE PANEL
2 - BUMPER
Fig. 5 Wheelhouse Splash Shield
1 - BODY
2 - WHEELHOUSE SPLASH SHIELD
3 - PUSH-IN FASTENERS
4 - RIVET
TJ
EXTERIOR
23 - 31
RADIATOR GRILLE PANEL (Continued)
SIDE VIEW MIRROR
REMOVAL
(1) Remove the screws attaching the mirror to the
door hinge (Fig. 6).
(2) Remove the mirror from the door hinge.
(3) Disconnect the electrical connector, if equipped.
INSTALLATION
(1) Clean the door hinge-mirror base contact sur-
face.
(2) Position the mirror base at the door hinge.
(3) Install the three screws attaching the mirror
base to the door hinge.
WHEEL OPENING FLARE
MOLDING
REMOVAL
(1) Remove the side marker lamp. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING
-
EXTERIOR/
MARKER LAMP UNIT - REMOVAL)
(2) Remove the screws that attach the flare to the
front fender or rear wheelhouse (Fig. 7).
(3) Separate the flare from the body.
INSTALLATION
(1) Clean the contact surface on the body.
Fig. 6 SIDE VIEW MIRROR
1 - MIRROR ASSEMBLY
2 - SCREWS (3)
Fig. 7 FENDER FLARES
1 - U-NUT
2 - FENDER FLARE
3 - NUTSERT
4 - SPLASH SHIELD
5 - RIVET
6 - NUTSERT
7 - FENDER FLARE
8 - U-NUT
23 - 32
EXTERIOR
TJ
(2) Clean the contact surface on the flare and posi-
tion it on the front fender or wheelhouse.
(3) Install the screws attaching the flares to the
front fender or wheelhouse.
(4) If removed, install the side marker lamp.
EXHAUSTER
REMOVAL
(1) Remove the spare tire carrier. (Refer to 22 -
TIRES/WHEELS/TIRES/SPARE TIRE CARRIER -
REMOVAL)
(2) Using a trim stick C-4755 or equivalent, sepa-
rate the exhauster from the tailgate. (Fig. 8)
INSTALLATION
(1) Install the exhauster and seat fully.
(2) Install the spare tire carrier. (Refer to 22 -
TIRES/WHEELS/TIRES/SPARE TIRE CARRIER -
INSTALLATION)
BODY SIDE GUARD
REMOVAL
(1) Remove the bolts from the lower support tabs.
(Fig. 9)
(2) Remove the side bolts and remove the side
guard. (Fig. 10)
INSTALLATION
(1) Install the body side guard and install the side
bolts.
(2) Tighten the bolts to 5 N·m (45 in. lbs.).
(3) Install the support tab bolts and tighten to 11
N·m (8 ft. lbs.).
Fig. 8 BODY EXHAUSTER
1 - TAILGATE HANDLE
2 - EXHAUSTER OPENING
3 - EXHAUSTER
Fig. 9 SIDE GUARD - LOWER
1 - BODY SIDE GUARD
2 - SUPPORT TABS (5)
3 - BODY FLOOR SILL
4 - BOLTS (5)
Fig. 10 SIDE GUARD - UPPER
1 - DOOR
2 - SIDE GUARD BOLTS (5)
3 - BODY SIDE GUARD
TJ
EXTERIOR
23 - 33
WHEEL OPENING FLARE MOLDING (Continued)
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