1999 Jeep TJ Wrangler Service Manual - 23. Body

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TJ
BODY
23 - 1
BODY
CONTENTS
page page
BODY COMPONENT SERVICE . . . . . . . . . . . . . . 11 GENERAL SERVICE INFORMATION . . . . . . . . . . . 1 PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL SERVICE INFORMATION

INDEX
page
GENERAL INFORMATION SAFETY PRECAUTIONS AND WARNINGS . . . . . . 1
GENERAL INFORMATION
SAFETY PRECAUTIONS AND WARNINGS
WARNING: EYE PROTECTION SHOULD BE USED WHEN SERVICING GLASS COMPONENTS. PERSONAL INJURY CAN RESULT. USE A OSHA APPROVED BREATHING FILTER WHEN SPRAYING PAINT OR SOLVENTS IN A CONFINED AREA. PERSONAL INJURY CAN RESULT. AVOID PROLONGED SKIN CONTACT WITH PETROLEUM OR ALCOHOL BASED CLEANING SOLVENTS. PERSONAL INJURY CAN RESULT. DO NOT STAND UNDER A HOISTED VEHICLE THAT IS NOT PROPERLY SUPPORTED ON SAFETY STANDS. PERSONAL INJURY CAN RESULT. CAUTION: When holes must be drilled or punched in an inner body panel, verify depth of space to the outer body panel, electrical wiring, or other components. Damage to vehicle can result. Do not weld exterior panels unless combustible material on the interior of vehicle is removed from the repair area. Fire or hazardous conditions, can result. Always have a fire extinguisher ready for use when welding. Disconnect the negative (-) cable clamp from the battery when servicing electrical components that are live when the ignition is OFF. Damage to electrical system can result.
Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. Do not use harsh alkaline based cleaning solvents on painted or upholstered surfaces. Damage to finish or color can result. Do not hammer or pound on plastic trim panel when servicing interior trim. Plastic panels can break.
Chrysler Corporation uses many different types of push-in fasteners to secure the interior and exterior trim to the body. Most of these fasteners can be reused to assemble the trim during various repair procedures. At times, a push-in fastener cannot be removed without damaging the fastener or the component it is holding. If it is not possible to remove a fastener without damaging a component or body, cut or break the fastener and use a new one when installing the component. Never pry or pound on a plastic or pressed-board trim component. Using a suitable fork-type prying device, pry the fastener from the retaining hole behind the component being removed. When installing, verify fastener alignment with the retaining hole by hand. Push directly on or over the fastener until it seats. Apply a low-force pull to the panel to verify that it is secure. When it is necessary to remove components to service another, it should not be necessary to apply excessive force or bend a component to remove it. Before damaging a trim component, verify hidden fasteners or captured edges holding the component in place.
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23 - 2
BODY
TJ
PAINT
INDEX
page page PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PAINTED SURFACE TOUCH-UP . . . . . . . . . . . . . 2 SERVICE PROCEDURES HARD TOP REPAIR . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION AFTERMARKET PAINT REPAIR PRODUCTS . . . . 3 BASE COAT/CLEAR COAT FINISH . . . . . . . . . . . . 2 FINESSE SANDING, BUFFING, AND POLISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
PAINT CODE
Exterior vehicle body colors are identified on the Body Code plate. The plate is located on the floor pan under the drivers seat. Refer to the Introduction section at the front of this manual for, body code plate description. The paint code is also identified on the Vehicle Safety Certification Label, which is located on the drivers door shut face The color names, provided in the Paint and Trim Code Description chart, are the color names used on most repair product cont a i n e rs .
PAINTED SURFACE TOUCH-UP

When a painted metal surface has been scratched or chipped, it should be touched-up as soon as possible to avoid corrosion. For best results, use Mopar Scratch Filler/Primer, Touch-Up Paints and Clear Top Coat. Refer to Introduction group of this manual for Body Code Plate information.
TOUCH-UP PROCEDURE
(1) Scrape loose paint and corrosion from inside scratch or chip. (2) Clean affected area with Mopar Tar/Road Oil Remover, and allow to dry. (3) Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the defect without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. (4) Cover the filler/primer with color touch-up paint. Do not overlap touch-up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch-up paint to dry hard. (5) On vehicles without clear coat, the touch-up color can be lightly wet sanded (1500 grit) and polished with rubbing compound. (6) On vehicles with clear coat, apply clear top coat to touch-up paint with the same technique as described in Step 4. Allow clear top coat to dry hard. If desired, Step 5 can be performed on clear top coat.
BASE COAT/CLEAR COAT FINISH

On most vehicles a two-stage paint application (base coat/clear coat) is used. Color that is applied to primer is called base coat. The clear coat protects the base coat from ultraviolet light and provides a durable high-gloss finish.
FINESSE SANDING, BUFFING, AND POLISHING

Minor acid etching, orange peel, or surface scratches in clear coat or single-stage finishes can be reduced with light finesse sanding, buffing, and polishing.I f t h e f i n i s h h a s b e e n w e t s a n d e d i n t h e p a s t , i t c a n n o t b e r e p e a t e d . We t s a n d i n g o p e r a tion should be performed by a trained automotive paint technician.
CAUTION: Do not remove clear coat finish more than .5 mils, if equipped (Use a paint thickness gauge to verify paint thickness). Base coat paint must retain clear coat for durability.
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TJ
GENERAL INFORMATION (Continued)
BODY
23 - 3
AFTERMARKET PAINT REPAIR PRODUCTS

EXTERIOR COLOR
EXTERIOR COLOR Flame Red Clear Coat Chili Pepper Red Medium Fern Pearl Coat Deep Amethyst Pearl Coat Forest Green Pearl Coat Desert Sand Intense Blue Pearl Coat Gun Metal Pearl Coat Black Clear Coat Stone White Clear Coat CHRY CODE * PR4 VEA RJP TCN SG8 WTD VB3 TQ7 DX8 SW1 S-W** M-S** 46916 54470 50270 52566 51062 56153 54468 52952 34858 90-5950 51539 AKZO NOBEL SIKKENS CHA93:PR4 CHA98:VEA CHA99:RJP CHA97:TCN CHA95:SG8 CHA99:WTD CHA98:VB3 CHA97:TQ7 CHA85:DX8 CHA96:SW1
PPG 4679 5361 4969 5246 5065 5474 5357 5248 9700 83542
DuPONT B9326 B9823 B9524 B9736 B9609 B9884 B9822 B9735 99 B9622
ICI** RNN6B HMT3B 7CD6B FNE4B 7MR8B KGC7B HMR9B ERA9B TC60B 8KY5B
HARD TOP
CHRY CODE* LTB VK9 BX7 SW1 S-W** M-S** 46487 58115 58115 52779 AKZO NOBEL SIKKENS CHA90:LTB CHAVK9M CHABX7M CHASWM1
HARD TOP Spice Carmel Black Stone White
PPG 27315 28589 9418 5072
DuPONT C9523 C9846 44219 C9622
ICI** FPP6 NVM9 NVN1 NNV6
INTERIOR COLOR
INTERIOR COLOR Agate Camel Camel / Dark Green CHRY CODE* AZ K5 KG S-W** M-S** 45994 51541 N/A AKZO NOBEL SIKKENS CHALAZI CHARJ5I N/A
PPG 9856 / 2-1461 27731 / 2-1584 N/A
DuPONT C9208 C9603 N/A
ICI** 7WC8 7VX6 K5/G8
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BODY
TJ
GENERAL INFORMATION (Continued)

NOTE: *Herberts Standox, Spies Hecker, and BASF use the Chrysler paint code as listed on the Body Code Plate and the Vehicle Safety Certification label. ** S-W = Sherwin-Williams, M-S = Martin Senour, ICI = ICI Autocolor.
(9) Apply the hardener/resin mixture to both sides of the fiberglass cloth. (10) Place the fiberglass cloth over the repair surface area. Next, place the aluminum foil over the cloth. Use a plastic spreader to smooth-out the cloth and resin. Use firm pressure to remove air bubbles and to smooth-out the cloth. (11) Allow the resin to cure. (12) S mo o th -o u t th e su rfac e a r ea to t h e c o n t o u r o f the hard top with a 50-grit disc. (13) Apply plastic filler to complete the repair. Finish smoothing the surface area with 80-grit paper. (14) Repeat the previous step on the inside surface area of the hard top. (15) Featheredge the repaired surface area. (16) Prime the re paire d surface are a with PPG Epoxy Primer, or an equivalent product. (17) Apply surface primer to the surface area. (18) Prime the surface area for the color coat. (19) Apply color coat to the repaired surface area.
SERVICE PROCEDURES
HARD TOP REPAIR
The hard top fiberglass material can be repaired. The required repair materials include: Fiberglass mat or cloth. Fiberglass resin and hardener. structural adhesive (3M brand or an equivalent product). Glazing putty. Plastic spreader.
HARD TOP HOLE REPAIR

(1) Use a grinder to remove the paint and outline the damaged area. Use a grade 24 grit disc for paint removal. (2) Grind the outlined surface area again with a 50 grit disc to prevent coarse scratches from appearing in the final finish. (3) If cracks extend from the hole, it will be necessary to stop-drill the crack(s) with a 3-mm (1/8-in) diameter drill bit. (4) Position a fiberglass mat or cloth on the repair surface area. Cut the mat to allow a 2.5-cm (1-in) overlap of the repair surface area. (5) Clean the repair surface area. (6) Place the fiberglass cloth on aluminum foil. (7) Pour the fiberglass resin into a clean container. ( 8 ) M i x t he a pp r o pr i a te am oun t of ha r dener and re s in. F o l l o w t he manu f ac t u re rs ins t ru c t io ns .
FRACTURE REPAIR
(1) Use a grinder to remove the paint (from both, the inner and outer surface areas of the hard top) and to outline the damaged area. (2) Stop-drill the crack(s) with a 3-mm (1/8-in) diameter drill bit. (3) Bevel the edges of the crack(s) on both sides with a rotary file.
NOTE: The edges should be beveled on the inside and outside of the top to ensure sufficient surface area for good bonding.
(4) Complete the repairs with fiberglass cloth and resin as described above in the hard top hole repair procedure.
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1999 Jeep TJ Wrangler Service Manual - 23. Body

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BODY COMPONENT SERVICE . . . . . . . . . . . . . . 11 GENERAL SERVICE INFORMATION . . . . . . . . . . . 1 PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . . . 5

GENERAL SERVICE INFORMATION

GENERAL INFORMATION SAFETY PRECAUTIONS AND WARNINGS . . . . . . 1

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PAINTED SURFACE TOUCH-UP

BASE COAT/CLEAR COAT FINISH

FINESSE SANDING, BUFFING, AND POLISHING

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AFTERMARKET PAINT REPAIR PRODUCTS

HARD TOP Spice Carmel Black Stone White

PPG 27315 28589 9418 5072

DuPONT C9523 C9846 44219 C9622

ICI** FPP6 NVM9 NVN1 NNV6

PPG 9856 / 2-1461 27731 / 2-1584 N/A

DuPONT C9208 C9603 N/A

ICI** 7WC8 7VX6 K5/G8

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GENERAL INFORMATION (Continued)

HARD TOP HOLE REPAIR

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