JK Hemi Conversion 2012 and Newer 6.4L Installation Guide

Dakota Customs 600 Cambell Street Rapid City, SD 57701

(605)-716-4123 www.dakota-customs.com

Last modified 24 April 2013

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Table of Contents OVERVIEW ........................................................................................................................................................................................3

General Assembly Comments .....................................................................................................................................................3

Kit Contents .................................................................................................................................................................................3

You Will Need to Provide ..................................................................................................................................................... 4

Aluminum Part Identification ......................................................................................................................................................4

VEHICLE PREPARATION ................................................................................................................................................................... 6

Remove Stock Engine .................................................................................................................................................................. 6

Steering Shaft Relocation .............................................................................................................................................. 7

Modify Transmission Cross-member ................................................................................................................................................ 9

ENGINE PREPARATION ........................................................................................................................................................................... 9

Transmission Bell Housing Swap .......................................................................................................................................... 9

A/C Compressor Modification ............................................................................................................................................ 11

Heater Bracket .................................................................................................................................................................. 12

Fuel Vapor Line ......................................................................................................................................................................... 13

Transmission Cooler Line Modification ........................................................................................................................ 14

ENGINE INSTALLATION ..................................................................................................................................................................15

Transfer Case ..................................................................................................................................................................... 16

Heater Hose ...............................................................................................................................................................................16

Harness Modification ........................................................................................................................................................ 18

Cruise Control Module Installation………………………………………………………………………………………………………………………………...21

Transmission Control Installation……………………………………………………………………………………………………………………………………27

INSTALLATION COMPLETE ............................................................................................................................................................ 31

Document Revision History ................................................................................................................................................... 32

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OVERVIEW Our kits are the best there is. Nowhere else can you buy a conversion kit that will be tailored just for your application. Nowhere else can you get an ECM that will be perfect for your motor, no matter which Hemi you use. Our stainless exhaust is trimmed and cut to fit and then welded together so it will work with any aftermarket suspension you want to use.

General Assembly Comments 2012-16 models will reuse the existing transmission cooler. For 2012-16 models, an auxiliary power steering cooler will be added. The OEM transmission skid will need to be removed and discarded. An aftermarket skid can be used if

desired but will require your own modifications to be used with the Hemi. The transmission fluid level is critical for proper operation. After the initial fill, start the engine and

shift through all gears, and then recheck fluid level in neutral. Do this a few times before driving,and then recheck level after driving, and correct as needed. Under and over-filling can both causeincorrect operation and premature failure of the transmission.

Double and triple check all of your vehicle wiring harness grounds and connections before ever trying tostart the car.

After finishing the exhaust system, it is important to thoroughly check all of your joints to insure thereare no leaks. Any leaks that are upstream of the oxygen sensors, or within 12" downstream of thesensors can cause faults related to the sensors and also incorrect fueling. Use a rag in the tailpipe andcompressed air to apply light pressure (5psi is enough) to the exhaust system and then spray the systemdown with soapy water to leak check.

Kit Contents

Heavy duty aluminum radiator

Plug n Play wiring harness computer checked for accuracy

Bolt-in motor mounts

Aluminum coolant reservoir

Preprogrammed ECM that is perfect for your motor

Air Conditioning lines

Radiator hoses

Power steering cooler

Steering shaft relocation bracket

Fuel line

Fastener kit

Custom Aluminum Air Box

Relocation kit for washer reservoir

Vehicle must have more than 25 miles on it before beginning installation.

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You Will Need to Provide

General automotive toolset

Angle grinder & cut-off wheels

Tubing flare tool that will do double flares

Miscellaneous nuts and bolts (bell housing to engine, motor mounts, fan shroud to radiator, etc.)

Airsaw Case of ATF-4 transmission fluid (transmission and power steering)

2 gallons of Chrysler antifreeze

Oil for your engineAluminum Part Identification Note: These parts may be revised at any time and the parts shipped with your kit may differ slightly from those shown here.

Airbox Bracket and Computer Mount Washer Fluid Reservoir Bracket

Power Steering Cooler Bracket

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VEHICLE PREPARATION

Remove Stock Engine Disconnect negative battery cable.

Evacuate A/C. Drain coolant.

Remove battery tray, radiator hoses, A/C lines, grill shell, driveshafts, motor and transmission, and the transfer case.

Cut the power steering line on the drivers side. Cut the line approx. 3 in after it bends towards the passenger side and flare. Discard the long piece that goes to the passenger side. Save the short piece that goes to the steering box.

Flare power steering line. Install power steering pressure hose and pressure hose adapter.

Remove high pressure power steering hose from power steering gear. Install supplied adapter and high pressure hose.

With an airsaw, remove washer fluid reservoir as shown in picture. Use caution not to cut wiring harness or fender liner.

Steering Shaft Relocation Using masking tape, hold steering wheel in place. If the wheel turns, the clock spring

could be damaged. Remove the steering shaft at the bolt in the base of the steering column.

Trace out the area to cut out of the firewall, using the steering shaft relocation bracket as a template.

Cut out the marked area with an airsaw.

Cut out a piece of foam padding as a weather seal using the steering shaft relocation bracket as a template. Set this piece aside.

Attach the steering shaft relocation bracket to the steering shaft as shown, using a rivet.

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Trim the factory steering shaft flange to match the outline of the steering shaft relocation bracket.

Glue the piece of foam padding to the back side of the steering shaft relocation bracket using spray adhesive.

Leave steering shaft out to allow clearance for exhaust headers.

Make sure to lock steering wheel in place or damage to the clockspring may occur.

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Lightly modify firewall for right rear valve cover.

Modify Transmission Cross-member Holes in the transmission mount and the transmission cross-member need to be slotted for the transmission to bolt on. Slot each hole as indicated in the following pictures by the yellow lines.

ENGINE PREPARATION

Transmission Bell Housing Swap It is necessary to swap the factory bell housing from the Nag1 transmission for a bell housing to fit the Hemi V8. Remove the two bolts on the outside of the Nag1 transmission with a Torx 45 bit.

Remove each of the Torx-45 and Torx-30 bolts on the inside of the bell housing.

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Remove the bell housing assembly by hitting upwards on it with a mallet.

With the bell housing assembly removed from the transmission, turn the bell housing over and remove the Torx bolts from the back side.

Turn it over again and partially re-insert two of the smaller Torx bolts in the front and use them to pound the clutch assembly out of the bell housing. When handling these parts, be very careful not to damage the orange seal, as they can be difficult to replace.

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Remove the fluid pump from the front side and the clutch assembly from the back. Swap the clutch assembly over to the new bell housing.

Re-install the fluid pump using the seven Torx bolts on the back side.

Use an air hose to blow any fluid out of the threads in the transmission case.

Install the new bell housing assembly onto the Nag1 transmission. Install the Torx-45 bolts on the inside of the housing using a crisscross pattern to 177 in- lbs. Install the Torx-30 bolts using a crisscross pattern to 89 in-lbs. Install the two Torx bolts on the outside of the transmission.

Remove the plugs and vent hose fitting from the old bell housing and install them in the new one.

A/C Compressor Modification

Trim the A/C compressor as shown below, to gain clearance for the steering gear box. Chamfer the top edge as shown.

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Counter-sink the bolt hole.

Re-install the A/C compressor using the supplied 3- 1/2 inch counter-sunk bolt.

Install A/C compressor onto the engine. Grind the top edge of the counter sunk bolt.

Heater Bracket Drill 17/64” holes in the heater bracket as shown in picture for transmission and transfer case vent hoses. Use pilot holes first. Using an appropriately sized metal shaft, bend the heater tubes back towards the firewall 1/2” to allow clearance for the intake manifold.

Attach the transmission and transfer case vent hoses to the heater bracket.

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Fuel Vapor Line The fuel vapor line needs to be modified. Cut the vapor line where shown.

Add 2.5 feet 3/8” fuel vapor hose to the vapor line. Wrap hose with braided sleeving. Remove quick disconnect fuel fitting on factory fuel line. Install supplied fuel line with quick disconnect.

Mount the fuel lines to the bell housing and fill tube.

Install wiring harness secure harness with zip ties.

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Transmission Cooler Line Modification Cut stock transmission cooler lines and flare as shown in pictures.

Cut cooler side of transmission hoses where circled and flare. Add supplied transmission cooler line with crimp fittings. Leave hoses off until engine is installed in vehicle.

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ENGINE INSTALLATION Loosely replace the transmission cross-member in the vehicle.

Using an engine hoist, lower the engine and transmission partially into the engine bay and rest the tail housing on the cross-member.

Install engine vibration isolators on motor mounts. Loosely install engine through bolts with spacers. The motor mount through-bolts require spacers. The 1/2–inch spacer goes on the driver side behind the mount, the 1-inch spacer goes on the driver side in front of the mount, and the 1 1/2-inch spacer goes on the passenger side behind the mount. Slide these spacers onto the motor mount through-bolts and install their respective nuts loosely.

Threaded loosely:

Drop the motor into the motor mounts, apply Loctite to the motor mount through-bolts, and install them finger tight. Tighten the engine block bolts.

Driver side, installed in the mount

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Passenger side, installed in the mount Heater Hose Reuse the factory heater hose, The hoses will be fliped side to side. You will have to trim appx. one inch off of each hose

DO NOT tighten the motor mount through-bolts at this time. The rest of the drivetrain must be installed first.

Transfer Case

Install the transfer case. Raise the transfer case off the transmission cross-member with a pole jack and remove the cross-member.

Install transfer case shifter bracket, driveshafts, transmission mount, transmission shifter bracket, and shifter cables.

Loosely replace the transmission cross-member. Tighten bolts to the transmission mount before the bolts to the frame so the cross-member can be moved up or down with the pole jack. Line up the transfer case output shaft and tighten the cross- member to the frame. Tighten the motor mount through-bolts now.

Make sure the cross-member is as high as it can go and then torque crossmember through bolts

Wrap heater hose in wiring conduit.

Assemble radiator support. Install power steering cooler on radiator support using supplied bracket.

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Set fan assembly on radiator. Trim fan shroud

where highlighted.

Cut the ribs off of the shroud to add clearance for the lower radiator hose. Make sure there are no sharp edges.

You will have to trim the shroud to make clearance for the radiator hoses as well as for the fill neck.

Transfer the rubber mounting pads and air deflectors from stock radiator.

Install radiator assembly on the radiator support. install radiator assembly in Jeep.

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Harness Modification

Portions of the harness will be rerouted. To allow this, pull the airbag sensor wires out of the harness back to the back end of the washer tray. Re-wrap the harness nicely.

Install battery tray, Install TIPM MAKE SURE GROUNDS ON FENDER BEHIND TIPM ARE TIGHT.

You will need to trim both radiator hoses to fit correctly. Install radiator hoses.

Install A/C lines. You will need to modify A/C lines at compressor to clear steering gear. Double check that A/C lines are clear of airbox/oil indicator tube.

Install serpentine belt.

Cut washer pump connector off harness and add supplied wire.

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Install intake manifold and torque to 105in/lbs

Assemble washer fluid/coolant over-fill bottle assembly. Attach hose with worm clamp to bottom of coolant overfill bottle. Install assembly. Route overfill hose to radiator cap.

Route washer pump connector and washer hoses through bottom of washer bracket and past the battery tray over to drivers side of engine bay. Install supplied washer hose splices and hook up washer hose.

Run vacuum hose to evap purge valve. Attach evap hose to purger valve.

Attach hoses to battery tray with zip ties.

Install vacuum hose from back of intake manifold to brake booster.

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Attach the Air Box bracket base to the mounts shown.

Don't forget to install your ECU on the back side of the Air Box as well.

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Cruise module installation instructions

Remove three torx screws out of steering column cover lightly pry covers apart. Remove knee blocker bracket cover by prying top corners of cover.

Remove two 10mm bolts and slide knee blocker bracket upward and out of the way. It is preferred to cut wire, add heat shrink and solder wires. If unable to solder wire use supplied wire taps. After splicing into wire with wire taps closely inspect to ensure proper fit of wiretap. Looking at the cruise module with the connector on the left side pin #1 will be the top pin.

Behind the knee blocker bracket there is a two pin connector that has the CAN wires.

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Start by tapping into the CAN wires. There is a grey two pin connector under dash to use, the white wire with black trace will be CAN (+) that will be pin#5 as labeled on the grey connector. The White wire with blue trace will be CAN (-) that will be pin#4 on the connector. Twist the can wire as pictured above. For splicing into the cruise signal wires it is easiest to splice into the wires at the clock spring connector.

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The VT/OR wire will be pin# 3 The OR/VT will be pin# 2 The VT/BR will be pin# 1 Heat shrink wire route down the steering column attach to harness with zip ties.

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The middle connector on the back of the clock spring will have the cruise control wires.

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Next route the ground wire (pin#6) to the kick panel attach eyelet to ground stud.

Pin #7 is battery +, Ignition power will set check engine light. Pin #3 at the clock spring connector red wire with black trace or a red wire. Secure wires with tape and zip ties, making sure wire will no chafe on metal brackets. Secure module behind steering wiring harness. Install steering and dash panels. Installation complete.

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Cruise adaptor Cruise adapter pin Pin #1 S/C Ground

Pin #2 S/C Signal 2

Pin #3 S/C signal 1

Pin #4 CAN –

Pin #5 CAN +

Pin #6 Ground

Pin #7 Battery power

Vehicle Harness Pin #5 at clock spring VT/BR wire

Pin #4 at clock spring OR/VT wire

Pin #6 at clock spring VT/OR wire

2 Pin connector under steering column White/Lt. Blue wire

2Pin connector under steering column White/Black wire

Attach eyelet to ground stud at driver kick panel

Pin #3 at clock spring RD/BK or Red wire

ConnectorVioletOrangeGrayBlueWhiteBlack

Red

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TRANSMISSION CONTROL MODULE INSTALLATION

INSTRUCTIONS

REMOVE KNEE BOLSTER BY PRYING ON TOP CORNERS OF PANEL. REMOVE TWO 10MM BOLTS THAT HOLD KNEE BLOCKER BRACKET IN PLACE.

WHILE LOOKING THROUGH DASH WHERE THE KNEE BOLSTER WAS REACH UNDER DASH AND REMOVE TWO CONTOLLER WIRING CONNECTORS.

THE TRANSMISSION CONTROL MODULE IS HELD BY TWO LOCKING TABS ON LOWER CONERS AND TWO PEGS IN TOP CORNERS.

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PRY LOWER TABS DOWNWARDS, WHILE PRYING TABS, PULL TCM OUTWARD AFTER THE TCM IS PAST LOCKING TABS. PULL TCM DOWN. REMOVE TCM FROM DASH SLIDE THE TOP PEGS OF THE NEW TCM INTO THE NOTCHES IN THE DASH BRACKET. ONCE PEGS ARE IN PLACE, FIRMLY PRESS ON BOTTOM OF TCM TO LOCK INTO PLACE. REINSTALL THE TWO WIRING HARNESS CONNECTORS, MAKING SURE THEY ARE LOCKED INTO TCM. REINSTALL KNEE BOLSTER BRACKET.

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Trim and install radiator cover

Trim the back of the coil covers to fit. Make sure cover will not touch wiring harness or A/C lines.

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Install exhaust. Add high temp RTV to exhaust joints. If there is an exhaust leak you will have a check engine light.

With a 10mm wrench check all of the ground wires

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INSTALLATION COMPLETE Connect battery. With front wheels off the ground fill power steering fluid and turn steering

from lock to lock to bleed any air out of the system.

Check oil level, engines may be shipped without oil.

Start the engine with the jeep in neutral and check

transmission fluid level.

With engine running, turn on your heater. You should have heat coming out of your vents as the engine temperature increases. If there is no heat from your vent you have air in your cooling system. Watch your temp gauge, you may have to increase rpm to get air out. Once it reaches operating temperature turn off and let sit.

Recheck coolant when cold.

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Document Revision History

26 October 2012 – Document first draft completed.

30 October 2012 – Added aluminum parts identification section. Added pictures of steering reservoir bracket outside of vehicle. Added pictures of coolant reservoir strapping bracket outside of vehicle.

5 November 2012 – Added section “Spacer Ring Removal”. Added section “Document Revision History”.

20 December 2012 – Converted installation manual to apply to 2012 and newer model years. Numerous additions and subtractions. Added detail to transmission cooler lines section.

24 April 2013 – Added instructions for bolt-in motor mount installation. Added section for A/C compressor modification.

10 January 2014 – Isolated Bolt-in only install instructions.