Page 1
3651 N Highway 89 • Chino Valley, AZ 86323
(928) 636-7080 • www.p-a-g.net
JEEP CHEROKEE, WAGONEER
(XJ)
FRONT BUMPER
INSTALLATION INSTRUCTIONS
1984-2001 KIT# 83202
1984-2001 W/ WINCH KIT# 83203
WARNING
Before you install this kit, read and understand all
instructions, warnings, cautions, and notes in this
instruction sheet and in the vehicle owner’s manual.
CAUTION
Proper installation of this kit requires knowledge of the
factory recommended procedures for removal and
installation of original equipment components. We recommend that the factory shop manual and any special
tools needed to service your vehicle be on hand during
the installation. Installation of this kit without proper
knowledge of the factory recommended procedures
may affect the performance of these components and
the safety of the vehicle. We strongly recommend that
a certified mechanic familiar with the installation of similar components install this kit.
WARNING
Many states and municipalities have laws restricting
bumper heights and vehicle lifts. Consult state and
local laws to determine if the changes you intend to
make to the vehicle comply with the law.
WARNING
Always wear eye protection when operating power
tools.
WARNING
Before you install this kit, block the vehicle tires to prevent the vehicle from rolling.
NOTE
Performance Automotive Group recommends using
the Loctite® supplied in the kit on the threads of all kit
nuts and bolts unless specified otherwise in these
instructions.
1 ‘84-’01 XJ Front Bumper - Kit 83202, 83203
Page 2
Before Starting Installation
Prepare to Install Kit
NOTE
Kit parts are prefaced by the word kit and appear in
bold print.
1. Carefully read all warnings and instructions completely before beginning.
2. Verify all parts have been received in this kit by
checking the parts list at the end of this document.
NOTE
If parts are missing from kit, please be prepared to provide the following information:
1. Name of purchase location
2. Bar Code on side of box
3. Date above bar code
4. Date inside box cover
5. Inspector # from inside box cover
3. Only install this kit on the vehicle for which it is
specified. If anytime during the installation you
encounter something different from what is outlined
in the instructions, call technical support at (928)
636-7080.
Front of Vehicle
1. Bumper
a. 1997-2001 Models: Remove push clips and pull
back wheel well liner from front bumper.
Wheel Well
Push Clip
Front
Bumper
b. 1997-2001 Models: Remove four bolts from
front bumper and two fenders.
Fender
4. Special tools needed:
a. Die grinder or similar tool capable of cutting
metal and plastic.
b. 7/32” drill bit
5. Park vehicle on a clean, dry, flat, level surface and
block tires so vehicle cannot roll in either direction.
Engine Compartment
1. Disconnect both battery cables. Disconnect negative cable first, then positive cable.
Positive
Cable
Battery
Bolts
Front
Bumper
c. Disconnect vacuum line from vacuum reservoir.
Vacuum
Line
Vacuum
Reservoir
Front
Bumper
Negative
Cable
2 ‘84-’01 XJ Front Bumper - Kit 83202, 83203
Page 3
d. Remove six bolts and bumper from vehicle.
g. 1997-2001 Models: Remove two bolts, two
nuts, and bumper corner cover from bumper.
Front
Bumper
Bolts
e. Remove four c-clip fasteners from vehicle.
Unibody
Front
Bumper
Bolts &
Nuts
Bumper
Corner Cover
h. 1997-2001 Models: Remove two torx bolts and
vacuum reservoir from bumper.
Front
Bumper
Torx
Bolts
Bumper
Corner Cover
C-Clips
f. 1984-1996 Models: Remove two bolts and vac-
uum reservoir from bumper.
Front
Bumper
Vacuum
Reservoir
Bolts
2. Horns
a. Disconnect two wire harnesses from two horns.
Bracket
Horn
Wire
Harness
b. Remove two bolts, two brackets, and two horns
from vehicle.
3 ‘84-’01 XJ Front Bumper - Kit 83202, 83203
Page 4
3. 1984-1996 Models: Lower valence & fender flares
a. Remove five screws from lower valence and
core support.
Core
Support
Screws
Lower
Valence
b. Remove eight bolts and two lower valence sup-
ports from two fenders and core support.
4. Remove three steering box bolts and washers from
driver side unibody and steering box.
Bolts &
Washers
Unibody
Steering
Box
Install Kit
Engine Compartment
Lower
Valence
Support
Bolts
Fender
c. Remove six nuts from two front wheel wells and
pull two fender flares away from front of fenders.
Fender Flare
Wheel Well
1. Cruise Control Models: Vacuu m lines
BEFORE
T-Connector
Reservoir
Line
AFTER
Manifold Line
Intake Manifold
Cruise Control
Vacuum Reservoir
Check Valve
Nuts
Fitting
*Not To Scale
4 ‘84-’01 XJ Front Bumper - Kit 83202, 83203
Page 5
WARNING
V acuum fittings and lines may have become brittle over
time. Use care when handling fittings and vacuum
lines. If necessary, use lengths of kit line (vacuum) in
place of cracked or damaged vacuum line.
f. Install vacuum reservoir onto two kit brackets
(2” step) with two factory c-clips and bolts. DO
NOT TIGHTEN.
C-Clips &
Bolts
a. Remove line from cruise control fitting and t-con-
nector.
b. Remove T-connector from reservoir line and
manifold line.
c. Trim manifold line, if necessary, and install onto
cruise control fitting.
d. Remove wiring harness and clips from driver
side inner fender.
Inner
Fender
Clips
Wiring
Harness
e. Install two kit bracket (2” step) onto driver side
inner fender with two kit bolts (5/16” x 3/4” self-
tapping). DO NOT TIGHTEN.
Vacuum
Reservoir
Vacuum
Reservoir
Kit Ties
(Zip)
g. Install wiring harness onto two kit brackets (2”
step) with two kit ties (zip).
h. TIGHTEN two kit bolts (5/16” x 3/4”) and two
factory bolts.
i. Remove manifold line and fitting from check
valve and intake manifold.
j. Install T-connector onto check valve.
k. Install manifold line into T-connector.
l. Install vacuum reservoir line into T-connector
and route vacuum reservoir line to vacuum reservoir.
m. Trim vacuum reservoir line, if necessary. Install
vacuum reservoir line onto vacuum reservoir
with rubber fitting.
2. Non-Cruise Control Models: Vacuum lines
Kit Bracket
(2” Step)
Kit Bolt
(5/16” x 3/4”)
a. Repeat above steps, ignoring cruise control pro-
cedures.
5 ‘84-’01 XJ Front Bumper - Kit 83202, 83203
Page 6
Front of Vehicle
2. Gap guard
1. Air temp sensor
a. Remove bolt and sensor from core support.
Install bolt back into core support.
Bolt &
Sensor
Wiring
Harness &
Clip
Core
Support
b. Disconnect wiring harness from sensor.
c. Remove sensor wiring harness and clip from
core support.
d. Route wiring harness connector next to passen-
ger side horn.
e. Install sensor onto passenger side bracket with
kit bolt (1/4” x 1”), two kit washers (1/4” SAE),
and kit nut (1/4” Nylock).
a. Install kit gap guard, dull side out, onto core
support with two kit clips (push) through top
driver and passenger holes of kit gap guard and
corresponding holes in core support.
Kit Clips
(Push)
Kit Gap
Guard
Core
Support
b. Drill four 7/32” holes into core support corre-
sponding to kit gap guard holes.
Kit Gap
Guard
Core
Support
Drill Here
Bracket
Kit Bolt
(1/4” x 1”),
Kit Washers
(1/4” SAE),
Kit Nuts
(1/4” Nylock)
Sensor &
Wiring Harness
NOTE
Drill 1/4” hole into bracket, if necessary.
f. Connect wiring harness onto sensor.
g. Install wiring harness onto bracket with kit tie
(zip).
Kit Tie (Zip)
c. Install 4 kit clips (push) into previously drilled
holes.
Kit Clip
(Push)
Kit Gap
Guard
Core
Support
6 ‘84-’01 XJ Front Bumper - Kit 83202, 83203
Page 7
Bumper
1. Center section
a. Install kit bumper (center) onto unibody with
two kit bolts (10mm x 40mm), and two kit washers (10mm). DO NOT TIGHTEN.
Kit Bumper
(Center)
Kit Bolt
(10mm x
40mm),
Kit Washer
(10mm)
Unibody
b. Apply a small amount of kit Loctite® (6ml bottle)
onto threads of three kit bolts (7/16” x 4-1/2”)
and install kit bracket (steering box), kit bumper
(center), steering box, and steering box spacer
onto unibody with three kit bolts (7/16” x 4-1/2”)
and three washers. DO NOT TIGHTEN.
c. Install two kit bolts (1/2” x 1-1/2”), two kit wash-
ers (1/2” SAE), and two kit nuts (1/2” flange)
onto kit bumper (center) and passenger side
unibody. DO NOT TIGHTEN.
Kit Bolts
(1/2” x 1-1/2”),
Kit Washers
(1/2” SAE),
Kit Nuts
(1/2” Flange)
Kit Bumper
(Center)
2. 1984-1996 Models: Driver fenders
a. Position kit corner (driver) onto kit bumper
(center) and using kit corner (driver) as a guide,
mark fender approximately 1” below side
marker.
Mark Fender
Kit Bolts
(7/16” x
4-1/2”),
Washers
Kit Bracket
(Steering
Box)
NOTE
A spacer exists between unibody and steering box.
Ensure kit bolts (1/2” x 4-1/2”) are installed through
steering box spacer.
Fender Flare
NOTE
For proper fender flare retention, attempt to cut fender
flare and bracket BELOW fender flare bracket stud.
NOTE
Further trimming of the fender and fender flare may be
required for desired fitment.
7 ‘84-’01 XJ Front Bumper - Kit 83202, 83203
Page 8
b. Cut fender along marked line.
3. Driver section
Fender
Marked Line
c. Test fit kit corner (driver) onto kit bumper (cen-
ter).
Cut Fender
Kit Bumper
(Driver)
d. Mark and cut fender flare and fender flare
bracket along marked line for desired fit.
Remove lower valence along with cut portions of
fender flares.
Cut Fender
Flare
a. Remove kit bolt (10mm x 40mm) and kit
washer (10mm) from kit bumper (center) and
unibody.
Kit Bolts
(1/2” x 1-1/2”),
Kit Washers
(1/2” SAE),
Kit Nuts
(1/2” Flange)
Kit Bumper
(Driver)
b. Install kit corner (driver) onto kit bumper (cen-
ter) with four kit bolts (1/2” x 1-1/2”), four kit
washers (1/2” SAE), four kit nuts (1/2” flange),
kit bolt (10mm x 40mm), and kit washer
(10mm). DO NOT TIGHTEN.
c. Repeat above steps for passenger side section.
d. Align and level kit bumper (center) and
TIGHTEN two kit bolts (10mm x 40mm), three
kit bolts (7/16” x 4-1/2”), and two passenger
side kit bolts (1/2” x 1-1/2”).
Kit Bumper
(Passenger)
Fender Flare
Stud Hole
Cut Fender
Flare Bracket
e. Install fender flare and fender flare bracket onto
fender with nut, if possible.
f. Repeat above steps for kit corner (passenger).
Kit Bumper
(Center)
e. TIGHTEN eight kit bolts (1/2” x 1-1/2”), kit cor-
ner (driver), and kit corner (p assenger).
8 ‘84-’01 XJ Front Bumper - Kit 83202, 83203
Page 9
4. Driver wheel well liner
a. Mark driver wheel well liner as desired and trim.
Mark Wheel
Well
c. Kit# 83203: Repeat above step for kit bracket
(support, passenger). DO NOT TIGHTEN.
Kit Bolts
(1/2” x 1-1/2”),
Kit Washers
(1/2” SAE),
Kit Nuts
(1/2” Flange)
Kit Bracket
(Support)
6. Kit# 83203: Driver Support Bracket & Winch
Bracket
Cut Wheel
Well
b. Repeat above step for passenger side wheel
well liner.
5. Driver Support Bracket
NOTE
Before installing top bolts, install kit grill guard hoop, if
purchased.
a. Install kit bracket (support, driver) onto driver
side unibody and kit bumper with four kit bolts
(1/2” x 1-1/2”), four kit washers (1/2” SAE), and
four kit nuts (1/2’ flange). DO NOT TIGHTEN.
NOTE
Before installing top bolts, install kit grill guard hoop, if
purchased.
a. Install kit bracket (winch) onto kit bumper (cen-
ter) with four kit bolts (7/16” x 1”) and four kit
washers (7/16” USS). DO NOT TIGHTEN.
Kit Bracket
(Center)
Kit Bolts
(7/16” x 1”),
Kit Washers
(7/16” USS)
Kit Bracket
(Winch)
b. Install two kit brackets (support) onto kit
bumper (center) with two kit bolts (1/2” x 1-1/2”)
and two kit washers (1/2” SAE). DO NOT
TIGHTEN.
Kit Bolts
(1/2” x 1-1/2”),
Kit Washers
(1/2” SAE),
Kit Nuts
(1/2” Flange)
Kit Bracket
(Support)
b. Kit# 83202: Repeat above step for kit bracket
(support, passenger). TIGHTEN all hardware.
Kit Bracket
(Support)
Kit Bumper
(Center)
Kit Bolt
(1/2” x 1-1/2”),
Kit Washer
(1/2” SAE)
9 ‘84-’01 XJ Front Bumper - Kit 83202, 83203
Page 10
c. Install kit bracket (winch) onto two kit brackets
(support) with two kit bolts (1/2” x 1-1/2”), two kit
washers (1/2” SAE), and two kit nuts (1/2”
flange).
Kit Bolts
(1/2” x 1-1/2”),
Kit Washers
(1/2” SAE),
Kit Nuts
(1/2” Flange)
b. Bend bracket tab as shown.
Bend Tab
Back
Horn
Bracket
Kit Bracket
(Winch)
d. TIGHTEN all hardware.
7. Kit# 83202: Install four kit plugs into kit bumper
(center).
Kit Plugs
Kit Bumper
(Center)
NOTE
Winch supplied mounting bolts may not be sufficient in
length.
c. Install bracket onto vehicle with bolt. DO NOT
TIGHTEN. Ensure bracket is positioned as
shown.
Bolt
Horn
Bracket
Vehicle
d. Install horn onto bracket with nut. TIGHTEN bolt
and bracket onto vehicle.
BACKSIDE
Nut
8. Driver side horn
a. Remove nut and bracket from horn.
Bracket
Nut
Horn
Wiring
Harness
Bolt
Horn
FRONTSIDE
e. Install wiring harness onto horn.
f. Repeat above steps for passenger side horn.
10 ‘84-’01 XJ Front Bumper - Kit 83202, 83203
Page 11
After Completing Installation
Engine Compartment
1. Connect both battery cables. Connect positive cable
first, then negative cable.
Positive
Cable
Battery
Negative
Cable
Miscellaneous
1. Check all fasteners to ensure they are tight.
CAUTION
Performance Automotive Group does not recommend
any particular wheel and tire combinations for use with
its bumpers and cannot assume responsibility for the
customer’s choice of wheels and tires.
Accessories
Kit# 87011 - Multi Light Mount
Kit# 87016 - Grill Guard Hoop
2. Ensure all wires, hoses, cables, etc. are properly
connected and there is ample slack.
3. Check vacuum system for leaks.
Dynamic Vehicle Check
1. Check steering and suspension in all positions to
ensure that there is no bind and adequate clearance
between all moving, fixed, and heated members.
Check tire-to-bumper clearance and ensure no contact in any position. Check battery connections and
electrical component operations. Test-drive vehicle .
Check cruise control, if equipped, and all vacuum
controlled vehicle systems. If vacuum leaks are
found, correct immediately.
NOTE
All warranty information, instruction sheets, and other
documents regarding the installation of this product
must be retained by the vehicle owner
contained in the instructions and on the warranty card
will be required for any warranty claims. The vehicle
owner needs to understand the modifications made to
the vehicle and how they affect vehicle handling and
performance. Failure to provide the customer with this
information can result in damage to the vehicle and
severe personal injury.
. Information
NOTE
Hi-Lift jacks can be mounted to kit bumper.
11 ‘84-’01 XJ Front Bumper - Kit 83202, 83203
Page 12
Kit Parts List
Qty. Description
Kit 83202 & 83203
1 Bracket (support, driver)
1 Bracket (support, passenger)
1 Bracket (steering box)
1 Bumper (center)
2 Cap (end)
1 Corner (driver)
1 Corner (passenger)
1 Gap guard
1 Line (vacuum)
Kit 83203
1 Bracket (winch)
1 ZH27 (Hardware Bag Kit)
2 Bracket (2” step)
2 Bolt (10mm x 40mm)
1 Bolt (1/4” x 1”)
2 Bolt (5/16” x 3/4” self-tapping)
4 Bolt (7/16” x 1”)
3 Bolt (7/16” x 4-1/2”)
20 Bolt (1/2” x 1-1/2”)
6 Clip (push)
1 Loctite® (6ml bottle)
1 Nut (1/4” Nylock)
20 Nut (1/2” flange)
4 Tie (zip)
2 Washer (10mm)
2 Washer (1/4” SAE)
4 Washer (7/16” USS)
22 Washer (1/2” SAE)
NOTE
Depending on the vehicle configuration some parts
may not be used.
Rev. 01, Copyright 12/05
Performance Automotive Group
www.p-a-g.net
12 ‘84-’01 XJ Front Bumper - Kit 83202, 83203
Loading...