JK HEMI Builder Kit - Installation Guide for 12+ JK Wrangler
Contents
1. 7 D ARNE JK V8 HEMI BUILDER KIT 9 71 6 4L VVT 2012 JK SWB LWB AEV30231AC Last Updated 10 23 14 TABLE OF CONTENTS 1 Overview 1 2 Vehicle Disassembly 1 Chassis Preparation 6 4 New Engine Preparation and Assembly 8 Di Engine Bay Preparation 21 6 Body Re Installation 29 New Engine Start Up Procedure 32 3 ProCal Programming 33 PLEASE READ BEFORE YOU START TO GUARANTEE A QUALITY INSTALLATION WE RECOMMEND READING THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING ANY WORK THESE INSTRUCTIONS ASSUME A CERTAIN AMOUNT OF MECHANICAL ABILITY AND ARE NOT WRITTEN NOR INTENDED FOR SOMEONE NOT FAMILIAR WITH AUTO REPAIR PLEASE NOTE THAT THIS KIT HAS NOT BEEN TESTED TO COMPLY WITH FMVSS STANDARDS AND MUST NOT BE INSTALLED IN ANY NEW VEHICLE PRIOR TO DELIVERY TO THE END USER WHILE ALL CORRECT EMISSIONS EQUIPMENT IS DESIGNED TO BE INSTALLED WITH THIS KIT THIS KIT MAY STILL NOT BE LEGAL FOR ON ROAD USE IN ALL STATES OR COUNTRIES AND AS SUCH IS CURRENTLY INTENDED FOR OFF ROAD USE ONLY IT IS THE USERS RESPONSIBILITY TO COMPLY WITH ALL REGULATIONS AEV DOES NOT RECOMMEND ANY MODIFICATIONS TO HEMI ENGINES OR TRANSMISSIONS TECH SUPPORT CAN NOT BE PROVIDED FOR ANY CONVERSIONS USING AFTERMARKET PERFORMANCE PARTS INCLUDING BUT NOT LIMITED CAMSHAFTS HEADS EXHAUST MANIFOLDS AFTERMARKET EXHAUSTS INTAKES THROTTLE BODIES PERFORMANCE ECU CALIBRATIONS STROKER KITS SUPERCHARGERS TURBO2. Highbeam Off position The routine has now started Press and hold the pedal all the way to the floor Move the headlight stalk forward to the Highbeam On position Release the pedal completely Move the headlight stalk back to the Highbeam Off position The routine is now completed A Turn the ignition OFF wait then start the engine Test the and verify that it is functioning prop erly If not repeat steps 2 8 35 AXLE RATIO PROGRAMMING Using the ProCal Module to program axle ratio once your new HEMI engine is installed requires a special mode Programming axle ratio is required after completeing your HEMI conversion even if you did not change your axle gear ratio There is no performance increase by adjusting this value to anything besides what the vehicle has physically installed Failure to program the axle gear ratio or programming the incor rect ratio will cause some vehicles to go into Limp In mode 1 the first 3 DIP switches as shown 2 Set switches 4 and 5 as shown 9 71 6 41 remaining switches based on the chart Once all the dip switches set please refer to the User Guide that came with your ProCal Module for the proper programming procedure 3 07 1 3 21 1 3 00 1 3 73 1 4 10 1 4 56 1 l e 4 88 1 0 13 1 0 38 1 0 67 1 TIRE SIZE PROGRAMMING You may now
3. hose and then install the hoses for the power steering lines fig 39 Figure 39 12 Connect the remaining AC lines at the fire wall fig 40 Figure 40 13 Connect the AC lines at condenser fig 41 VAY Figure 41 26 14 Trim and connect upper radiator hose using the AEV supplied spring clamp fig 42 19 16 17 18 19 20 21 22 23 24 Figure 42 Pre install provided M6 u nuts into the AEV supplied battery tray Connect 34 way connector at fire wall under the battery tray location Install the battery tray Install the head to fire wall ground strap Install the seal onto the AEV air box and install air box into the Jeep Plug in the fan Install the TIPM tray Install battery Connect the battery harness LEAVE THE NEGATIVE BATTERY CABLE OFF fig 43 Figure 43 Install the purge solenoid 27 25 Connect power wire to the TIPM and attach the TIPM to the TIPM bracket 26 Modify and install the air intake tube as shown fig 44 TRIM 6 4 ONLY 21 28 a DO NOT use the throttle body screws that come with the 6 4L engine ONLY use the screws plied with the AEV intake FAILURE TO USE THE CORRECT SCREWS WILL BREAK THE INTAKE MANI FOLD AND VOID YOUR AEV WARRANTY b 6 41 engines ONLY use 2 3 section of heater core hose to connect the crank vent tube to the engine DRILL FOR CRANK VENT 5 7 8 6 4 Figure 4
4. procedures for disassembling and re assembling an auto matic transmission we recommend having a qualified transmission technician perform these steps Improper torque converter depth may cause damage to the transmission DO NOT draw sub assemblies together with bolts components should be completely seated before installing bolts Reinstall transmission mount using the new hardware and spacers provided in the JK Hemi Mount W A580 and torque to 40 ft Ibs fig 14 Figure 14 ASAE 3 Locate the two supplied jumper harnesses for the throttle body Use the jumper harness that has the proper connectors for your engine s throttle body 4 Remove the wiring harness that came with the new engine 5 Remove the intake manifold on a 6 4L refer to the factory service manual Use a grinder to bevel the engine block as shown in Figure 15 Verify by dry fitting the AEV intake manifold to check for clearance BEFORE final installation Once clearance has been verified change the water pump Sourced from 2011 and newer engines and install AEV intake manifold a This intake must be used in conjunction with an AEV PCM that has been programmed to take full advantage of the long and short runners b Use the 6 4L throttle body only c There are ten 10 seals on the bottom of the manifold one 1 between the intake manifold actuator and intake and one 1 between the throttle body and intake Be sure all
5. running one tank of premium through the system PRIOR TO beginning the conversion process VEHICLE DISASSEMBLY Discharge AC system Disconnect battery and remove Remove plastic engine cover Disconnect and remove air intake tube and air box Disconnect and remove purge solenoid from the battery tray Do U S 2142 Unplug the 34 way connector from the battery tray then remove the harness from the battery tray and loosen at the fire wall fig 1 Figure 1 8 10 11 12 13 14 15 a Remove the battery harness from the TIPM battery tray and fender Disconnect the power steering reservoir from behind the headlamp and discard the mounting bracket Remove the battery tray from the Jeep Be sure to remove the bolt on the bottom first fig 2 Figure 2 Disconnect the ground located on the passenger side of the fire wall fig 3 Unplug the 34 way connector located under and behind the passenger side headlamp Disconnect and remove the ECM computer Disconnect AC lines from the compressor Remove vacuum lines from the brake booster Separate the vacuum line to vacuum pump next to the AC line near grill then remove the fir trees from the line to separate it from the area next to the radiator fig 4 Figure 3 Figure 4 3 16 Disconnect the steering at the fire wall WARNING Steering wheel contains a clock spring DO NOT ROTATE steering wheel after steering shaft i
6. 4 Pre assemble AEV coolant bottle and install Will need to re use the original coolant bottle tube and cap from the factory coolant bottle Use only MOPAR Coolant for your model year Jeep DO NOT mix coolant from different model years Other brands may harm the seals or cause cooling problems Trim and install engine cover 5 7L HEMI V8 conversions can utilize either a Grand Cherokee or Com mander engine cover however it will need to be modified prior to installation using the template pro vided at the end of these instructions For 6 41 HEMI conversions you can utilize the Grand Cherokee engine covers but the side will require modification For 6 4L HEMI V8 engines please remove the highlighted portion as shown in figure 45 5 7L HEMI V8 engines please use the template on the last page Figure 45 remove highlighted portion 28 ASS nevi REPOSITION HOIST TO UNDER CHASSIS AND RAISE JEEP FOR UNDERSIDE ACCESS 29 30 32 52 34 35 36 37 38 Reposition the hoist under the chassis and raise the vehicle for underside access Reinstall all body mount hardware and torque to factory specifications refer to factory service manual Reinstall shifter linkage refer to factory service manual Reinstall drive shafts refer to factory service manual Reconnect fuel filler and NVLD charcoal canister refer to factory service manual Reconnect parking brake cables refer to factory service
7. AEV supplied fuel lines Refer back to photo group A Install alternator and alternator sheild making sure wiring is routed behind Refer to photo group A Torque to 40 ft Ibs You will use the dipstick bolt from the 3 6L engine for the alternator sheild Install AEV supplied AC hoses onto power train Refer to photo group A Install lower radiator hose using the supplied AEV spring clamps fig 23 DO NOT use over the counter hose clamps Install the serpentine belt fig 23 224 16 D Figure 23 25 Modify brake booster as shown fig 24 and install with fresh cut end to engine Figure 24 Remove highlighted portion BACK TO CHASSIS 26 Install new power train into chassis 27 Modify the power steering return line to accept the supplied gear to cooler return line fig 25 and then install on the steering gear fig 26 28 Install the supplied power steering pressure line fig 26 gy PPSA Figure 25 Modifying power steering return line 17 Figure 26 Before and After 29 Remove the block from the factory transmission lines 30 Assemble the AEV supplied transmission oil cooler lines to the block fig 27 Figure 27 31 Install the new transmission oil cooler line assembly to the power train fig 28 13 Figure 28 32 Connect the fuel lines you will need the blue clip you saved earlier 33 Inst
8. CHARGERS SHIFT KITS OR ANY OTHER NON PRODUCTION ITEM This product is covered under the AEV Parts Limited Warranty a copy of which can be found at aev conversions com warranty 11 ASS nevi I OVERVIEW Congratulations on purchasing your AEV JK V8 HEMI Builder Kit These instructions have been written for shops or DIY individuals with advanced mechanical ability and welding experience AEV also assumes that this kit will be installed in a shop environment with access to professional shop equipment Please obtain a Factory Service Manual for your model year Jeep Wrangler Factory service manuals are available from any Chrysler dealership In addition to AEV JK V8 HEMI Builder Kit you will also need to purchase all of the Chrysler parts as indicated on the Bill of Materials to complete this conversion The Bill of Materials can be found on our website and is based on using a current model year 5 7L or 6 4L engine If you are using any engine other than the current model year some components listed on the Bill of Materials may vary Using the wrong part can cause serious damage to other components Please contact AEV to ensure that you have the correct Bill of Materials for your specific model year engine AEV strongly recommends obtaining all of the parts listed on the Bill of Materials BEFORE you begin the installation process PLEASE NOTE If you are installing a 6 4L HEMI V8 it is required to use only premium fuel AEV recom mends
9. all AEV supplied exhaust system Refer to photo group B PLEASE NOTE The supplied AEV exhaust system is designed to fit both the 5 7L and 6 4L engine in a stock application BOTH the 5 7L and 6 4L engines will require the use of the 5 7L exhaust manifolds gaskets and bolts that are listed in the Bill of Materials The routing has been configured assuming a stock suspen sion and bumpers The use of aftermarket suspensions bumpers or other components may require modifi cations to the exhaust system or other components We find it easiest to start from the rear of the chassis DO NOT tighten the exhaust at this time Refer to photo group a Q Install the cross member hanger fig 29 Install the supplied isolators onto the frame fig 30 Install the exhaust system photo group B Shorten one of the down tube to manifold bolts by 3 4 to use in upper mounting location DO NOT TIGHTEN EXHAUST AT THIS TIME Install 02 sensors Figure 29 Figure 30 19 Photo Group B 20 ENGINE BAY PREPARATIONS Remove the factory coolant bottle Remove fan assembly Remove AC lines Save the pressure switch and O Ring for later use Remove the cooling module Strip the cooling module Everything will be reused except the radiator D e N P Install the supplied power steering cooler Use the AEV supplied spring clamps NOT the hose clamps provided with the cooler fig 31 Figure 31 7 In
10. down re check all fluid levels AEV recommends at least 2 cooling cycles before programming the throttle tolerance This will allow cooling system to purge any air and give you a chance to triple check all of your work PROCAL MODULE PROGRAMMING Please refer to the User Guide and Quick Reference Guide that came with your ProCal for correct program ming procedure THROTTLE TOLERANCE PROGRAMMING This mode allows the user to program throttle tolerance and effectively pair a PCM and pedal When a new PCM or pedal has been installed the previous values stored in the PCM may not match the specific toler ance of the pedal and need to be reprogrammed Notes This mode requires simultaneous inputs from a user on the throttle pedal as well as the multifunc tion light stalk When programming follow the steps in a deliberate but not rushed manner The entire process should take approximately 3 4 seconds If the process is completed either too fast or too slow the pairing will fail Procedure Set the DIP switches as shown below With the engine off and ignition on plug the module into the OBD port and follow the steps below 1 When the module is ready the Electronic Throttle ETC Indicator a lightning bolt surrounded by two vertical lines will flash on the dash 2 To start the pedal routine pull the headlight stalk back into the Highbeam Flash position then re lease the headlight stalk allowing it to fall back into the
11. factory ser vice manual 26 Disconnect the fuel filler charcoal canister and fuel filler vent fig 9 gt DISCONNECT _ ee 9 27 Disconnect the parking brake cables at the axle 28 Remove the axle vent from the passenger side inner fender 29 Remove the trailer harness from the frame only if equipped 30 Remove all body mount bolts and nuts There are 10 body mount bolts on a 4 door JK Wrangler and 8 body mount bolts on a 2 door JK Wrangler Lower the jeep back to the ground 31 Disconnect and remove heater core lines and coolant hoses from the front of the engine and radiator At this point you are ready to lift the body off of the chassis Place the hoist arms at a suitable location on the body Double check your work making sure nothing was overlooked or missed SLOWLY raise the body off the chassis paying special attention to all lines and wiring so as not to damage or snag anything 32 Carefully push the chassis out from underneath the body space permitting 33 Remove the power train from the chassis You will need to disconnect the fuel lines SAVE the BLUE CLIP from the evap return line next to the transmission it will need to be relocated to the AEV sup plied line later power steering and exhaust SAVE THESE ITEMS Figure 10 III CHASSIS PREPARATION 1 Removethe top from the upper control arm heat shields 2 Begin fra
12. manual Connect transmission oil cooler lines to transmission cooler fig 46 Figure 46 Install and tighten transmission mount bolts refer to factory service manual Reinstall skid plates refer to factory service manual Make sure that the exhaust system has clearance around everything front to back then tighten from the front to the back We would also recommend welding each joint with stainless wire to prevent the exhaust from shifting 29 39 Install Universal Speed Control Module a Release steering wheel adjustment arm to free the lower steering wheel trim panel b Remove the knee panel located under the steering column fig 47 Remove the three 20 Torx head screws from the lower steering wheel trim panel fig 48 Figure 47 Figure 48 d Remove the six wire connector from clock spring should look like A trim the top of A to look like B fig 49 A 2 d 702000 RRR Figure 49 50 e Route long side of module wiring harness through instrument panel fig 50 Be sure the harness is routed away from the pedals and secured Figure 50 f Plug in AEV harness as shown fig 51 Figure 51 51 it Remove both 10mm ground nuts from the lower driver side inner body located next to floor pedals Connect routed through module harness to module connector E Reinstall both 10mm ground nuts fig 52 Figure 52 h Reinstall all trim pa
13. me prep Cut off motor mounts Trim upper control arm mounts as shown fig 11 WARNING Cover open fuel lines and fuel filler hose before cutting grinding or welding Figure 11 3 Weld AEV supplied Engine mounts fig 12 Figure 12 4 Paint frame covering up any bare metal that was exposed after grinding welding follow proper paint procedure 5 Remove and discard the vacuum pump located at the front of the frame but SAVE the hose for later use ORIGINAL ENGINE TEAR DOWN PROCEDURE 6 Remove the vent tubes from the transfer case transmission and SAVE for later use fig 10 Remove the idler pulley from the 3 6L and the short bolt from the idler pulley and SAVE for later use fig 10 8 Remove the starter alternator and AC compressor and SAVE all hardware as most will be re used 9 Remove the torque convertor bolts accessed through the starter hole 6 bolts total ASS nevi 10 Remove small dust shield on the passenger side fig 13 11 Remove the transmission from the engine Figure 13 IV NEW ENGINE PREPARATION AND ASSEMBLY 1 In this step you will change the torque converter and converter housing on the transmission to the parts listed in the Bill of Materials BOM Refer to the factory service manual for proper procedure and torque values Failure to follow proper procedures and torque values may cause transmission damage If you are unfamiliar with the processes and
14. nels Position V8 Decals as shown LER 6 4L VS 3 4 PLEASE NOTE The new position of the V8 motor on top of and in front of the front axle causes approxi mately 430 lbs of weight to be shifted to the front axle and suspension Stock springs will see approxi mately 1 of drop Aftermarket springs will vary depending on the manufacturer of the springs VII NEW ENGINE START UP PROCEDURE 1 Double check all connections wiring mechanical fittings and fasteners 2 Fill all fluids Refer to factory service manual for proper fluids for your model year Jeep Engine oil cap will specify viscosity and type Use dip sticks to verify proper fill levels Check to ensure transmission coolant brake and power steering fluids are all filled Use only MOPAR 4 Transmission Fluid in the transmission DO NOT FORGET TO BLEED YOUR BRAKES Follow proper brake bleeding procedures as outlined in your service manual 32 04 3 Connect the battery 4 Once all fluid levels and connections have been checked AND double checked you may now start your engine Once the engine is running check for any possible fluid leaks under the vehicle If any leaks are detected shut engine off and locate and correct the leak before restarting 5 engine will run very rough for the first couple minutes AEV recommends letting the engine come up to operating temperature before shutting it off 6 During engine cool
15. s disconnected We find it convenient to use zip ties to prevent steering wheel rotation 17 Remove the four 4 brake lines shaded in Figure 5 ENGINE BAY FENDER Figure 5 Although it is not required we recommend using a two post hoist to remove the body from the vehicle The JK Wrangler was designed by Chrysler to have the body and chassis built as two complete assemblies which are then mated together on the assembly line Because of this the removal of the body from the chassis requires less than two hours The procedure is outlined in these instructions 18 Remove factory plastic air dam from under the front bumper if it still remains on the vehicle 19 Disconnect and drain transmission oil cooler lines from the factory transmission cooler located be hind the driver s side inner fender A special tool is recommended refer to factory service manual 20 Drain coolant from the engine and radiator 21 Remove the upper control arm lower heat shield bolts fig 6 Figure 6 22 Remove the transmission and transfer case skid plates fig 7 23 Remove the three 3 transmission mount nuts fig 7 REMOVE TRANSMISSION MOUNT NUTS Figure 24 Remove the front and rear drive shafts Make sure to mark these before removal to ensure proper orientation and balance later fig 8 Figure 8 ASS nevi 25 Disconnect shift linkage and 4WD linkage at the transmission and transfer case refer to
16. seals are properly installed d Torque manifold bolts to 9 ft lbs in the exact order shown in Figure 16 Figure 15 Figure 16 6 Install ground strap head to head fig 17 Figure 17 10 EL 12 1 9 Change the crank pulley torque to 129 ft Ibs water pump torque to 18 ft Ibs 6 4L ENGINE ONLY Change the steel water pump hose neck 6 4L ENGINE ONLY Remove the factory installed oil cooler and discard Install the oil filter re locator torque to 9 ft Ibs Swap out the oil pan and oil pickup assembly with the parts listed on the Bill of Materials Make sure to reference your factory service manual regarding the torque to yield main bearing cap bolt and ALWAYS use a new bolt Install transmission to engine make sure the intermediate plate is installed AEV recommends using Blue Loctite Torque the bell housing bolts to 35 ft Ibs for the four 4 3 8 bolts and 50 105 for the two 2 7 16 bolts Install the torque convertor bolts using Blue Loctite and torque to 31 ft Ibs Install structural dust cover fig 18 Torque to 40 ft Ibs Figure 18 Modify AC Compressor using the following steps Using a 7 8 countersink bit drill out the factory hole a b Usea grinder to bevel the corner of the mounting point removing the shaded portion as shown z Grind the raised portion of housing flush d When mounting the A C compressor to the engine block
17. stall the AC condenser transmission oil cooler steering cooler assembly onto the supplied AEV Hemi radiator using the factory hardware and supplied p clips and petcock fig 32 21 8 2 77 ps Figure 33 Modify fan shroud 22 2 D ARE Install the cooling module back into the body Notice the positioning of steering cooler lines shown in Figure 34 9 Figure 34 10 Install the fan assembly onto the back of the radiator using the factory hardware 11 Trim and install the upper radiator shroud Also remove the factory decal on the upper shroud and install the supplied AEV decal fig 35 O cup Figure 35 12 Modify wiring at fire wall as shown fig 36 Figure 36 23 13 Modify and install steering relocation kit photo group a From the engine side of the vehicle remove the upper intermediate shaft BE SURE THAT THE STEERING WHEEL IS SECURED TO PREVENT ROTATION This will ensure that the clock spring is not damaged From the engine side of the fire wall mark a cut line as shown You will need to open the hole in the fire wall up approximately 9 16 at the arc s maximum Using a die grinder or similar tool cut the crescent shape to enlarge the hole Use touch up paint on the edge to prevent corrosion Install the AEV steering wheel relocation bracket to the intermedia
18. te shaft bearing Install the intermediate bearing and AEV Bracket assembly onto the engine side of the fire wall using a small bead of black silicone to seal the plate to the fire wall Now install the intermediate shaft into the intermediate bearing Because the AEV bracket is installed on the engine side of the fire wall you will need to trim the mounting studs a small amount Check the entire assembly for clearance to the vacuum booster there should be approximately 1 8 of clearance Photo Group C 24 14 Remove horn and horn bracket located on inner fender next to the brake booster Modify the bracket as shown in Figure 37 to relocate horn BEFORE AFTER REMOVE SHADED PORTION Figure 37 VI BODY RE INSTALLATION 1 S O 2 Lower the body back onto the chassis Pay special attention to all lines and wiring so as to dam age or pinch anything Install and reconnect everything in the engine bay Attach the heater core lines at the fire wall Connect the lower radiator hose at the radiator Reconnect brake lines Connect brake booster Route the wiring harness to the PCM Computer Connect the ground to the stud located next to the brake booster on the inner fender Install the horn bracket and the AEV supplied HVAC to condenser line at the original horn bracket location fig 38 Figure 38 25 04 10 Reconnect the steering linkage 11 Cutthe
19. use the ProCal Module to program your tire size Please use the Quick Reference Guide and User Guide that came with your ProCal Module for the proper programming procedure 34 FIG 2 hemi cover edge Retain this side of the paper to align with shape of hemi Remove this cover edge hemi section of badging H plastic cut along these lines x 1in hemi din badging H
20. use the supplied flat head bolt with anti seize in the upper mounting hole a factory bolt in the lower and a factory bolt in the rear with the supplied spacer between the compressor and engine block 10 Before After supplied bolt w anti seize supplied spacer factory bolts 14 Install the starter torque to 40 ft Ibs modified A C compressor torque to 18 ft lbs and the engine idler pulley torque to 40 ft Ibs 15 Locate the supplied 3 8L heater core hoses and modify and install as shown fig 19 5 L 6 4 L Cut and save lighter portion Figure 19 16 Cut prep paint and install transmission dip stick bracket fig 20 Figure 20 Cut and save lighter portion 12 17 Install battery harness as shown fig 21 p i sl 1 lt m a y lt 7 pr 64 4 P gt gt 18 Install AEV power train harness Refer to photo group gt Figure 21 15 Photo Group A 14 Photo Group A cont 15 19 20 21 22 25 24 2 D ARE If the upper alternator mounting hole is not a pass through hole you will need to drill it open We recom mend starting with a 13 64 then a 21 64 and finally ending with a 13 32 drill bit fig 22 Figure 22 Drill out upper alternator mounting hole Install
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