Time to install your FMHE, IC pump, and your hoses.
This write-up is based off of the current ZZP/WBS IC core that is shipped with all of their kits. If you have a frozenboost or other aftermarket style install will be similar, but you may need to cut more stuff or route your hoses differently.
All steps below are assuming that you are using the Bosch pump and you are routing your hoses as I did mine
*If you are routing your hoses differently make sure they don't contact the belt or become kinked anywhere/can rub against a metal edge
First step is to remove the front bumper cover.
Pull every push pin/clip in the center latch area along with the 6 10mm bolts holding the plastic tray to the frame and the headlight brackets.
Remove the plastic tray and air diverters.
Remove the 10mm bolt in each wheel well that holds the bumper to the fenders. You will feel a small recessed area in the fenders edge, this is where the 10mm bolt is.
Unplug your fog lights (unhook your HIDS if applicable)
Remove your driver side headlight (removing the passenger side isn't necessary, but it does free up a little room)
Remove the splash guard thingy from under the car. It is held in with 3 10mm bolts. (it's a little stubborn to remove, but it will come out)
Now remove your bumper cover. Should leave you with a mess like this.
*I left all the center stuff in, but it would have been easier to remove them first*
Center area should look like this.
The long loomed wire draped over the front is for my HIDS so don't freak out that you dont have this.
We need to modify the following spash tray thingymabob as such
This piece does NOT get reused
Now to mount the FMHE
If you look under the curved section of bumper there are a bunch of holes. we are going to utilize 2 of them (2nd farthest out I believe, but the tabs will align perfectly if you hold the FMHE centered)
I used 2 small carriage bolts, but you can use whatever tickles your fancy. They worked perfectly for me, but no reason a standard bolt/washer wont.
(there are large holes stamped out of the bumper bracing that give you juuuustttt enough room to get a 1/4 drive flex ratchet in there, but I got really upset so i cut between the outer most lower and the one next to it as seen in the above picture to get a little more swing on each nut)
Above shot
(the large center mounting will either need to be bent out of the way, or you can do as I did and drill a hole in the center hood latch support, and zip tie that thing like a true car modder)
Install your fittings into the FMHE. I personally used teflon tape to ensure a perfect seal
I relocated the horn to mount my pump. I had to extend my foglight harness to do this.
Horns stuffed into the fender. They fit snug, sound the exact same and are the same loudness.
I used a standard 4" by 4" 90* bracket to mount my IC pump along with 6 zipties. (mightycarmods style)
To get a little more clearance for the hoses I cut a small section out of the headlight bracket and put some trim around the cut edges to protect the IC hoses.
Sorry for the lack of pics from this point on, but the temp got down to below freezing in the garage and I was pretty upset, so I just wanted it done. If you have any questions about routing, cutting, or anything, PM me.
Hoses installed.
Routing goes as follows:
Bottom of FMHE to Pump inlet
Pump outlet to IC Core (doesnt matter which fitting)
IC Core to top FMHE fitting
*Thought behind this setup is that the bottom of the FMHE will always have fluid so the pump can't suck in air and burn itself up, and that the pump will be getting the COOLED fluid, as opposed to the hot fluid straight from the core, which should prolong the pump's life*
How I decided to mount my fill tube. It has since been replaced with a clear high temp hose so I can view coolant levels.
Just drill 2 small holes and use 1 ziptie to hold it secure, but not too tight or the cap wont fit
All plumped up
Now to the IC core side
You can see the 5/8 heater hose (black hose) used to connect the core to the 90* 5/8's fittings.
You can see about how long they are cut to
Wire the pump up. Find a good ground source and ground it out, and a switched 12v source for the pump/relay.
I ran an 'add a fuse' off my fuel pump fuse in the underhood panel.
Pin 85 is your ground
Pin 86 is from the 'add a fuse' (switch source)
Pin 87 is from your battery (power wire)
Pin 30 is to the Relay (positive)
Then you ground the other pump wire
Ensure it turns on and prime the system. (start adding coolant) Let it run for a few minutes and keep adding coolant/distilled water (or premix) until it starts to come up the fill tube, let it run until it quits taking more fluid.
Reinstall the front bumper cover, and all the center latch area parts (tray, air diverters and stuff)
Don't forget the 10mm bolts in the fender. Yes they are a PITA.
You'll end up with something like this
If you have any questions feel free to PM me or post in this thread. Remember to use the search feature if you need an immediate response.
