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JK V8 HEMI Instruction Guide |
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JK V8 HEMI Conversion Instructions
5.7L, 6.1L, 6.4L Truck HEMI or LX HEMI
2007-2013 Jeep Wrangler JK- SWB, LWB
This Kit may not be legal in all states do to Emission Warranties.
It is the users responsibility to comply with all regulations.
While all correct emissions equipment will be installed with this kit and our computer will run all emissions monitors.
We do not need to pull the body off the Jeep to do the install, but you will need to take the Jeep to an AC shop to evacuate the AC.
Step 1: Discharge the AC.
Step 2: Disconnect the battery.
Step 3: Drain the coolant.
Step 4: Pull the battery box and unplug the plugs going to the grill. (In the TIPM/pull air box)
Step 5: Pull the grill, disconnect the AC lines, transmission lines, radiator hoses and unplug marker lights.
Step 6: Put WD40 on the exhaust bolts at the manifolds.
Step 7: Pull the wiring on the computer and the C100 plug at the fire wall.
Step 8: Pull the power steering pump, we might need some parts off the old pump, so keep it.
Step 9: Go under the Jeep and pull the exhaust system, if you are going to reuse the system. We cut off the first to cats and reuse the exhaust flanges. Install new pipe to the cats.
Step 10: Pull the T Case and drive lines, we are going to reuse these parts.
Step 11: Pull the gas and evap line, we are going to reuse the evap line.
Step 12: Disconnect the trans cable, T-case cable, we might reuse the t-case cable mount. So keep it.
Step 13: Put a plug in the trans, because ATF will come out.
Step 14: We put a pull chain on both exhaust manifolds and the engine will balance out good to pull the engine.
Step 15: Pull the engine out (It should take about 3 to 4 hours to pull an engine).
Step 16: You will need to keep the battery cables, ground wires to body, evap line and computer for a core.
Step 17: Now you will need to cut the engine mounts off using a plasma cutter or a die grinder.
Step 18: Next you will need to pull the lower steering shaft and then the upper steering shaft (Make sure you do not turn the steering wheel with the steering shaft off, you will damage the clock spring) to install the pillow bearing relocation mount. You will need to die grind about 3/16 of an inch toured the booster.
Step 19: Installing the mounts, our mounts are made for the HEMI and the Chevrolet LS. So when installing the HEMI you will need the mount to line up with the oval hole in the frame, putting the mount forward.
When putting a Truck Hemi in you will need to use the upper holes to mount the engine, If you are using a WK, XK engine you will need to use the lower holes.
For the Power Steering mod, we need to pull off the reservoir and add our adapter for the JK reservoir. You might also need to cut the pressure fitting so the power steering hose will fit.
Also you will need to add our reservoir mount. This is a 2009 pump for the 2010-2013 we include a tube.
AC pump mod, we need to drill a hole to countersink the allen bolt for the VVT Truck Hemi and the WK, XK engines (2009-2013)
Oil filter mod, you will need to change out the oil filter adapter, so we weld on a nut to get the threaded bung out.
Installing engine, We install the engine with the trans and no engine mounts on the engine. We put the mounts on after the engine is in the Jeep.
Here is the non VVT Truck HEMI power steering pump, mods.
Fan shroud mods, You will need to cut out the old electric fan for the Manuel fan. You will need to cut to fit, we are working on a new fan shroud.
Fuel line adapter, this takes the 5/16 line to 3/8 line. We reuse the Truck fuel line.
Battery Box install, you will need to reroute the wiring that went under the box to go over the box. |
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JSS BOM - Build of Material |
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PART NUMBERS
We are listing out the pieces you will need for various builds.
This page will continue to grow and expand so you have access to all of the part #'s you may need.
The following part numbers are for Hemi swaps on 1997-2006 LJ and TJ Jeeps
Fan for a 1997-2006 TJ/LJ (Chrysler Part #: 52027893)
Fan Clutch (Napa Part #: 271368)
Quantity of 2 - O2 Sensor - Front (Chrysler Part #: 56028994AB)
Quantity of 2 - O2 Sensor - Rear (Chrysler #: 56029049AA)
Left Exhaust Manifold (Chrysler Part #: 53013606AB)
Right Exhaust Manifold (Chrysler Part #: 53013606AB)
Fuel Pump (Chrysler Part #: 05161335AB)
Fuel Pump Gasket - Works with 1997-2004 TJ and LJ's(Chrysler Part #: 1-52018808)
Throttle Pedal (Chrysler Part #: 52109683AC) - You can also use a 2006-2007-2008 Truck Pedal as well
Radiator Hoses:
Upper Radiator Hose (Napa Part #: 8030)
Lower Radiator hose (Napa Part #: 7759)
Battery Cables (Chrysler Part #: 56051599AC)
Transmission Mount that's 1" taller than the stock TJ Mount (Chrysler Part #: 52019998)
Air Temperature Sensor (Chrysler Part #: 05149025AA)
Vacuum Booster Valve Tee (Chrysler Part #: 5072522AA)
Works with TJs, LJs, JK VVT and JK NON-VVT: Capacitor (Chrysler Part #: 56041889AA)
Overdrive Switch (Chrysler Part #: 56047020AA)
Oil Sender (Chrysler Part #: 05149097AA)
The following part numbers are for VVT Truck Hemi swaps on 2007-2011 JK Jeeps
15" Engine Fan from Flex-a-lite (Flex-a-lite Part #: 5715)
Fan Clutch - Screw-On Rotation (Derale Part #: 21061)
Radiator Hoses:
Upper Radiator Hose (Napa Part #: 7369)
Lower Radiator hose (Napa Part #: 7759)
Valve Body - if you have a 2011-2012 545 RFE Automatic Transmission (Chrysler Part #: RL166834AD)
Works with VVT, NON-VVT Hemi's and Chevrolet LS Engines: Quantity of 2 - Engine Mount to Frame Bolts (Chrysler Part #: 06508081AA)
Works with VVT, NON-VVT Hemi's and Chevrolet LS Engines: Quantity of 2 - Engine Mount to Frame Nuts ( Chrysler Part #: 6502585)
Works with VVT, NON-VVT Hemi's: Quantity of 2 - O2 Sensors (Chrysler Part #: 56029049AA)
Works with VVT, NON-VVT Hemi's: Oil Filter Adapter (Chrysler Part #: 53013680AD)
Works with VVT, NON-VVT Hemi's: Oil Filter Adapter Bolts (Chrysler Part #: 06102041AA)
Works with VVT, NON-VVT Hemi's: Oil Filter Adapter O-Ring - Outer (Chrysler Part #: 53021661AA)
Works with VVT, NON-VVT Hemi's: Trans Shift Cable Bracket (Chrysler Part #: 52104371AG)
Works with VVT, NON-VVT Hemi's: Trans Shift Lever (Chrysler Part #: 52109706AC)
Transmission Parts Compatible with WK (Grand Cherokee) and 5-45 Transmissions
Works with VVT, NON-VVT Hemi's: 4WD Adapter (Chrysler Part #: 52119433AB)
Works with VVT, NON-VVT Hemi's: 4WD Seal (Chrysler Part #: 52119498AA)
Works with VVT, NON-VVT Hemi's: Coolant Bottle Mount (Chrysler Part #: 52028065AF)
2007-2013 VVT, NON-VVT Hemi's and Chevrolet LS Engines: Engine Mount "WK - Grand Cherokee" (Chrysler Part #: 52090304AG)
2007-2013 VVT, NON-VVT Hemi's and Chevrolet LS Engines: Engine Mount "WK - Grand Cherokee" (Chrysler Part #: 52090305AG)
VVT Hemi only: Right Exhaust Manifold (Chrysler Part #: 53013858AD)
VVT Hemi only: Left Exhaust Manifold (Chrysler Part #: 53013857AD)
NON-VVT Hemi only: Right Exhaust Manifold (Chrysler Part #: 53013606AB)
NON-VVT Hemi only: Left Exhaust Manifold (Chrysler Part #: 53013605AB)
Works with VVT, NON-VVT Hemi's: Power Steering Hose (Napa Part #: 7-6052)
Quantity of 16 Bolts - 10mm x 25mm - These are the bolts for the engine mounts and the transmission mounts
Quantity of 8 Nuts - 10mm x 1.5mm zinc coated- These are for the transmission mounts (Fastenal Part #: 1190702)
The following part numbers are for 2007-2011 NON-VVT Hemi swaps
Fan Clutch (Napa Part #: 271367)
Compatible with VVT, NON-VVT Hemi's and Chevrolet LS Engines: Hayden Transmission Cooler (Hayden Part #: HDA-679 or Napa Part #: 1-7510)
Engine Fan (Chrysler Part #: 52027888)
Upper Radiator Hose (Napa Part #: 7311)
Works with TJ, LJ, NON-VVT JK's and VVT JK's: Lower Radiator Hose
Oil Filter Bung - Small Tread (Chrysler Part #: 04104511)
The following parts are needed to convert your manual to an automatic:
JK 4WD Shift Bracket (Chrysler Part #: 52121833AC)
Auto Shifter (Chrysler Part #: 52060162AB)
Nut (Chrysler Part #: 5127449AA)
Shift Cable (Chrysler Part #: 52060164AD)
Park Interlock Cable (Chrysler Part #: 52060163AD)
Sled - Auto (Chrysler Part #: 52060490AD)
Nut (Chrysler Part #: 6506603AA)
Brake Pedal (Chrysler Part #: 52059871AC)
Shaft - Brake Pedal (Chrysler Part #: 52060460AC)
Transmission Isolator (Chrysler Part #: 52059945AB)
'07-'09 Console in Grey (Chrysler Part #: 1FG731D5AA)
'07-'09 Console in Beige (Chrysler Part #: 1FG731J3AA)
Bezel - Auto (Chrysler Part #: 1CG44XDVAB)
The following part numbers are for Chevrolet LS Engine Swaps
Mass Air Flow Sensor Mount (GM Part #: 19166574)
Mass Air Flow Sensor -Works with GM Part #: 19166574 (GM Part #: 15865791)
Quantity of 2 - O-2 Sensors - Upstream (GM Part #: 12583804)
Quantity of 2 - O-2 Sensors - Downstream (GM Part #: 12609457)
Quantity of 3 - Torque Converter Bolts (GM Part #: 11589040)
Crank Shaft Bolt (GM Part #: 12557840)
Transmission Cooler Lines (GM Part #: 92236244)
Right Trailblazer Exhaust Manifold (GM Part #: 12600527)
Left Trailblazer Exhaust Manifold (GM Part #: 12600526)
Gas Pedal (GM Part #: 25832864)
Heater Hose one end of hose is 3/4" & the other is 5/8" (Napa Part #: 10084)
Power Steering Hose that works with GM Truck Power Steering Pump (Napa Part #: 7-3392)
Upper Radiator Hose (Gates Part #: 21821)
Oil Block-Off Gasket (GM Part #: 12611384)
Oil Pan Block-Off Plate for JK Oil Sender (GM Part #:12551587)
Mass Air Flow Sensor with honey cell (GM Part #: 15900023)
Mass Air Flow Sensor without honey cell (GM Part #: 15900024)
Mass Air Flow Sensor works with 2009-2012 GM Truck (GM Part #: 10393948)
Transmission Isolator (Chrysler Part #: 52059945AB)
Brake Booster Nipple (GM Part #: 12559760)
Quantity of 2 - Exhaust Manifold Gaskets (GM Part #: 12617944)
Exhaust Flange Gasket - Driver Side (GM Part #: 15077362)
Exhaust Flange Gasket - Passenger Side (GM Part #: 15035747)
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