Front fascia yank and clean... [Archive] - ZR-1 Net Registry Forums

Schrade

09-30-2013, 07:11 PM

ed.:
Any harnesses ground up front here, that need re-seating?
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Will we ever get a perfect burn in the twister??? Always SOMEthin' will come up besides

RodB's comment kinda' bothered me, about melted lens assemblies, and my bulbs ARE lit up....

Ok. Just so you think your posts aren't read. I suspect the arm in question belongs to Gordon K as he did most of the C4 manuals. Maybe he will autograph the page for you! As far as my 90 the bumper cover needs to be removed to get to the lens. It the bulb is removable as the picture shows from under the hood. Follow the wires and you have to turn the grommet 1/4 turn and pull it out. It is on a stem about 5" long and there isn't much room to pull it out. The bulb is on the end if the stem. Reassembly is reversed but be sure the bulb seats and twists that 1/4 turn. If not the bulb will just lay in the plastic tube and melt the mounting tabs and will require replacement of the lens assembly. Don't ask how I know but believe me, it will happen!

...so DataMaster aside, and front fascia off. Does it ever end?

Out with the spray lube, and silicone spray.

Fender well screws...
http://www.zr1.net/forum/attachment.php?attachmentid=2758&stc=1&d=1380578873

Lower dam bolts...
http://www.zr1.net/forum/attachment.php?attachmentid=2759&stc=1&d=1380578973

http://www.zr1.net/forum/attachment.php?attachmentid=2760&stc=1&d=1380579033

Schrade

09-30-2013, 07:17 PM

Upper fascia trim bolts - break 'em loose, then work 'em back and forth while spray lube-ing...

http://www.zr1.net/forum/attachment.php?attachmentid=2761&stc=1&d=1380579203

Last 2, center, to hold it and and see what's left to disconnect, and impede removal...
http://www.zr1.net/forum/attachment.php?attachmentid=2762&stc=1&d=1380579371

http://www.zr1.net/forum/attachment.php?attachmentid=2768&stc=1&d=1380580102

Bulbs from below.
http://www.zr1.net/forum/attachment.php?attachmentid=2763&stc=1&d=1380579441

Schrade

09-30-2013, 07:22 PM

Bulbs D side.
http://www.zr1.net/forum/attachment.php?attachmentid=2764&stc=1&d=1380579518

Separation.
http://www.zr1.net/forum/attachment.php?attachmentid=2765&stc=1&d=1380579609

Cleaner than one would expect for 23 years' debris collection (only 32k tho')
http://www.zr1.net/forum/attachment.php?attachmentid=2766&stc=1&d=1380579704

Schrade

09-30-2013, 07:26 PM

Lens assemblies.

Does the lens separate easily from the lens body? Mine are intact, but like most, I imagine, they have cracks at the edges...
http://www.zr1.net/forum/attachment.php?attachmentid=2767&stc=1&d=1380579876

Z51JEFF

09-30-2013, 07:54 PM

While I dont think these come apart the fronts do.I polished mine awhile ago,took forever but well worth it.The fronts are coated with a clear so you will need to sand through that first.The lenses have a part number but these are impossible to find.I have a nice driver side marker for $75 if your interested.By the way I didnt pull the lenses from the housings on the front driving lights,too much of a chance breaking them.

mike100

09-30-2013, 10:34 PM

Waiting to see how your reinstall goes. I have found it difficult to line it up flush with the hood line. I did this to perform a repair on another C4.

ghlkal

09-30-2013, 11:27 PM

What a job Schrade. How long did it take to get the fascia off?

Are you doing this to remove the side marker lights only, or will you pull the front driving lights too?

Z51JEFF

10-01-2013, 03:13 AM

What a job Schrade. How long did it take to get the fascia off?

Are you doing this to remove the side marker lights only, or will you pull the front driving lights too?

This job is pretty straight forward,the hardest part of the install is getting the 9 bolts started along the top edge of the bumper.Getting the bumper lined up along the hood edge isnt a problem,there is no adjustment as least this is what I found on my 91.I had to pull the bumper to replace a driving light.

We Gone

10-01-2013, 11:04 AM

Great job and will be well worth your efforts when done.

Actually there are quite a few adjustments that can be made all along the attachment areas for height and level and the shims behind the crash bar for hood gap and angle. With that said if it did not need any and you did not change them no need to. One thing I see is that the underside bumper cover center is missing/modified? No accesses covers to fog lamps.

Schrade

10-01-2013, 12:45 PM

This job is pretty straight forward,the hardest part of the install is getting the 9 bolts started along the top edge of the bumper.Getting the bumper lined up along the hood edge isnt a problem,there is no adjustment as least this is what I found on my 91.I had to pull the bumper to replace a driving light.

Yep - pretty accurate. No real 'Cautions' to consider here when you do this...

Took a few hours, only because I didn't know what to expect, with '90 frame under '91'-95 body.

And there's already been evidence of '90 / '91-5 mis-match , with the air dam mounting. The triangular cut in the air dam sides was obviously to accommodate extra curve.

(do body parts have 'year'? )

Only did it to re-insert the fog lamp bulbs there ghlkal - and sure didn't want to have melted lens bodies.

I can't take stuff apart without thorough cleaning, including screw threads and bolt holes. Cleanup is in order here too...

And there's paint dings - no better time to address them. One nasty mark circled...

http://www.zr1.net/forum/attachment.php?attachmentid=2771&stc=1&d=1380641363

Then start knocking off road jam from the insides - scribe markings for the mounting plates...

http://www.zr1.net/forum/attachment.php?attachmentid=2772&stc=1&d=1380641570

The same OUTboard bolt (yellow arrow) was missing from both sides. Any ideas?

http://www.zr1.net/forum/attachment.php?attachmentid=2773&stc=1&d=1380642144

Schrade

10-01-2013, 01:03 PM

We Gone

10-01-2013, 02:04 PM

............

10-01-2013, 02:58 PM

Nice project !

Z51JEFF

10-01-2013, 03:12 PM

Is your bumper cover fiberglass? on the original 91 the assembly mounts to the impact bar. from the pics you posted it looks like you will have to pull the outside first like its hinged in.

This is correct.I stand corrected in regards to the no adjustment statement.After seeing the picture of the upper bracket I remember now I bolted it back together using the witness marks left by the bolt washers.http://i10.photobucket.com/albums/a136/FLYTYM/DSCN1034_zpsd754e42e.jpg

Z51JEFF

10-01-2013, 03:15 PM

HELP?

How DO the '91 - '95 front / fog lens body assemblies separate from the fascia? JEFF???

2 screws (removed) still do NOT ALLOW removal of the assembly, from the assembly mounting blocks.

http://www.zr1.net/forum/attachment.php?attachmentid=2774&stc=1&d=1380643287

http://www.zr1.net/forum/attachment.php?attachmentid=2775&stc=1&d=1380643287

The bolt at the very bottom center is the adjuster for the light when used with the OEM setup,you have something going on there that might be a hassle trying to work with.This looks like it could turn into a snowball job.

Z51JEFF

10-01-2013, 03:21 PM

When I reliezed Id have to take the bumper off the car it was something I put off until I couldn't get around it anymore but when I got the bumper off the car I couldn't believe how easy it was.

Schrade

10-01-2013, 03:30 PM

The bolt at the very bottom center is the adjuster for the light when used with the OEM setup,you have something going on there that might be a hassle trying to work with.This looks like it could turn into a snowball job.

Already has Sir... (not YOUR first day either, huh)

Still not following here the lens body removal from the fascia...

Little housecleaning behind the crash bar...

http://www.zr1.net/forum/attachment.php?attachmentid=2776&stc=1&d=1380652022

Schrade

10-01-2013, 05:24 PM

Vac pump, horn, overflow cleaned and zipped up

(and I still need help on lens assembly removal, from the fascia - anyone here???)

http://www.zr1.net/forum/attachment.php?attachmentid=2777&stc=1&d=1380658851

and what it this [bracket], at the side lens opening? (it's missing on the drivers side)

(brush soap into the matting, before scrubbing)

http://www.zr1.net/forum/attachment.php?attachmentid=2778&stc=1&d=1380658962

We Gone

10-01-2013, 06:24 PM

.........

Franke

10-01-2013, 06:50 PM

Schrade, gotta admit you sure do get into it all the way. I'm wondering if there are led lights that could go in there to do 2 things. 1. less heat given off and 2. longevity. Does anyone make these led lamp replacements so that you don't have to do it again if a lamp goes out.

Z51JEFF

10-02-2013, 12:40 AM

Schrade

10-02-2013, 10:25 AM

O.K. lets look at this another way.The bumper isnt stock,some hack cobbled that together to get it on the car.If you want everything to fit correctly you will need to get all OEM hardware.I have no idea how the driving lights are attached to the bumper,I assume you have removed the screws and it still wont come apart.The driving lights have brackets that attach to the impact bar and half of the driving light hardware is not on that car.

Got it. I see your snappic,

http://i10.photobucket.com/albums/a136/FLYTYM/DSCN1034_zpsd754e42e.jpg

and thought your lenses were just dry-fit in the crash bar. And the adjustment screws in mine - thinking on it now, no way to do an 'adjustment'...

Can't go OEM - that would be the WHOLE body.

Do my mounting blocks look like they're from the later body style?

The job (that I'm looking at) just looks too well done to be a HOME hack. THis was very well done.

No one else on the boards has '90 with 91 - 95 body? And have you had your front fascia off?

Seems 3 out of 4 '90's on eBay DID have this body upgrade, when I was looking for mine...........

Hello Dremel :neutral: Gonna' have to cut the mounting blocks to allow re-mounting in the same way, otherwise, I'll have a snowball job in orders of magnitude :neutral:

And I don't know how the fog lamps are gonna' find their way into the sockets at re-assembly :confused:

Schrade, gotta admit you sure do get into it all the way. I'm wondering if there are led lights that could go in there to do 2 things. 1. less heat given off and 2. longevity. Does anyone make these led lamp replacements so that you don't have to do it again if a lamp goes out.

Yup - can't do a job without going all the way. You learn more... Don't get to drive her as much, but you KNOW the car...

We Gone

10-02-2013, 10:45 AM

I've done the conversion on a 90 C4 but we changed everything front inner wells crash bar and related parts, lights all over stock to 91-95.

Schrade

10-02-2013, 01:17 PM

Post Dremel...

Those mounting blocks are at least 3/8" thick.

The lens housing and lens were obviously snapped together AFTER placement in FRONT of the mounting blocks. No way to separate them once installed. They came out ONLY as a unit...

An 'L'-shaped recess had to be cut into each mounting block. Then the assembly pulled rearward, and rotated out of place.

http://www.zr1.net/forum/attachment.php?attachmentid=2783&stc=1&d=1380730377

I don't know HOW they were aligned (or ever will be), without removal and guesswork...

Z51JEFF

10-02-2013, 01:42 PM

Got it. I see your snappic,

http://i10.photobucket.com/albums/a136/FLYTYM/DSCN1034_zpsd754e42e.jpg

and thought your lenses were just dry-fit in the crash bar. And the adjustment screws in mine - thinking on it now, no way to do an 'adjustment'...

Can't go OEM - that would be the WHOLE body.

Do my mounting blocks look like they're from the later body style?

The job (that I'm looking at) just looks too well done to be a HOME hack. THis was very well done.

No one else on the boards has '90 with 91 - 95 body? And have you had your front fascia off?

Seems 3 out of 4 '90's on eBay DID have this body upgrade, when I was looking for mine...........

Hello Dremel :neutral: Gonna' have to cut the mounting blocks to allow re-mounting in the same way, otherwise, I'll have a snowball job in orders of magnitude :neutral:

And I don't know how the fog lamps are gonna' find their way into the sockets at re-assembly :confused:

Yup - can't do a job without going all the way. You learn more... Don't get to drive her as much, but you KNOW the car...
This is my car.Might check and see what you can get the inpact bar and related parts for used,you already have the bumper most likely it will fit with the correct OEM parts.The main bracket for the lamps is not used in your setup.I would venture to say that the parts to put this to an OEM setup wouldnt cost that much,from what I see an impact bar and honeycomb pad from a 91-96 and complete fog lamps from a 91-96 and the small parts associated is all you need...................for the most part.Theres a guy by the name of Kelly that parts out Corvette and the last time I talked to him he had a 95 that he was parting out,I can send him an email to see what he has if you like.Brett has dealt with this guy,super nice but will talk your ear off.

Schrade

10-02-2013, 05:42 PM

WOW. UPS guy just stopped by (on vacation), and wants my car in a car show for the 5th.

Pffttt - right - I'll get all the pieces on a trailer).......

Then after :45 minutes car chat, he wants me to be a JUDGE. THE ONLY judge.

I said 3 would be better. When I start critiquing locals' pimp-mobiles, I don't want the windows in my house taking rock-hits :eek: :mad:

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Anyway - cleaning progress (the lone mis-placed fog lamp might actually find it's way home - one day here...)

Crash bar and fascia alignment skids cleaned - marked for re-install

http://www.zr1.net/forum/attachment.php?attachmentid=2784&stc=1&d=1380746091

BEFORE getting all the kids out of the house (west of the framerails, behind crash bar, forward of wheelwell, just as over on the 'east' side (http://www.zr1.net/forum/attachment.php?attachmentid=2777&stc=1&d=1380658851) )

http://www.zr1.net/forum/attachment.php?attachmentid=2785&stc=1&d=1380746181

Work some silicone / Armor All into the rubber hoses, to facilitate removal, with a small screwdriver under the edge - they'll really come off easy

http://www.zr1.net/forum/attachment.php?attachmentid=2786&stc=1&d=1380746485

Schrade

10-02-2013, 05:49 PM

YIKES - what a myriad of wire!!!

http://www.zr1.net/forum/attachment.php?attachmentid=2787&stc=1&d=1380746659

Don't forget to clean behind your ears

http://www.zr1.net/forum/attachment.php?attachmentid=2788&stc=1&d=1380746723

Kids are scrubbed, IN ORDER OF REMOVAL

http://www.zr1.net/forum/attachment.php?attachmentid=2789&stc=1&d=1380746914

Schrade

10-02-2013, 06:13 PM

EVERY wire / hose, wiped with paintbrush and sponge, drying - connector sockets ready for canned air spray, ready for re-population and silicone / alcohol mix (facilitates evaporation) - wipedown

and the pump intake... foam lining (hard to see in the snappic) inside, at the pump connection - this is some sort of baffling for the incoming air???

http://www.zr1.net/forum/attachment.php?attachmentid=2790&stc=1&d=1380748309

We Gone

10-02-2013, 06:22 PM

Schrade

10-02-2013, 07:23 PM

Its to filter the air going thru the air system. It is also supposed to be a slip over sock on the knife end where the slots are. The other inner fenders are a piece of cake to pull while your at it. As much work as you are putting into this why not find the correct hardware and re-install it when you put things back?

http://imageshack.us/a/img694/2049/ymka.jpg
http://imageshack.us/a/img708/9172/5br5.jpg
http://imageshack.us/a/img853/2083/qh9l.jpg

Could do that WeGone; but what year is my crash bar? Is '90 CB the same as '91 - '95? Is mine even '90? Or later???

Hacking the lens mounts isn't creating any problem - except possibly for the job objective - fog lens socket access... The forward lens assemblies will still mount sturdily.

Anyway - time for a sipper - gin + OJ, and refer back to snappics for EVAP cannister hose routing. Damn mosquitoes can't find the blood bank, so they gonna' get a buzz, if they can stand my OFF skin marinade ;)

Fenderwell components re-assembly so far here

http://www.zr1.net/forum/attachment.php?attachmentid=2791&stc=1&d=1380752564

We Gone

10-02-2013, 07:48 PM

The side supports I posted a pic of are missing on yours, they also are for the hood bumper as seen in the pic, someone has mounted your hood bumper to the fender housing. Any 91-96 side support will work with your 91- up bumper cover.

The 90 had the same set up also tho I'm not sure it would work with a 91-up cover.

Franke

10-02-2013, 07:51 PM

So far so good Schrade. Maybe you'll make that car show after all.:)

Schrade

10-02-2013, 08:01 PM

These cows have come home.

http://www.zr1.net/forum/attachment.php?attachmentid=2792&stc=1&d=1380754812

Finish cleaning the lens assemblies, remount, and fascia back up front... YikES!!!

Schrade

10-03-2013, 03:14 AM

Its to filter the air going thru the air system. It is also supposed to be a slip over sock on the knife end where the slots are. The other inner fenders are a piece of cake to pull while your at it. As much work as you are putting into this why not find the correct hardware and re-install it when you put things back?

http://imageshack.us/a/img694/2049/ymka.jpg
http://imageshack.us/a/img708/9172/5br5.jpg
http://imageshack.us/a/img853/2083/qh9l.jpg

I see the part now - hood bumpstop, FORWARD of the fender liner...

As far as getting additional hardware, like I said before, I don't know what MOUNTING parts that I have are still OEM '90, and what mounting hardware is for '91 - '95.

I'm sure the hood bumpstop bracket will bolt in - it's INDEPENDENT of any other mount points, besides the inner fender, and wheelwell liner (or is it???).

But without a '90 AND '91 in the driveway, I can't tell whether additional parts that I might buy will fit. And fabbing is gettin' old fast.............

We Gone

10-03-2013, 11:28 AM

I looked up the part numbers for the side reinforcements that hold the hood bumper, They are the same for the 90-96 part 19 in pic.
#10149203
#10149204
http://imageshack.us/a/img19/4152/tv55.jpg

Schrade

10-03-2013, 12:37 PM

I looked up the part numbers for the side reinforcements that hold the hood bumper, They are the same for the 90-96 part 19 in pic.
#10149203
#10149204
http://imageshack.us/a/img19/4152/tv55.jpg

Excellent - same parts config for '90 - '96.

So I can re-mount the fascia, and bolt in these parts when they come.

I'm not gonna' tangle with the forward lens mounting - they're securely affixed - albeit a hack, to the front fascia.

When the tech info shows, I should be able to find info on a missing bolt for the lower bracket; EVAP cannister...

http://www.zr1.net/forum/attachment.php?attachmentid=2793&stc=1&d=1380814623

We Gone

10-03-2013, 12:52 PM

Schrade

10-03-2013, 01:18 PM

Yes the 90 had some additional reinforcements to hold the side markers, I'll post up a pic of it. In fact the part #19 (#27 on 90 pic) may be the same for all earlier C4's. A lot of these parts will only be available used as they are discontinued.
1990 View
http://imageshack.us/a/img7/6355/hkeh.jpg

Ok here... I'm studying this one here Steve... I see what's NOT on mine - I'm trying to see what I DO need, that will mount for the later fascia here...

Need to printout side-by-side and have both to compare...

No wonder the fascia came off so easy. Nothing holding it on (and to think I pushed it to 104 mph last week once) :nono:

PO had a great job done for the forward lens body mounting blocks, but left lots of mounting parts in the driveway :rolleyes: And the air dam... pretty horrid there...

We Gone

10-03-2013, 01:40 PM

Schrade

10-03-2013, 02:13 PM

I think what you are missing are some of the small support parts that go with the original urethane bumper 90 or 91-up, and most of the radiator air ducting in the center that may not go back as the center of your fiberglass bumper is not the same. This is the only pic I have that shows part of what is in the center.

http://imageshack.us/a/img211/1544/x0op.jpg

Jeez - clean as a whistle. Neat. Wanna' trade?

Repair time - broken mounting tab on the P side lens body.

http://www.zr1.net/forum/attachment.php?attachmentid=2794&stc=1&d=1380820081

Shortest screw I have - it shouldn't protrude into the reflector body too much, after the brace and washer are in place...

Pilot hole:

http://www.zr1.net/forum/attachment.php?attachmentid=2795&stc=1&d=1380820130

Check clearance of bolt head - might have to Dremel it down, but looks ok here...

http://www.zr1.net/forum/attachment.php?attachmentid=2796&stc=1&d=1380820330

We Gone

10-03-2013, 02:28 PM

Add some JB Weld to that tab stuff works great.

http://www.jbweld.com/product/j-b-plasticweld/

Schrade

10-03-2013, 02:29 PM

In place

http://www.zr1.net/forum/attachment.php?attachmentid=2797&stc=1&d=1380820520

Even lucked out, and got the curvature right, from tab to tab...

http://www.zr1.net/forum/attachment.php?attachmentid=2798&stc=1&d=1380820552

and dry fit, for hole alignment

still a slight gap, and NOT because of the bolt head :confused: may have to put a washer shim between the corner brace and the tab

http://www.zr1.net/forum/attachment.php?attachmentid=2799&stc=1&d=1380821262

Schrade

10-03-2013, 02:38 PM

Does JB have any 'give'?

Should I dis-assemble, and put JB under the brace, and at the tab break?

Will it seal the hole pretty well, that I drilled into the reflector body?

We Gone

10-03-2013, 02:44 PM

Yes to all, than replace you screws for insurance if you want It works great used on plastic tabs many times. Also fixed a 350 block with it when I was young that someone did not use anti-freeze and had cracked.

Schrade

10-03-2013, 03:00 PM

Got it - done. You been a big help! :thumbsup: and Jeff too

5ABI VT

10-03-2013, 10:34 PM

Little off topic but since you were in that area.. do the foglight lenses have any adjustability?

Schrade

10-03-2013, 11:25 PM

Little off topic but since you were in that area.. do the foglight lenses have any adjustability?

Yes, but not independent of the driving light.

Circled screw, with question mark:

http://www.zr1.net/forum/attachment.php?attachmentid=2775&stc=1&d=1380643287

Schrade

10-04-2013, 04:28 PM

Wow.

2 hours to remove, 5 to re-install (fascia alone).

Got the EVAP cannister bracket bolt at the hardware store - measured 1/4" too long, no conflict. edit HAHAHA WRONG

http://www.zr1.net/forum/attachment.php?attachmentid=2800&stc=1&d=1380912333

Then secured for forward lens bodies - cleaned, lens faces polished, to the fascia. Swung carefully over the crash bar mount skids, bottom free, to swing outward, and get the lenses filled with bulbed sockets.

From underneath, the fog lamps were no problem. But the driving lights' harnesses were just short enough, that by the time I swung the fascia forward, not enough harness to reach.

Fascia off again.

I thought maybe I re-routed the harnesses in-correctly after cleanup. NoPE!!! With the fascia back on again, NO forward swing while hooked up top, I COULD actually fit my hand far in enough to feel the bulb in the lens, but NO-GO still - couldn't find the socket 'keys' to rotate.

Then I saw why. Notice that the wire re-enforced connectors are backed up against the crash bar!!! (kinda' hard to see here, and this is afterwards)

http://www.zr1.net/forum/attachment.php?attachmentid=2803&stc=1&d=1380913480

When in place, no problem. But after you unlock them, you can't pull rearward. Like the ratchet sometimes - as soon as you unscrew the bolt, the ratchet is backed up into something. NO wonder they wouldn't center, to rotate and lock.

Fascia off again. :confused:

I added in 8" extension to each driving light, so I could lock in the sockets, while holding the fascia forward.

3 leads / light, 2 sides = 12 splice connectors, 24 wire insulation strippings, 3 feet of red wire plastic loom, 12" electrical tape, 2 turtledoves and a partridge in a pear tree.

Fascia up again. ALL ZIPPED UP.

The last crash bar skid bolt was in before removal at about 45 degrees - actually OVER the tapered edge of the skid, not in the hole. The very last hole, I couldn't even find with a bagtie. I'm startin' to shake. And sweat. http://images-cdn.perfectworld.com/en/rh/content/ohnoes.gif Where's the HOLE?

Fascia off again? (I can't wait for plenum work)

Pulled the fascia rearward, away from the mount skid, and found the skid hole. Then just grabbed the Dremel, and 'moved' the hole in the fascia lip, to match up. Nice fiberglass powder all over my housecleaning. :mad:

But the bolt is square.

http://www.zr1.net/forum/attachment.php?attachmentid=2806&stc=1&d=1380914652

Ready for a spin (and new dirt).

Next - DataMaster? Or housecleaning BETWEEN the framerails, in FRONT of the block???

Franke

10-04-2013, 07:20 PM

Schrade, so all of this extra wiring work etc was because of the lights being mounted to the fascia because of a different year bumper correct?

Schrade

10-04-2013, 10:07 PM

Schrade, so all of this extra wiring work etc was because of the lights being mounted to the fascia ... What's up Franke... Yeah - the wiring extension (only for the Parking lamps) turned out necessary, since the lights were affixed to the fascia...
... because of a different year bumper correct ? ... because of a different year bumper, with some different year bumper MOUNTING PARTS, and some SAME YEAR mounting parts...

Confused? Me too http://forums.totalwar.org/vb/images/smilies/gc/gc-dizzy2.gif

But I only recently noticed that Parking light very dim. I thought it was a bad ground, or corrosion in the bulb socket. No sense log scanning with bad electricity flow. Then I found the bulb lit up, and out of the light reflector.

And there was no way to re-insert the bulb into the lens body with the fascia ON. Whoever assembled it in the first place SURELY put them in the lens bodies with the fascia off, AND REALLY MUST HAVE PULLED THE WIRES HARD to make it. I didn't care to pull them like that, and have chafed wire cause another problem.

But NOW, it AIN'T over. NOT BY A LONGSHOT :cry:

I forgot to put the Driver's side marker lens back. Here's what I noticed (besides something missing DUH), looks like real estate on Park Avenue / Manhattan - not much available real estate:

http://www.zr1.net/forum/attachment.php?attachmentid=2809&stc=1&d=1380934006

Oops - 2 more minutes; big deal.

(Yep - BIG deal - notice carefully the encircled cannister mark)

http://www.zr1.net/forum/attachment.php?attachmentid=2810&stc=1&d=1380935098

I had taken out the lens for fascia clearance (pre-cautionary - it looked close):

and notice BEFORE REMOVAL, the angle of the EVAP cannister bracket, against the backside of the crash bar, and HEIGHT of the cannister, IN THE BRACKET - that's why I didn't remember the Torx bolt being blocked - it WASN'T...
http://www.zr1.net/forum/attachment.php?attachmentid=2762&stc=1&d=1380579371

Franke

10-04-2013, 10:18 PM

Oh yeah. Looks like it (Canister assembly) was lowered or modified to allow the light fixture to fit in. correct?

Schrade

10-04-2013, 10:27 PM

When I was bolting down the EVAP cannister Torx bolt to the crash bar, yesterday, I couldn't get at it - blocked by the cannister.

:confused: I don't remember the block @ dis-assembly...

Then I looked at my reference snappics:
BEFORE getting all the kids out of the house (west of the framerails, behind crash bar, forward of wheelwell, just as over on the 'east' side (http://www.zr1.net/forum/attachment.php?attachmentid=2777&stc=1&d=1380658851) )
http://www.zr1.net/forum/attachment.php?attachmentid=2785&stc=1&d=1380746181

At re-assembly, I had raised UP the EVAP cannister, onto the lower bracket lip, and clamped it (and the Torx bolt was 'blocked').

And that's when I saw the missing bolt too...
http://www.zr1.net/forum/attachment.php?attachmentid=2811&stc=1&d=1380936268

Schrade

10-04-2013, 10:34 PM

Now I know why that bolt was missing.

Originally, the BRACKET was rotated counter-clockwise, WITH the cannister loose in the bracket clamp, and DOWN, catty-wampus, OUT OF THE WAY OF THE SIDE MARKER LENS.

http://www.zr1.net/forum/attachment.php?attachmentid=2786&stc=1&d=1380746485

The missing EVAP bracket LOWER bolt was missing on purpose.

Schrade

10-04-2013, 10:42 PM

So how to get the side marker lens in place?

By getting the EVAP bracket lower bolt out.

Simple. Remove the fascia; unscrew the bolt.

http://www.zr1.net/forum/attachment.php?attachmentid=2800&stc=1&d=1380912333

http://forums.randi.org/images/smilies/cry1.gif

http://forums.randi.org/images/smilies/cry1.gif

http://forums.randi.org/images/smilies/cry1.gif

Schrade

10-04-2013, 11:35 PM

Oh yeah. Looks like it (Canister assembly) was lowered or modified to allow the light fixture to fit in. correct?

Yup - dead on ! Pretty sharp :thumbsup: to be able to follow these worms, as they get out of THIS can-o-worms... cause I sure couldn't :o

Thanks again there to Steve too - his diagrams showed SOMEthing was wrong - I just didn't see it at the time...

Plenum pull has GOTTA' be easier than this...

We Gone

10-05-2013, 09:07 AM

Great job sorting out the mess you found while doing some cleanup. Your luck looks like mine jump into what appears to be a straight forward job than try and dig your way back out.

Schrade

10-07-2013, 09:38 PM

This looks like it could turn into a snowball job.

You need to start up Jeff's Psychic Hotline (for 'entertainment purposes only', of course), cause you called this one...

...................................
"It ain't over til the fat lady sings..."

Not only is the fat lady NOT singing; neither is my driver's side HORN! It already sounds wimpy with STEREO horns, but now it's Mono. Good thing tho' that it's driver's side horn that's out, cause I know Sign Language, if someone pulls out in front of me:

http://cur.cursors-4u.net/smilies/images1/smi35.gif

(maybe I can get George to ride shotgun)
http://www.youtube.com/watch?feature=player_embedded&v=D0IJkD0znCQ

Anyway here, horn won't fit after rotating the EVAP cannister, to stop binding on the side marker lens body. Talk about the 'horns of a dilemma'!!!

http://www.zr1.net/forum/attachment.php?attachmentid=2818&stc=1&d=1381189800

So it's time for some more fab / hack work. About 3/8" out of the horn mounting arm, then re-weld, will get me all the clearance needed here.

http://www.zr1.net/forum/attachment.php?attachmentid=2819&stc=1&d=1381190096

I thought about mounting above the headlight controller module, but flipping the headlights and hearing a gouging sound isn't too appealing.

Even had to re-route one of the EVAP can purge solenoid tubes, around in FRONT of the cannister, back to the vac source, but still no go.

http://www.zr1.net/forum/attachment.php?attachmentid=2820&stc=1&d=1381192552

to be continued...