Jeep Cherokee (XJ): Service procedures. Removal and installation

Service procedures

REAR GLASS HEATING GRID REPAIR

Repair of the rear glass heating grid lines, bus bars, terminals or pigtail wires can be accomplished using a Mopar Rear Window Defogger Repair Kit (Part Number 4267922) or equivalent.

WARNING: MATERIALS CONTAINED IN THE REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION.

THE KIT CONTAINS EPOXY RESIN AND AMINE TYPE HARDENER, WHICH ARE HARMFUL IF SWALLOWED.

AVOID CONTACT WITH THE SKIN AND EYES. FOR SKIN CONTACT, WASH THE AFFECTED AREAS WITH SOAP AND WATER. FOR CONTACT WITH THE EYES, FLUSH WITH PLENTY OF WATER.

DO NOT TAKE INTERNALLY. IF TAKEN INTERNALLY, INDUCE VOMITING AND CALL A PHYSICIAN IMMEDIATELY. USE WITH ADEQUATE VENTILATION.

DO NOT USE NEAR FIRE OR FLAME. CONTAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE REACH OF CHILDREN.

(1) Mask the repair area so that the conductive epoxy can be applied neatly. Extend the epoxy application onto the grid line or the bus bar on each side of the break (Fig. 4).

Fig. 4 Grid Line Repair - Typical
Fig. 4 Grid Line Repair - Typical

1 - BREAK
2 - GRID LINE
3 - MASKING TAPE

(2) Follow the instructions in the repair kit for preparing the damaged area.

(3) Remove the package separator clamp and mix the two conductive epoxy components thoroughly within the packaging. Fold the package in half and cut the center corner to dispense the epoxy.

(4) For grid line repairs, mask the area to be repaired with masking tape or a template.

(5) Apply the epoxy through the slit in the masking tape or template. Overlap both ends of the break by at least 19 millimeters (0.75 inch).

(6) For a terminal or pigtail wire replacement, mask the adjacent areas so the epoxy can be extended onto the adjacent grid line as well as the bus bar. Apply a thin layer of epoxy to the area where the terminal or pigtail wire was fastened and onto the adjacent grid line.

(7) Apply a thin layer of conductive epoxy to the terminal or bare wire end of the pigtail and place it in the proper location on the bus bar. To prevent the terminal or pigtail wire from moving while the epoxy is curing, it must be wedged or clamped.

(8) Carefully remove the masking tape or template.

CAUTION: Do not allow the glass surface to exceed 204 C (400 F) or the glass may fracture.

(9) Allow the epoxy to cure 24 hours at room temperature, or use a heat gun with a 260 to 371 C (500 to 700 F) range for fifteen minutes. Hold the heat gun approximately 25.4 centimeters (10 inches) from the repair.

(10) After the conductive epoxy is properly cured, remove the wedge or clamp from the terminal or pigtail wire. Do not attach the wire harness connectors until the curing process is complete.

(11) Check the operation of the rear window defogger glass heating grid.

Removal and installation

Defogger switch

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

(1) Disconnect and isolate the battery negative cable.

(2) Remove the center bezel from the instrument panel. See Instrument Panel Center Bezel in Group 8E - Instrument Panel Systems for the procedures.

(3) Remove the three screws that secure the accessory switch bezel to the instrument panel (Fig. 5).

Fig. 5 Accessory Switch Bezel Remove/Install
Fig. 5 Accessory Switch Bezel Remove/Install

1 - ACCESSORY SWITCH BEZEL
2 - SCREW

(4) Pull the accessory switch bezel out from the instrument panel far enough to access the wire harness connectors.

(5) Unplug the wire harness connectors from the rear of the accessory switches and the cigar lighter/ power outlet.

(6) Remove the accessory switch bezel from the instrument panel.

(7) With a small thin-bladed screwdriver, gently pry the snap clips at the top and bottom of the rear window defogger switch receptacle on the back of the accessory switch bezel and pull the switch out of the bezel.

(8) Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the accessory switch bezel are fully engaged. Tighten the mounting screws to 2.2 N·m (20 in. lbs.).

Defogger relay

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

(1) Disconnect and isolate the battery negative cable.

(2) Remove the fuse access panel by unsnapping it from the right cowl side trim panel.

(3) Remove the stamped nut that secures the right cowl side trim to the junction block stud (Fig. 6).

Fig. 6 Right Cowl Side Trim Remove/Install
Fig. 6 Right Cowl Side Trim Remove/Install

1 - RIGHT FRONT DOOR SILL
2 - COWL SIDE TRIM PANEL
3 - SCREW
4 - SILL TRIM
5 - FUSE ACCESS PANEL
6 - PUSH-NUT

(4) Remove the screw located above the fuse access opening that secures the right cowl side trim to the right cowl side inner panel.

(5) Remove the screw that secures the right door sill trim and the right cowl side trim to the right door opening sill.

(6) Remove the right cowl side trim panel from the vehicle.

(7) Unplug the rear window defogger relay from the junction block.

(8) Install the defogger relay by aligning the relay terminals with the cavities in the junction block and pushing the relay firmly into place.

(9) Connect the battery negative cable.

(10) Test the relay operation.

(11) Reinstall the right cowl side trim and the fuse access panel. Tighten the mounting screws to 2.2 N·m (20 in. lbs.).

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