Step 1 Remove the driver’s side hood cover by prying upward with both hands.
Step 2 Remove the driver’s side windshield molding. Do not peel off the rubber seal or separate from roof molding.
Step 3 Remove 4 screws from driver’s side roof railing. Remove roof and windshield molding and set it down on the table.
Step 4 Measure 1” from the beginning of the roof railing and mark on the masking tape the spot to drill ½” hole for your harness.
Step 5 Install relays onto driver’s side engine compartment behind the battery, (See Step 6)
Step 6 Ground two short black wires leading from relays to screws holding the relays. Run yellow wires towards the corner of engine compartment.
Step 7 Run blue switch wire through the existing rubber grommet in the fire wall next to the relay’s location (Step 6).
Step 8 Pull both fuses out of fuse holders to protect from falsely activating the harness.
Step 9 Connect both red wires leading from relays to the battery’s positive terminal.
Step 10 Run both yellow wires with black wire alongside the windshield and up to the roof. Use electric tape to help hold down your wires.
Step 11 Continue with yellow and black wires on the roof. Set down the roof molding placing the wires in the molding cradle. Bolt the
molding down to the roof.
Step 12 Place left post of light bar inside roof railing. Mark 4” from beginning. Connect blind side of red wire to any hot wire under dash board.
Ex: Red wire leading from the break pedal.
Step 13 Insert the pins from yellow wires into the outside pin holes of the receptacle. Insert the pin from black wire into the middle pin hole.
Step 14 Slightly remove the top rubber seal on the top of the bar and secure with screws (provided).
Step 15 Repeat Step 14 on the other side of the vehicle securing down your light bar to the posts.
Step 16 Plug in the light bar plug into the harness receptacle. Close off both sides of the bar with cover and lock the key for safety.
Step 17 You are now ready to install switches. The easiest location is under the steering column. Mark two spots for your ¾” holes.
Step 18 Drill two holes. Snap both switches in place. Connect short red wires to one prong of each switch.
Step 19 Connect blue wire leading from relay through the fire wall to one prong on each switch.
Step 20 Connect the blind side of the red wire to any hot wire under the dash board. Ex: Red wire leading from the break pedal.
Slide Housing Bracket over bolt at #12 hole location (Photo 3), keeping the bracket between the cargo management rail and lock washer (Diagram 4). Fully tighten and repeat for the other side. Place the small Rubber Gasket (Photo 5) provided between the Housing Bracket and the bed rail (Diagram 6). Note: Place the notched end of the gasket on the bulkhead. Repeat for the other side. Place the Bulkhead Flange over the bulkhead rail (Photo 7). Insert the black plastic push pins to secure the flange (Photo 8).
1. From under the vehicle use a measuring tape to measure from the muffler box seam back along the axis of the muffler inlet pipe 59mm (2.32”) and mark the point on the exhaust pipe. ( see figure 1) Note: This cut position is the same on both LH & RH side Exhaust Pipes.
2. Confirm the mark is in the correct location and cut the pipe along the marked cut line.
3. Remove the muffler from its rubber hangers and discard the old muffler. ( see figure 2) De-burr the end of the exhaust pipe.
4. Slide the exhaust clamp onto the new exhaust pipe. Install the replacement muffler onto the rubber exhaust hangers and slide the muffler onto the exhaust pipe. ( see figure 3)
5. Position tip in rear valence and tighten the clamp bolt to 32-35 FT.-LBS. ( see figure 4)
6. Repeat instructions for the opposite side.
Disconnect battery & remove all existing accessory drive brackets and components from motor. Remove water pump, scrape away any existing gasket material with a gasket scraper and dress surface with a Scotch Brite? pad. Clean and prep threads on engine block at water pump (3/8-16) and driver side bosses (7/16-14) by crank (for power steering kits). Use a 3/8-16 & 7/16-14 thread chaser if necessary. Thread chasers are available at your local auto parts store or tool dealer and are different from a thread cutting tool. Apply RTV sealer to one end of the four 3/8-16 x 3” threaded studs and thread studs into the water pump mounting holes and tighten. The studs can easily be tightened by threading two 3/8-16 zinc coated nuts onto the stud and tighten them against each other to act as a drive nut.
Installation manual introduction
This installation manual includes useful information to prevent problems from occurring during installation.
1. Please read through this manual before installation.
2. Installation work has to be done by a professional installer who will use the product safely.
3. Please do not use the product wrongfully nor modify the parts. In such case, we will not take any responsibility.
4. We will not accept any claim nor return as this product is used predominately for racing and specification may change without prior notice.
5. Please keep this manual following installation.
INSTALLATION PROCEDURES:
The saddle mount kit is designed to be used with 1987-95 YJ Wranglers. This mount is designed around a stock oil pan. If you are using an aftermarket oil pan, the maximum depth in the front is 4-1/2″. GM part number 12557558 (1986 and newer) has a front depth of only 3-1/2″ and provides the most mount to pan clearance We have designed this mount to position your new engine in the best location possible. Driveshaft modifications may be necessary depending on your application. We have had requests to allow some lateral adjustment with this mount. To supply this adjustment we have provided two 5/8″ spacers. Using these spacers, you can space the stock rubber mount 5/8″ to the front or rear of the saddlemount location.
Before Starting Installation
1. Carefully read all warnings and instructions completely before beginning.
2. Verify all parts have been received in this kit by checking the parts list at the end of this document.
3. Only install this kit on the vehicle for which it is specified. If anytime during the installation you encounter something different from what is outlined in the instructions, call technical support at (928) 636-7080.
4. Park vehicle on a clean, dry, flat, level surface and block tires so vehicle cannot roll in either direction.
Step 1 – Vehicle Preparation
Remove the negative battery cable. With the vehicle on a solid level surface, chock the front wheels. Using a jack rated for the weight of your vehicle, raise the wheels off the ground. Lower the vehicle frame onto jack stands rated for the vehicle weight, making sure the suspension is fully extended. (Do not use wood or concrete blocks to support the vehicle.)
