Killerglass Install DIY with pictures.

[Tonkatoy02]

Sorry for the huge delay on the pics and Instructions, but here it goes.....

1) First i started by locating the upper hose, where the cap is, and the drain on the radiator. The drain is the small black butterfly plastic piece on the driver side of the engine bay to the left of the cooling fan. You are going to have to bend over the grille and look straight down to see it. Once you locate it then you are going to look under the front bumper on the drivers side of the car. You will find a square opening in the splash shield, that is where the antifreeze is going to drain out when you open the drain plug. Start by opening and removing the cap on the radiator by turning while pressing down counter-clockwise. Next carefully turning the drain plug counter-clockwise, remember its only plastic, watch until antifreeze begins to come out of the drain hole into an appropriate container for reuse, or disposal. I chose to reuse my coolant because i just flushed the system a few months ago. If the coolant is more than a year old i would dispose it and have some new on hand for this install. Once you have drained out about a quart or two of coolant, close the drain plug gently till its snug and no coolant is coming out of the drain and then we are ready to move on. A good container that i find handy is a gallon container with a hole cut into the side. You can also use your oil catch pan if you have one for oil changes.

[Tonkatoy02]

2) Now that we have drained the coolant down so we can remove the upper radiator hose, we are going to locate the two clamps that need to be loosened and removed to allow this. The first clamp closest to the radiator is right in front of the cap which you saw when you removed the coolant. Mine had already been replaced when i performed the flush, so i just loosened it and slid it off the nipple of the radiator, if you still have the spring clamp installed then use a pair of channel locks or comparable pliers to relieve the tension and slide the clamp toward the motor away from the radiator. The second clamp is located on the right side of the engine block underneath all the hoses and wiring to the left of the stock air box if you still have it installed. My box has short ram installed so i didnt have to remove this part. This clamp can be a huge PITA if you do not have the proper tools. It looks easy here but it gives a good fight before is comes out. In the third pic you can see the part number on the clamp pliers i used. Its cable actuated so your hands don't do any of the hard part of squeezing the clamp. Once you have relieved and held the tension of the clamp, slide it over the hose away from the motor and relieve the tension. Now you should be able to twist the hose loose from the radiator and the fitting on the block. Be careful with the radiator because it is only plastic and can be brittle and crack if your box has a lot of miles on it. At this point the hose should be free and you can remove it completely out of the car.

[Tonkatoy02]

4 more photos of the process of step two. You can see the nipple on the radiator above the fan, and the steel nipple on the block where you removed that MOFO clamp.

[Tonkatoy02]

3) Step three..... With the hose removed from the car and your Killer glass at hand, take both and hold them next to each other on a bench and make your marks where you want the glass to be in the car. I made my marks based on the ability for the hose to flex and move with the movement of the engine when you accelerate. Take note that you need to mark the hose where the killerglass is going to be viewable not the full length of the glass, because then the hose would be too short to put back in the car once you slide the hose onto the glass for clamping.

4) Step four..... Once you are 100 percent sure that you like where the glass is in position on the hose and your marks are made, then take an appropriate hose cutter, like the one i used, or use a sharp knife or razor blade and make the two cuts completely through the hose, and lay everything down on a table the same way it was before the cuts to be sure not to confuse the position of the ends for installation to the glass. Be very careful not to slip and cut yourself. Take your time there is no rush, measure twice and cut once or you will be on a trip to the parts store for a new hose, or on your way for some stitches.

[Tonkatoy02]

5) Step five...... Now take the middle section of the hose that is going to be replaced by the Killerglass and dispose of it. Lay your killerglass in between the two end pieces and get ready to install the heat shrink tubing pieces that came with the kit. Start by sliding the hoses onto the killerglass and bring the complete assembly over to the car and hold it up for a test fit. Make any adjustments now by turning the hose on the glass until the proper angle is achieved and bring the assemble back to the bench. Now slide the heat shrink tubing over the hoses right up to the edge of the glass. To heat these to shrink them i used an industrial heat gun, but you can use a hairdryer on the hottest setting to achieve the shrinkage as well. Evenly heat the shrink tubing while turning the assembly not to "burn" any section of the tube. After about 2 minutes of heating each side they should be completely shrunk. Time will vary based on the tool being used to heat. Now your hose is finished with the modification part and is ready for installation back into the car. :)

[Tonkatoy02]

6) Step six..... Installation back into the car. The only two pieces that did not come with the kit is the clamps that i would use to install the hose back into the car. I personally do not like or trust spring clamps. I use screw type clamps and they are relatively cheap and available at any hardware store or through me if u need them for a couple of bucks each. Once you have obtained these, Position the clamps loosely on each end of the hose and reinstall the hose in the same position that it was in the car before you removed it making sure that the hose slides all the way flush to the radiator and the block so it does not leak. Once you have done that, hold the clamps in place, radiator side- so that the 8mm screw head faces directly up at you, and the block side- so that the screw is on a 45 degree angle facing towards the top of the radiator to ease the tightening process. Using a 1/4" ratchet and long 30" extension to reach, tighten both clamps hand tight, until you see the hose start to get "squished" by the clamp. Its hard to describe, but dont over or under tighten the hose clamp because you can either damage the hose or you may end up with a leak if its too lose. Usually its about 18ft lbs of torque that does the trick.

[Tonkatoy02]

7) Step Seven..... Now that the hose is installed back in the car, you can now fill the coolant back up, which you will now see going back into the car and filling the Killerglass which is awesome to watch knowing you just did the Install yourself. I used a small funnel and kept adding coolant until no more would go into the radiator. It should be about the same as you removed, possible a bit more if some spilled out of the block when you took the hose out. Once i finished putting the coolant in, now you are going to reinstall the cap on the radiator by pressing down and turning clockwise till it stops and start the car. Put the heat on in the car and let it idle for about 10-15 minutes until all of the air bubbles are gone from the Killerglass. You may need to take the box for a ride to get all the bubbles out because coolant flow is slow in these little motors when they are idling, they have a small water pump. We'll thats pretty much it. If you have any questions hit me up. I also have dye for the coolant to make it red, or pink that im willing to sell in the proper dose for the specific vehicle that you have. This is my first published DIY, so if you like it please leave me some feedback. Thanks for Reading and Have fun installing your new KIllerGlass. Peace -Mike-