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I installed my ZeroStart today. Instructions are included for 2001 Jetta 2.0L, with AVH (drive by wire) engine. Use at your own risk, etc. etc.
Parts used from ZeroStart kit:
3/4"-5/8" Y connection
6x 5/8" hose clamps
bolt/nut/lockwasher
Extra parts that did not come with kit:
1/4" bolt, 3.5" long, and nylock nut
5/8" T connector (Princess Auto)
6 feet 5/8" heater line (Canadian Tire)
2x 3/4" hose clamps (for 3/4" hose) (Rona)
Parts I made:
2 clips for attaching to battery tray
Spacer (for clips)
Angle bracket
Steps:
1. Made forward bracket out of some angle. Installed on inboard bolt for attaching fan control module under battery. Installed ZeroStart on bracket with nut/bolt/lock washer that came with kit.
2. Made aft attachment. Spacer from ZeroStart up to edge of battery tray, couple of clips that grip onto the edge of the tray, bolt through every thing. Bolt head on side of ZeroStart, nylock nut on top of clips.
3. Tighten bolts down. ZeroStart now held rigidly in place.
Looking down at ZeroStart, beside and below battery:
Looking out towards drivers side:
(Red outline is brackets, Blue is ZeroStart, Green is new hoses)
4. Disconnect lower oil cooler hose and drain coolant from block.
5. Install 2" of 5/8" heater hose on left "arm" of T connection. Install 6" of 5/8" heater hose on perpendicular leg of T connection. Tighten down hose clamps on T.
6. Slip 5/8" hose clamp on 2" heater hose on T. Install on oil cooler connection. Do not tighten clamp.
7. Cut rubber connecting oil cooler inlet/outlet hoses. Slide original oil cooler hose onto right arm of T. Use original spring clamp.
8. Rotate T to align 6" hose to prevent kinks when routed to ZeroStart. Slip 5/8" hose clamp on 6" heater hose. Install on lower (inlet) ZeroStart connection.
9. Tighten all hose clamps on T and 2" and 6" hoses.
Looking at oil cooler connection:
10. Cut 30" of heater hose. Slip 5/8" hose clamp on end. Install on upper (outlet) ZeroStart connection.
11. Realize I don't have enough hose clamps. Plug 30" line with 5/8" rod. Refill coolant, drive to Rona, get 5/8" hose clamps, get dinner because now the coolant has to cool before I can work on it again.
12. Now that car has cooled, disconnect larger hose going to heater core at the firewall. Remove hose from engine block outlet flange. Drain coolant.
13. Cut original heater hose at centre of straight section near middle of hose.
14. Discover that hose to heater core is not 5/8" as I thought, but actually 3/4". Hose clamps I have (5/8") don't fit. Getting late, don't want to reassemble and get correct hose clamps. Make due.
15. Slip 3/4" hose clamps onto cut ends of heater hose. Insert Y connection into original heater hose, using the straight through ends. Align text on hose for correct orientation.
16. Route 30" hose from ZeroStart along top radiator hose, towards heater core connection.
Looking towards firewall, under intake hose:
(Yellow is original hose that was cut)
17. Test fit hose with Y connection. Rotate Y until it points at 30" hose. Tighten hose clamps on Y.
18. Slip 5/8" hose clamp on 30" heater hose. Install Y connector with original hose onto 30" hose.
19. Pour coolant into upper hose, with 30" hose pointing down to prime the ZeroStart. Pour slowly and hold it up and it will run down the Y into the pump, not out the other end.
20. Install ends of original hoses back in original positions, top at firewall and bottom at engine block outlet flange.
Looking down at Y connection, under intake hose:
20. Tighten all hose clamps.
21. Route power wire from ZeroStart to the front right corner of the bumper, and into the centre lower vent. Tye wrap in place.
22. Refill coolant. Added about 1L-1.5L total after filling the pump/hoses and spillage etc. Start car to pump coolant through system. Check for leaks.
23. Turn car off, plug in ZeroStart. Let run until it heats up and starts pumping. Was able to see through the Y connection for flow. There were a lot of bubbles, so it will need to be bled for correct operation. Re-check with car running, no bubbles in system, so car fine to run until ZeroStart can be bled.
24. Bleed ZeroStart by removing heater core return line. Plug in ZeroStart and let coolant pump until no bubbles come through. WARNING: Coolant will be HOT!
So thats about it. Step 11 and 14 are obviously somewhat comical problems I had. Try not to repeat them yourself.
PM me if you would like to buy a kit with the brackets/clips I made for $20. The clips require trimming a small notch in the battery cover if you are using it.
Parts used from ZeroStart kit:
3/4"-5/8" Y connection
6x 5/8" hose clamps
bolt/nut/lockwasher
Extra parts that did not come with kit:
1/4" bolt, 3.5" long, and nylock nut
5/8" T connector (Princess Auto)
6 feet 5/8" heater line (Canadian Tire)
2x 3/4" hose clamps (for 3/4" hose) (Rona)
Parts I made:
2 clips for attaching to battery tray
Spacer (for clips)
Angle bracket
Steps:
1. Made forward bracket out of some angle. Installed on inboard bolt for attaching fan control module under battery. Installed ZeroStart on bracket with nut/bolt/lock washer that came with kit.
2. Made aft attachment. Spacer from ZeroStart up to edge of battery tray, couple of clips that grip onto the edge of the tray, bolt through every thing. Bolt head on side of ZeroStart, nylock nut on top of clips.
3. Tighten bolts down. ZeroStart now held rigidly in place.
Looking down at ZeroStart, beside and below battery:
Looking out towards drivers side:
(Red outline is brackets, Blue is ZeroStart, Green is new hoses)
4. Disconnect lower oil cooler hose and drain coolant from block.
5. Install 2" of 5/8" heater hose on left "arm" of T connection. Install 6" of 5/8" heater hose on perpendicular leg of T connection. Tighten down hose clamps on T.
6. Slip 5/8" hose clamp on 2" heater hose on T. Install on oil cooler connection. Do not tighten clamp.
7. Cut rubber connecting oil cooler inlet/outlet hoses. Slide original oil cooler hose onto right arm of T. Use original spring clamp.
8. Rotate T to align 6" hose to prevent kinks when routed to ZeroStart. Slip 5/8" hose clamp on 6" heater hose. Install on lower (inlet) ZeroStart connection.
9. Tighten all hose clamps on T and 2" and 6" hoses.
Looking at oil cooler connection:
10. Cut 30" of heater hose. Slip 5/8" hose clamp on end. Install on upper (outlet) ZeroStart connection.
11. Realize I don't have enough hose clamps. Plug 30" line with 5/8" rod. Refill coolant, drive to Rona, get 5/8" hose clamps, get dinner because now the coolant has to cool before I can work on it again.
12. Now that car has cooled, disconnect larger hose going to heater core at the firewall. Remove hose from engine block outlet flange. Drain coolant.
13. Cut original heater hose at centre of straight section near middle of hose.
14. Discover that hose to heater core is not 5/8" as I thought, but actually 3/4". Hose clamps I have (5/8") don't fit. Getting late, don't want to reassemble and get correct hose clamps. Make due.
15. Slip 3/4" hose clamps onto cut ends of heater hose. Insert Y connection into original heater hose, using the straight through ends. Align text on hose for correct orientation.
16. Route 30" hose from ZeroStart along top radiator hose, towards heater core connection.
Looking towards firewall, under intake hose:
(Yellow is original hose that was cut)
17. Test fit hose with Y connection. Rotate Y until it points at 30" hose. Tighten hose clamps on Y.
18. Slip 5/8" hose clamp on 30" heater hose. Install Y connector with original hose onto 30" hose.
19. Pour coolant into upper hose, with 30" hose pointing down to prime the ZeroStart. Pour slowly and hold it up and it will run down the Y into the pump, not out the other end.
20. Install ends of original hoses back in original positions, top at firewall and bottom at engine block outlet flange.
Looking down at Y connection, under intake hose:
20. Tighten all hose clamps.
21. Route power wire from ZeroStart to the front right corner of the bumper, and into the centre lower vent. Tye wrap in place.
22. Refill coolant. Added about 1L-1.5L total after filling the pump/hoses and spillage etc. Start car to pump coolant through system. Check for leaks.
23. Turn car off, plug in ZeroStart. Let run until it heats up and starts pumping. Was able to see through the Y connection for flow. There were a lot of bubbles, so it will need to be bled for correct operation. Re-check with car running, no bubbles in system, so car fine to run until ZeroStart can be bled.
24. Bleed ZeroStart by removing heater core return line. Plug in ZeroStart and let coolant pump until no bubbles come through. WARNING: Coolant will be HOT!
So thats about it. Step 11 and 14 are obviously somewhat comical problems I had. Try not to repeat them yourself.
PM me if you would like to buy a kit with the brackets/clips I made for $20. The clips require trimming a small notch in the battery cover if you are using it.
If it's smoken it ain't broken
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