American-expedition-vehicles JK HEMI Builder Kit - Installation Guide for 12+ J Manuale Utente

INSTALLATION GUIDEJK v8 Hemi builder kit5.7L, 6.4L VVT hemi2012+ JK- swb, lwbAEV30231AALast Updated: 04/24/14

810. Remove small dust shield on the passenger side (g 13).11. Remove the transmission from the engine.Figure 13IV. NEW ENGINE PREPARATION AND ASSE

93. Locate the plug to the throttle body. This will need to be tested on the new Hemi throttle body. If it does not t, you will need to remove the p

107. Change the crank pulley (torque to 129 ft/lbs), water pump (torque to 18 ft/lbs).8. 6.4L ENGINE ONLY– Change the steel water pump hose neck.9.

11ABBefore AfterCCCCBefore

1215. Cut and install the heater core hoses, re-using the factory hose clamps. 5.7L engines will re-use the original 3.6L heater core hoses, 6.4L eng

1317. Install battery harness as shown (g 21).Figure 2118. Install AEV power train harness. Refer to photo group A.

14Photo Group A

15Photo Group A cont.

1619. 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

17Figure 2325. Modify brake booster as shown (g 24) and install with fresh cut end to engine.Figure 24: Remove highlighted portionBACK TO CHASSIS26.

iitable of contents1. Overview 12. Vehicle Disassembly 13. Chassis Preparation 64. New Engine Preparation and Assembly 85. Engine Bay Preparat

18Figure 26: Before and After.29. Remove the block from the factory transmission lines.30. Assemble the AEV supplied transmission oil cooler lines t

19Figure 2832. Connect the fuel lines (you will need the blue clip you saved earlier).33. Install AEV supplied exhaust system. Refer to photo group

20Photo Group B

21V. ENGINE BAY PREparations1. Remove the factory coolant bottle.2. Remove fan assembly3. Remove AC lines. Save the pressure switch and O-Ring for

228. Modify the factory fan shroud for coolant bottle and lower radiator hose clearance as shown in Figure 33.BEFOREAFTER AFTERBEFOREFigure 33: Modif

239. Install the cooling module back into the body. Notice the positioning of steering cooler lines shown in Figure 34..Figure 3410. Install the fan

2413. Modify and install steering relocation kit (photo group C).a. From the engine side of the vehicle, remove the upper intermediate shaft. BE SUR

2514. 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.REMOV

2610. Reconnect the steering linkage.11. Cut the hose and then install the hoses for the power steering lines (g 39).Figure 3912. Connect the rema

2714. Trim and connect upper radiator hose using the AEV supplied spring clamp (g 42).Figure 4215. Pre-install provided M6 u-nuts into the AEV supp

1I. OVERVIEWCongratulations on purchasing your AEV JK V8 HEMI Builder Kit. These instructions have been written for shops or DIY individuals with adva

2825. Connect power wire to the TIPM and attach the TIPM to the TIPM bracket.26. Modify and install the air intake tube as shown (g 44).a. DO NOT

29REPOSITION HOIST TO UNDER CHASSIS AND RAISE JEEP FOR UNDERSIDE ACCESS29. Reposition the hoist under the chassis and raise the vehicle for underside

3039. Install Universal Speed Control Module.a. Release steering wheel adjustment arm to free the lower steering wheel trim panel b. Remove the kne

31e. Route long side of module wiring harness through instrument panel (g 50)Figure 50f. Plug in the AEV harness as shown (g 51).ACBDEACDBEFigure

32g. Remove both 10mm ground nuts from the lower driver side inner body located next to oor pedals. Connect routed through module harness to module

333. Connect the battery.4. Once all uid levels and connections have been checked AND double-checked, you may now start your engine. Once the engin

34axle ratio programmingUsing the ProCal Module to program axle ratio once your new HEMI engine is installed requires a special mode. Programming axle

cut along these lines* Retain this side ofthe paper to alignwith shape of hemicover edge / hemibadging “H”.hemi coveredgehemi badging “H”1in1inRemove

27. Remove the battery harness from the TIPM, battery tray, and fender.8. Disconnect the power steering reservoir from behind the headlamp and disca

316. Disconnect the steering shaft at the re wall. WARNING: Steering wheel contains a clock spring. DO NOT ROTATE steering wheel after steering shaf

4Figure 622. Remove the transmission and transfer case skid plates (g 7).23. Remove the three (3) transmission mount nuts (g 7).TRANSMISSION MOUNT

525. Disconnect shift linkage and 4WD linkage at the transmission and transfer case (refer to factory ser-vice manual).26. Disconnect the fuel ller

6SAVE THESE ITEMSFigure 10III. CHASSIS Preparation1. Remove the top bolt from the upper control arm heat shields.2. Begin frame prep. Cut off motor

73. Weld on AEV supplied Engine mounts (g 12).Figure 124. Paint frame, covering up any bare metal that was exposed after grinding/welding (follow p