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part I: Overview and Tips
Congratulations on purchasing your AEV JK HEMI Installation kit. These instructions have been
written for shops or DIY individuals with experience in general mechanics and welding. AEV also as-
sumes that this kit will be installed in a shop environment with access to general shop equipment.
If you are not familiar with JK systems, please reference the Jeep Service Manual available at any
Chrysler dealership.In order to help facilitate installation, we have composed a series of tips below:
This kit requires a 2007-2010 Grand Cherokee engine. If using a 2011 engine you must change
the water pump and crank pulley to ‘07-‘10 parts.
TIP 1:
Although it is not required, AEV recommends using a two post hoist to remove the body from the
vehicle. The Jeep 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; removal
of the body only requires about 45 minutes. The general procedure is outlined below:
1. Discharge the AC system
2. Disconnect the steering shaft at the rewall.
3. Disconnect the appropriate brake lines at the ABS Module.
4. Disconnect the battery harness from the battery, rewall, and right front fender.
5. Unplug the 34 way powertrain connector at the rewall (C100) and the 34 way Chassis con-
nector (C300) on the right hand side of the radiator.
6. Unplug the PCM (C1, C2, C3, and C4.) Remove the harness from left front fender and rewall.
7. Disconnect the front left O
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sensor located below the master cylinder (pre-2011) or on the
rewall (post-2011.)
8. Drain and disconnect the radiator and heater hoses.
9. Disconnect the transmission cooler lines at the radiator.
10. Remove the power steering reservoir from the body.
11. Disconnect the vacuum line from the brake booster and rewall.
12. Disconnect the ground strap from the hood and rewall.
13. Remove the battery tray and air lter
14. Remove the heater core hoses from the engine.
15. Remove the drive shafts
16. Remove the trailer harness if equipped.
17. Remove all the body mounts
18. Disconnect the emergency brake cables at the rear axle.
19. Disconnect the transmission and transfer case cables
20. Disconnect the fuel ll hose.
21. Disconnect all vapor lines at the purge valve.
22. Disconnect the top of the rear axle vent line.
(13 pages)
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