exj_1399 jeep xj service manual
TRANSCRIPT
-
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
REMOVAL AND INSTALLATION
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
-
7/29/2019 EXJ_1399 jeep xj service manual
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)
-
7/29/2019 EXJ_1399 jeep xj service manual
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
XJ FRAM E AND BUM PERS 1 3 - 3
REMOVAL AND INSTALLATION (Continued)
-
7/29/2019 EXJ_1399 jeep xj service manual
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
1 3 - 4 FRAM E AND BUM PERS XJ
REMOVAL AND INSTALLATION (Continued)
-
7/29/2019 EXJ_1399 jeep xj service manual
5/8
FRAME
INDEX
page page
REMOVAL AND INSTALLATION
FRONT SKID PLATE . . . . . . . . . . . . . . . . . . . . . . 5
FUEL TANK SKID PLATE . . . . . . . . . . . . . . . . . . . 5TRAILER HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRANSFER CASE SKID PLATE . . . . . . . . . . . . . . 5SPECIFICATIONS
FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . . . . 6FRAME TORQUE SPECIFICATIONS . . . . . . . . . . 8
REMOVAL AND INSTALLATION
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
XJ FRAM E AND BUM PERS 1 3 - 5
-
7/29/2019 EXJ_1399 jeep xj service manual
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
1 3 - 6 FRAM E AND BUM PERS XJ
REMOVAL AND INSTALLATION (Continued)
-
7/29/2019 EXJ_1399 jeep xj service manual
7/8
Fig. 6 Frame Dimensions
XJ FRAM E AND BUM PERS 1 3 - 7
SPECIFICATIONS (Continued)
-
7/29/2019 EXJ_1399 jeep xj service manual
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.)
1 3 - 8 FRAM E AND BUM PERS XJ
SPECIFICATIONS (Continued)