EXJ_1399 jeep xj service manual

7/29/2019 EXJ_1399 jeep xj service manual

1/8

FRAME AND BUMPERS

CONTENTS

page page

BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

BUMPERS

INDEX

page page

REMOVAL AND INSTALLATION

FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . 1

FRONT BUMPER END CAP . . . . . . . . . . . . . . . . . 1FRONT TOW HOOK . . . . . . . . . . . . . . . . . . . . . . . 2

REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . 3REAR BUMPER END CAP . . . . . . . . . . . . . . . . . . 2

REAR TOW HOOK . . . . . . . . . . . . . . . . . . . . . . . . 4


FRONT BUMPER END CAP

REM OVAL

(1 ) R e m o v e t h e r i v e t a t t a c h i n g t h e e n d c a p t o t h e

air deflector.

( 2 ) R e m o v e t h e b o l t s a n d n u t s a t t a c h i n g t h e e n dcap to the bumper (Fig. 1).

(3) Pull back the wheelhouse l iner and remove the

s c r e w s a t t a c h i n g t h e e n d c a p t o t h e f r o n t f e n d e r .

(4) L ift in g t h e en d ca p f rom t h e b ot t om , t ilt

s l ig h t l y u p w a r d a n d s l id e i t o u t w a r d t o d i se n ga g e t h e

retainer tab from the bumper (Fig. 2).

(5) Se p a r a t e t h e e n d c a p f r om t h e bu m pe r.

INSTALLATION

(1) Position the end cap on the bumper and engage

t h e r e t a i n in g t a b .

(2 ) I n s t a l l t h e s c r e w s a t t a c h i n g t h e e n d c a p t o t h e

front fender.

( 3 ) I n s t a l l t h e b o l t s a t t a c h i n g t h e e n d c a p t o t h e

bumper. Tighten t he nut to 9 Nm (7 ft . lbs.) torque.

(4) I n s t a l l t h e r i ve t a t t a ch i ng t h e e n d ca p t o a i r

deflector.

FRONT BUMPER

REMOVAL

(1) Remove bumper end caps.

(2) I f e q u ip pe d , d i s en g a g e f og l a m p w i r e h a r n e s s

connectors.

(3) Disconnect vacuum line from reservoir (Fig. 3).

(4) Remove Torx-head bolts tha t at ta ch bumper tomounting brackets (Fig. 1).

(5) Remove bumper from vehicle.

(6) I f n e ce ss a r y, r e m ov e bol t s a t t a c h i n g bu m pe r

mounting brackets to frame.

INSTALLATION

(1) I f r em ov ed , i n st a l l b ol t s a t t a ch i ng b u mp er

mounting bra ckets t o fra me. Tighten bolts t o 55 Nm

(41 ft. lbs.) torque.

(2) Position bumper on front of vehicle.

(3) I n s t a l l Tor x -h e a d bol t s t h a t a t t a c h bu m pe r t o

m ou n t i n g br a c ke t s . Ti g h t en bol t s t o 55 N m (41 f t .

lbs.) torque.(4) Connect vacuum line to reservoir.

(5) If equipped, engage fog lamp wire harness con-

nectors.

(6) Instal l bumper end caps.

XJ FRAM E AND BUM PERS 1 3 - 1


2/8

FRONT TOW HOOK

REM OVAL(1) R e m ov e bo lt s a t t a c h i n g t ow h ook t o t o w h ook

reinforcement (Fig. 4).

(2) Separate tow hook from reinforcement.

(3) I f n e ce ss a r y, r e m ov e bol t a t t a c h in g t o w h ook

reinforcement to frame.

INSTALLATION

(1) I f r em ov ed , i n st a l l b ol t a t t a ch i ng t ow h ook

reinforcement to frame. Tighten bolt to 30 Nm (22 ft.

lbs.) torque.

(2) Position tow hook on reinforcement.

(3) I n s t a l l b ol t s a t t a ch i ng t ow h ook t o t ow h ook

reinforcement. Tighten bolts to 100 Nm (74 ft . lbs.)

torque.

REAR BUMPER END CAP

REMOVAL

(1) R em ove t h e b olt s a n d n ut s a t t a ch in g t h e

underside of the end cap to the bumper (Fig. 5).

(2) R e mov e t h e s cr ew a t t a ch i ng t h e f r on t of t h e

e n d c a p t o t h e u n d e r s i d e o f t h e q u a r t e r p a n e l .

Fig. 1 Front Bumper

Fig. 2 Bumper End Cap

Fig. 3 Vacuum Reservoir

1 3 - 2 FRAM E AND BUM PERS XJ

REMOVAL AND INSTALLATION (Continued)


3/8

(3) L i f t t h e e nd ca p s li gh t l y u pw a r d a n d s li de i t

r e a r w a r d t o r e l e a s e i t f r o m t h e r e t a i n e r .

(4) Separate the end cap from the vehicle.

INSTALLATION

(1) Position the end cap on the rear of the retainer

and the outer edge of the bumper.

(2) S l i de t h e e nd ca p f or w a r d on t o t h e r et a i n er.

E n su r e t h e en d ca p ov er la p s t h e l ip of t h e r ea r

wheelhouse liner.

(3) I n s t a l l t h e s cr e w a t t a ch i n g t h e f r o n t o f t h e e n d

c a p t o t h e u n d e r s i d e o f t h e q u a r t e r p a n e l .

(4 ) I n s t a l l t h e bo l t s a n d n u t s a t t a c h i n g t h e u n d e r -

s i d e o f t h e e n d c a p t o t h e bu m p e r .

REAR BUMPER

REMOVAL

(1) F or v eh i cl es eq u ip pe d w i t h a t r a i l er h i t ch ,remove hitch before removing bumper. If necessary,

r e f e r t o r e m o v a l p r o c e d u r e w i t h i n Gr o u p 1 3 , Fr a m e

a n d B u m p e r s .

(2) Remove bumper end caps.

(3) Rem ov e u pper n u ts t h a t a t t a c h b um per t o

bumper support brackets (Fig. 5).

(4) Rem ov e l ow e r b ol ts t h a t a t t a ch b um per t o

bumper support brackets.

(5) Remove bumper from vehicle.

(6) If necessary, remove bumper support brackets

f r om t h e r e a r s i ll .

INSTALLATION(1) If removed, instal l bumper support brackets on

t h e r ea r s il l. Ti gh t en b ol t s t o 55 N m (41 f t . l bs .)

torque.

(2) Position bumper on support brackets.

(3) I n st a l l b ol t s t h a t a t t a c h b um per t o b um per

support bra ckets. Tighten nuts to 55 Nm (41 ft . lbs.)

torque.

(4) Instal l bumper end caps.

(5) If removed, instal l trai ler hitch.

Fig. 4 Front Tow Hook

Fig. 5 Rear Bumper




4/8

REAR TOW HOOK

REM OVAL

(1) Remove bolts that attach tow hook bracket and

tow hook to frame rai l (Fig. 6).

(2) Remove bracket and tow hook from frame rai l .

INSTALLATION

(1) Position bracket and tow hook on frame rai l .

(2 ) I n s t a l l bo l t s t h a t a t t a c h t o w h o o k br a c k e t a n d

t o w h ook t o f r a m e r a i l . Ti g h t en bol t s t o 94 N m (70

ft . lbs.) torque.

Fig. 6 Rear Tow Hook




5/8

FRAME

INDEX

page page


FRONT SKID PLATE . . . . . . . . . . . . . . . . . . . . . . 5

FUEL TANK SKID PLATE . . . . . . . . . . . . . . . . . . . 5TRAILER HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 6

TRANSFER CASE SKID PLATE . . . . . . . . . . . . . . 5SPECIFICATIONS

FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . . . . 6FRAME TORQUE SPECIFICATIONS . . . . . . . . . . 8


FRONT SKID PLATE

REM OVAL

(1) R em ov e t h e s cr ew s t h a t a t t a ch s ki d p la t e t o

side sills.( 2 ) R e m o v e t h e n u t s t h a t a t t a c h t h e s k i d p l a t e t o

the crossmember (Fig. 1).

(3) Remove the skid plate from the vehicle.

INSTALLATION

(1) P os i t ion t h e s k id p la t e a t f r on t cr os s m em ber

and side si l ls .

(2) I ns ta l l t h e n ut s t o a t t a ch t h e s kid pla t e t o

crossmember.

( 3 ) I n s t a l l t h e s c r e w s t o a t t a c h s k i d p l a t e t o s i d e

sills.

TRANSFER CASE SKID PLATE

REMOVAL

(1) Support skid plate.

(2) R e m ov e b ol t s t h a t a t t a ch s ki d p la t e t o t r a n s -

mission support crossmember and frame si l l (Fig. 2).

(3) Remove support and skid plate from vehicle.

INSTALLATION

(1) P os it i on a n d s u pp or t s ki d p la t e a t f r a m e s i l l

an d tra nsmission support crossmember.

(2 ) A t t a c h s k i d p l a t e t o f r a m e s i l l a n d c r o s s m e m -

ber w i t h bol t s . Ti g h t en bol t s t o 22 N m (16 f t . l bs.)

torque.

FUEL TANK SKID PLATE

REMOVAL

(1) Position a support under skid plate.

(2) R e m ov e bol t s t h a t a t t a c h s k id p la t e t o u n d er -

body side rai ls (Fig. 3).

(3) Remove support and skid plate from vehicle.

INSTALLATION

(1) P os it i on a n d s u pp or t s ki d p la t e u n d er f u el

t a n k .

Fig. 1 Front Skid Plate

Fig. 2 Transfer Case Skid Plate



6/8

(2 ) I n s t a l l bo l t s t o a t t a c h s k i d p l a t e t o u n d e r bo d y

ra ils . Tighten bolts to 74 Nm (55 ft . lbs.) torque.

(3) Remove support from under skid plate.

TRAILER HITCH

REM OVAL

(1) I f n e ce ss a r y, r e mov e t h e t r a i l e r t ow w i r e h a r -

ness connector from the hitch (Fig. 4).

(2) Support the hitch.

(3 ) R e m o v e t h e bo l t s t h a t a t t a c h t h e t r a i l e r h i t c h

to t he fra me si l ls a nd reinforcement brackets (Fig. 5).

(4) If equipped, remove the fuel tank skid plate.

NOTE: The reinforcement brackets are held on the

frame sills with two blind rivets.

INSTALLATION

(1) I n st a ll fr a me r ein for cem en t b ra ck et s, ifremoved. Slide the brackets through the vehicle rear

s i l l o p e n i n g s a n d a t t a c h t o t h e f r a m e s i l l s w i t h bl i n d

rivets.

(2) Using an adequate l i ft ing device, position hitch

at the proper location for instal lation on vehicle and

support i t .

(3) I f e q u ip pe d , p o si t i on f u el t a n k s k id p la t e on

vehicle frame si l ls .

(4) L o os el y i n st a l l t h e b ol t s t o a t t a ch t h e t r a i l er

hitch (and t he skid plate) to frame si l ls a nd r einforce-

ment brackets.

(5) Tighten al l bolts/nuts to 74 Nm (55 ft . lbs.)

torque.(6) Remove t he l ift/support .

(7) If removed, attach the trai ler wire harness con-

n e ct o r t o t h e h i t ch .

SPECIFICATIONS

FRAM E DIM ENSIONSFr a m e d i m en s i on s a r e l is t e d i n m i ll i me t er s ca l e .

All dimensions are from center to center of Principal

Locating Point (PLP), or from center to center of PLP

and fastener location (Fig. 6).

Fig. 3 Fuel Tank Skid Plate

Fig. 4 Trailer Hitch Harness Connector

Fig. 5 Trailer Hitch




7/8

Fig. 6 Frame Dimensions


SPECIFICATIONS (Continued)


8/8

FRAME TORQUE SPECIFICATIONS

DESCRIPTION TORQUE

Fr o n t Sk i d P l a t e S cr e w . . . . . . . . . . . . . . . . 4 2 N m

(31 ft. lbs.)

Fr o n t Sk i d P l a t e Nu t . . . . . . . . . . . . . . . . . . 17 Nm

(125 in. lbs.)Tr a n s f er C a s e Sk id P l a t e B ol t . . . . . . . . . . . 22 Nm

(16 ft. lbs.)

Fu e l Ta n k S k i d P l a t e B ol t . . . . . . . . . . . . . . 74 Nm

(55 ft. lbs.)

Fr o n t B u m p e r E n d C a p t o

M ou n t i n g B r a ck et Nu t . . . . . . . . . . . . . . . . 9 N m

(7 ft. lbs.)

Front Bumper Mounting

B r a c ke t t o Fr a m e B ol t . . . . . . . . . . . . . . . 55 Nm

(41 ft. lbs.)

Fr o n t B u m p e r t o

M ou n t i n g B r a ck et B o l t . . . . . . . . . . . . . . . 55 N m

(41 ft. lbs.)

Front Tow Hook B olt . . . . . . . . . . . . . . . . . 100 Nm

(74 ft. lbs.)

Fr ont Tow H ook

Reinforcement Bolt . . . . . . . . . . . . . . . . . . 30 Nm

(22 ft. lbs.)

R e a r B u m p e r t o

M t g . B r a ck et N u t . . . . . . . . . . . . . . . . . . 55 N m

(41 ft. lbs.)

R e a r B u m p er M t g . B r a c k et t o

R e a r Si l l B o l t . . . . . . . . . . . . . . . . . . . . . . 55 Nm

(41 ft. lbs.)

Rear Tow H ook B olt . . . . . . . . . . . . . . . . . . . 94 Nm(70 ft. lbs.)

Tra iler Tow

R e in f or ce m en t B r k t B ol t . . . . . . . . . . . . . 74 Nm

(55 ft. lbs.)


SPECIFICATIONS (Continued)

EXJ_1399 jeep xj service manual

Documents

Transcript of EXJ_1399 jeep xj service manual