American-expedition-vehicles JK Hemi Builder Kit - Installation Guide for 07-11 Manuel d'utilisateur

INSTALLATION GUIDEJK v8 Hemi builder kit5.7L, 6.1L, 6.4L hemi2007—2011 JK- swb, lwbAEV30207AALast Updated: 08/30/12

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

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9Part II: Engine & transmission mounting5.7L, 6.1L, and 6.4L WK or XK Powertrains with Dodge 4WD Adapter in place.2007+ JK—SWB, LWB, LHD onlya. mo

10Fig. 2c. installation of the transmission mount1. All 5–45 Transmissions must have the 3/4 Ton or 1 Ton Dodge 4WD adapter (Mopar 52119433AB) instal

11Fig. 3

12Part III: wiring harness installationEvery AEV HEMI JK Wiring Harness is 100% computer checked for quality and accuracy before shipment. The harness

13b. harness to body1. Install the 10-way gray connector to the inside of the rewall using the double push-pin fastener included in the connector.2.

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16Part iv: battery traya. remove the factory battery1. Remove the factory air box, purge valve, and battery.2. Release the TIPM (fuse block) from th

iitable of contents1. Overview 12. Engine and Transmission Mounts 93. Wiring 134. Battery Tray 175. Steering Shaft Relocation 236. Plumbing 2

17D. 3.8L air box mounting1. Mount the included brackets as shown to the front of the AEV Battery Tray. Install the bolts from inside the battery tra

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22Part v: STEERING SHAFT RELOCATIONIn order to provide ample clearance between the steering shaft, ignition coils, and valve cover, a relocation brack

23Fig. 2Fig. 3

24Fig. 4Fig. 5

25Fig. 6Fig. 7

26Fig. 8Fig. 9

iiiThis product is covered under the AEV Parts Limited Warranty, a copy of which can be found at aev-conversions.com/warranty.PLEASE READ BEFORE YOU S

27PART VI: PLUMBINGA. AEV HEMI Fuel Line1. Remove the locking clip out of the plastic fuel line at the tank as shown (g. 1.)2. Install the stud pro

28b. Power steering linesThis step is to be performed after the powertrain has been installed. Be sure you are using the correct power steering pump (

29c. AEV AC Lines (body side)1. Install the liquid line (Condenser to Firewall.) Use the stock hardware to connect the lines.2. Fasten the line to t

30f. heater hosesCut the stock 3.8L hoses as shown (g. 8a) keeping the center sections. Fit these sections to the completed powertrain before mating

31h. radiator hoses1. Install the lower radiator hose as shown (g. 9.)2. Fan shroud may need to be trimmed to ensure proper clearance from radiator

32Part vii: exhaustAEV’s HEMI exhaust is designed specically for the 5.7L HEMI but can be used for 6.1L and 6.4L engines as long as the 5.7L manifold

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1part I: Overview and TipsCongratulations on purchasing your AEV JK HEMI Installation kit. These instructions have been written for shops or DIY indiv

2Once the body is separated, it is easy to remove the stock powertrain, weld in the new mounts and to install the assembled 5.7, 6.1L, or 6.4L powertr

3TIP 7:The stock JK transfer case cable bracket must be modied in order to clear the oorpan as shown in Figure 1. Fig. 1TIP 8:The AEV Harness is the

4Fig. 3TIP 11:Use only Mopar +4 Transmission Fluid and Mopar Coolant. Other brands may harm the seals or cause cooling problems.Tip 12.Position the V8

5AC compressor modificationThe 3.8L AC Compressor must be modied to clear the steering gear.A. Using a 7/8-in countersink bit, drill out the factory

6factory boltssupplied bolt supplied spacerA. Mount AC compressor to engine block. Use the supplied at head bolt in the upper mounting hole, a facto