Removal of Secondaries

[chriskinzel]

I had some free time today so I thought I would remove the secondaries. After a few problems (like broken bolts) I got everything off I needed to. I now have a few questions.

1. I think I have all of the vacuum lines off that need to be removed. There are 2 smaller lines that go by the power steering pump then disappear. Where do they end up going? Do I need them?

2. What is the larger diameter vacuum hose for? Do I need it?

3. How do I get the secondary posts out?

Thanks in advance for all the help you guys offer. If it wasn't for the brethren
, and sisters too, I would be in waaaaay over me head. More than I am now!

Chris

[GOLDCYLON]

Chris look at Dynomite (Cliffs) post ups on removing the secondaries

[Dynomite]

1. I think I have all of the vacuum lines off that need to be removed. There are 2 smaller lines that go by the power steering pump then disappear. Where do they end up going? Do I need them? I would have to think again :D but I think that is a separate vacuum system associated with passenger side of plenum (HVAC and Cruize) which are left in place.......I have to take a peak at my 91' to make sure or someone else can chime in as I only remember one line. That vacuum source is obtained from center of passenger side of Plenum.

2. What is the larger diameter vacuum hose for? Do I need it? You must have a 91' as that is a coil under plenum that connects to the front of plenum and goes back and out passenger side to gas tank purge. That system can be eliminated or left in place with no chip modification.
3. How do I get the secondary posts out? see links below

Thanks in advance for all the help you guys offer. If it wasn't for the brethren
, and sisters too, I would be in waaaaay over me head. More than I am now!

Chris

LT5 Eliminated Systems (http://forums.corvetteforum.com/c4-zr-1-discussion/2942569-tech-info-lt5-eliminated-systems.html)
Vacuum Systems (Secondary and Cruize/HVAC) (http://forums.corvetteforum.com/c4-zr-1-discussion/3005470-tech-info-lt5-modifications-rebuild-tricks-500-hp-2.html#post1581460752)
Removing Secondaries TIPS (http://www.zr1.net/forum/showthread.php?t=19842&highlight=removing+secondaries)
Removing Secondary Vacuum System Questions TIPS (http://www.zr1.net/forum/showthread.php?t=9370)
Secondary Removal TIPS (http://www.zr1.net/forum/showthread.php?t=19842)
Eliminated Secondary Throttles/shafts Tricks (http://forums.corvetteforum.com/c4-zr-1-discussion/3005470-tech-info-lt5-modifications-rebuild-tricks-500-hp-2.html#post1581460759)
Secondary vaccum system removal (http://www.zr1.net/forum/showthread.php?t=9370)
Secondaries removed picture (http://www.zr1.net/forum/showthread.php?p=87097)
Remove secondary throttle plates and shafts (http://www.zr1.net/forum/showthread.php?p=87122)
Dorman plug for removed secondary throttle shafts (http://www.zr1.net/forum/showthread.php?p=77547)

[GOLDCYLON]

Cliff to the rescue and no bat signal was needed

[chriskinzel]

So that larger diameter vacuum hose is for the EVAP purge vacuum system. It is not needed? I am still trying to figure out how to pull the shafts out. Can the crankcase vent plate be removed without pulling the A/C compressor? Also, my intake runners are black on the inside, is this normal

Thanks for the help
Chris

[Dynomite]

So that larger diameter vacuum hose is for the EVAP purge vacuum system. It is not needed? See #1 below

I am still trying to figure out how to pull the shafts out. See #2 below

Can the crankcase vent plate be removed without pulling the A/C compressor? See #3 below

Also, my intake runners are black on the inside, is this normal I have seen that myself

Thanks for the help
Chris

1. Marc says the EVAP Purge can be removed as you like without any CHIP modifications but I left mine remain on my 91' even with the secondary vacuum system removed (That charcoal canister and EVAP Purge does serve a purpose). On the 90' the Charcoal canister is located under the drivers side headlight so a different situation on the associated vacuum lines.

EVAP Purge Vacuum on 91'
http://i287.photobucket.com/albums/ll142/dynomite007/C%20Engine%20LT5/043c368f-b6f9-4a47-bbb3-a23761fafa4e.jpg

2. Your best bet for YOUR secondary removal is to NOT remove the secondary shafts but rather tie the secondaries open. Almost impossible to do the job correctly (remove secondary shafts) without removing the Heads which you obviously are doing this job with engine in car :cheers:
A CHIP modification might be in order if you remove/tie open the secondaries (Power Key ON at all times and function of secondary injectors for example).

3. You can remove the 4 bolts holding the AC compressor and the couple/three screws holding the AC accumulator....then........While making sure the AC lines going into the Evaporator do not experience any twisting pressure gently move the AC compressor and accumulator forward out of the way over the radiator.

[Paul Workman]

With regard to pulling the secondary shafts, it is EASILY done with the heads in place by fabricating a little puller jig.

All that is needed is a short piece of steel electrical conduit; maybe 3/4" long (with just big enough inside diameter to span the diameter of the secondary shaft bearing), and a fender washer.

Once the leaver is removed from the shaft and the secondary throttle plate removed (best to plug the runner with a wad of paper towels to avoid a screw from falling into the cylinder...a real pisser!), the piece of conduit is placed on the boss surrounding the bearing, the fender washer placed over the end of the piece of conduit tubing with the threaded shaft sticking through the hole in the fender washer.

Next the little nut removed to take the control leaver off is now screwed down against the fender washer. (A little grease under the nut and on the threads under the washer is a good idea.) gripping the shaft with pliers while screwing the nut down against the fender washer will draw the shaft and bearing out of the seat.

The Bearing is replaced with a Dorman 555-108 steel freeze plug with a smear of JB Weld around the circumference to seal it. Placing a freeze plug on the end of a 7/16" socket, the socket with a short extension will drive the plug home to bottom out against the bearing boss. Done deal.

Note: In order to get the shafts out of the runners of the front 4 cylinders, the breather box needs to be removed to remove the rods, before replacing it.

Hope this helps.

[Dynomite]

With regard to pulling the secondary shafts, it is EASILY done with the heads in place by fabricating a little puller jig. Best to plug the runner with a wad of paper towels to avoid a screw from falling into the cylinder.


Thanks Paul :handshak:
Paul............. This is right up there with Removing Cam Covers with engine in car :D

This Link shows the AC Compressor set aside for Cam Cover Removal and Top End Reconditioning with engine in car......in this case the Secondaries were reconditioned and left in place fully operational :p

Removing Cam Cover and Camshaft Timing Inspection (http://forums.corvetteforum.com/c4-zr-1-discussion/3005470-tech-info-lt5-modifications-rebuild-tricks-500-hp-4.html#post1581665190)

[Paul Workman]

Glad to help the cause.

On another note (OT) I used the same type of jig to draw out the wedge on my shift knob (that had been mercilessly hammered in place by someone).

I drilled and tapped a small hole down the center of the wedge and threaded a screw through the fender washer into the wedge as the puller's anchor. (No conduit piece required, as the fender spanned the top of the shift knob opening to provide a solid rest.) A nut also threaded on the screw was then screwed down against the fender washer, and (voila!!) the wedge came out easy-pleasy.

I used a plastic mallet to seat the soft metal wedge back into place, to avoid destroying the tapped anchor hole should I need to remove the wedge again.

HTH.

P.

[Dynomite]

Good stuff there Paul :thumbsup:

Glad to help the cause.

On another note (OT) I used the same type of jig to draw out the wedge on my shift knob (that had been mercilessly hammered in place by someone).

I drilled and tapped a small hole down the center of the wedge and threaded a screw through the fender washer into the wedge as the puller's anchor. (No conduit piece required, as the fender spanned the top of the shift knob opening to provide a solid rest.) A nut also threaded on the screw was then screwed down against the fender washer, and (voila!!) the wedge came out easy-pleasy.

I used a plastic mallet to seat the soft metal wedge back into place, to avoid destroying the tapped anchor hole should I need to remove the wedge again.

HTH.

P.

[Schrade]

I had some free time today so I thought I would remove the secondaries. After a few problems (like broken bolts) I got everything off I needed to. I now have a few questions.

1. I think I have all of the vacuum lines off that need to be removed. There are 2 smaller lines that go by the power steering pump then disappear. Where do they end up going? Do I need them?

2. What is the larger diameter vacuum hose for? Do I need it?

3. How do I get the secondary posts out?

Thanks in advance for all the help you guys offer. If it wasn't for the brethren
, and sisters too, I would be in waaaaay over me head. More than I am now!

Chris

Brethren! (and sisteren too (didn't know we had 'em ) )

A few more snappics here:

https://lh4.googleusercontent.com/-W4jwQyFIXfc/Uo0mJTCFF_I/AAAAAAAAC8E/IujsILr4-Zc/s1280/Untitled.jpg

and here:

https://lh6.googleusercontent.com/-xI_sS470lJo/Uokv8kGWkjI/AAAAAAAAC4U/vf8dqQi2To8/s1280/HPIM7546.JPG

including vac test shots, page 37.................... (http://www.zr1.net/forum/showthread.php?t=21439&page=37)

[chriskinzel]

Thanks for all the help!! I am out of town until Friday. I can't wait to try all of the new ideas. Thanks for not letting me scratch my head looking for ideas too long.
Chris