100_0234
Before the swap
Date: 06/24/2010
Here is my 2003 TJ before the engine swap. I started in mid-April 2010 but soon discovered some front-clip damage that had to be repaired. The fab and paint work set me back a few weeks. I also took the time to replace or repair anything that needed attention.
100_0235
Take note of harness routing and heater vacuum line
Date: 06/24/2010
Some before shots to record how the fuse block (PDC) harness is routed and how the HVAC vacuum line is hooked up. Glad I had these shots at the end of the build.
100_0242
2004 Hemi 5.7L
Date: 06/24/2010
The engine is from a 2004 Ram. We've replaced the passenger manifold for exhaust clearance.
100_0243
2003 Ram 4x4 adapter
Date: 06/24/2010
We used the adapter and seal for a 2003 Ram 5.7L 4x4 to mate the transmission to the transfer case.
100_0246
TJ fuse block (PDC)
Date: 06/24/2010
This is the TJ PDC that you will need to send in to us for modification.
100_0247
Power steering lines
Date: 06/24/2010
We used the lower ends of the stock TJ power steering lines to hook up to the new Hemi P/S pump. We had the high pressure line crimped with a new fitting at our local CarQuest.
100_0248
Heater lines
Date: 06/24/2010
These pictures of the heater lines show that the top line is the outlet side and the bottom is the return. You'll want to take note of this for the end of the build.
100_0253
Broken radiator support
Date: 06/24/2010
You can see here that the bottom of the radiator support has broken free. This allowed the whole nose to drop about an inch and cost some time for the fab work and some new paint.
100_0254
Ready to pull the 4.0L
Date: 06/24/2010
With the front clip removed we are ready to pull the 4.0L
100_0266
Transfer case shift-linkage
Date: 06/24/2010
We had to modify the shift linkage support after we installed the 1" body lift. This is a reference shot from before the drivetrain was pulled.
100_0272
EVAP Purge solenoid
Date: 06/24/2010
This is the Evaporator Purge. You need to retain this piece to get a full emissions swap with a working check-engine light.
100_0283
Pulling the 4.0L
Date: 06/24/2010
Here are a few shots of the old drivetrain being pulled from the TJ.
100_0292
Transfer case moved to Hemi
Date: 06/24/2010
Here we've moved the 241 transfer case over to the Hemi. The transfer case bolted right up to the truck adapter with no modifications needed.
100_0296
Repairing the radiator support
Date: 06/24/2010
Both sides of the radiator support needed new bottom pieces fabbed in to fix the damage. Both front fenders also needed some significant welding.
100_0298
Fuel pump change
Date: 06/24/2010
All 1997 to 2004 TJ Hemi conversions should upgrade the fuel pump module to a 2005-2006 part number in order to get the correct fuel pressure for the Hemi. The next few shots show how that went with my 2003.
100_0303
Fitting the new pump
Date: 06/24/2010
The new fuel pump module has to be slightly modified to fit in the older tank. The tab on the left had to be cut off and the overall diameter of the upper seal area had to be cut down. Be careful not to get debris in the pump as you trim it down. An air-sander with quick, smooth motions made it an easy job.
100_0312
Remove old motor mounts
Date: 06/24/2010
The next few shots show how to cut the old motor mounts off the frame. If you're careful you can save the mounts to sell with the 4.0L.
100_0319
Prepping the body parts for paint
Date: 06/24/2010
We decided to go with a single-stage paint to simplify later repairs. We are decided to paint the firewall now to make sure the color will match when the Jeep is finished.
100_0322
New motor mounts installed
Date: 06/24/2010
Here is a shot of the Advance Adapters Hemi motor mounts installed and painted on the TJ frame. Sorry for the darkness of the pic.
100_0328
Pedal installed
Date: 06/24/2010
The Hemi pedal is installed using the Teraflex pedal bracket. It's a very simple, bolt-in install.
100_0330
Transfer case shift linkage adapter
Date: 06/24/2010
Here is the Teraflex shift linkage adapter installed on the TJ bracket.
100_0331
Firewall and new motor mounts
Date: 06/24/2010
Here is a better shot of the Advance Adapters motor mounts installed on the TJ.
100_0332
Wiring harness installation
Date: 06/24/2010
This set of shots shows how to install the wiring harness for a TJ conversion. It is much easier to install the harness on the engine before you put it in the Jeep.
100_0333
Harness routing
Date: 06/24/2010
Note how the trunk line of the harness fits in the void under the back of the Hemi intake. The trunk then drapes up over the passenger head.
100_0334
Transmission routing
Date: 06/24/2010
The main transmission wiring feeds down the driver's side of the transmission and back to the transfer case.
100_0335
Injector routing
Date: 06/24/2010
The main branches to the front of the engine are zip-tied along the fuel rails and routed over the front of the block.
100_0338
Rear Oxygen sensors
Date: 06/24/2010
The rear oxygen sensors and the trans-line pressure wiring is routed down the passenger side of the transmission. I zip-tied it to the trans filler tube.
100_0347
Leak detection pump modifications
Date: 06/24/2010
Here is the stock TJ Leak Detection Pump. We removed the solenoid and the vacuum line that went to the old intake manifold on the engine. These are not needed for the new NVLD setup.
