Pulling the plenum / IH Some pics !!

[5ABI VT]

Thought I would just make a thread here with some pics. Will be sending the plenum and IH out for porting and a re-tune for the chip. Will be removing the secondaries as well as having the coolant plugged for the plenum/TB.

I just went over a few old threads and posts and theres a ton of info on this site so figuring things out should be pretty easy. One thing I wanted to say was I have a noticeable amount of oil in the plenum.. Ill take better pics in the light tomorrow. :)

pics for my own reference if needed..
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/2F51DFDA-12FC-4807-8CB9-286B11E59BF3_zpsbbizk1p1.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/2F51DFDA-12FC-4807-8CB9-286B11E59BF3_zpsbbizk1p1.jpg.html)

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/3ED4DC22-896F-4892-921D-3B7D2EE8D17D_zpsf9bwc5m8.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/3ED4DC22-896F-4892-921D-3B7D2EE8D17D_zpsf9bwc5m8.jpg.html)

Parts starting to pile up
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/A14FF83D-6150-4F68-AFB7-EE67BF512866_zpsmxwy9jif.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/A14FF83D-6150-4F68-AFB7-EE67BF512866_zpsmxwy9jif.jpg.html)
Had to loosen this fuel.. connection? to get to this bolt. I also removed the fuel rail cap and tried to relieve pressure... there was no fuel to come out at all. bad thing?
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/1AFA14DB-DA46-480B-9FCB-02EF96DDFD52_zpspnrsvto4.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/1AFA14DB-DA46-480B-9FCB-02EF96DDFD52_zpspnrsvto4.jpg.html)
Getting there..

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/02F71DA1-7537-4E70-9A0B-56D1C661C048_zpsp9pdjp48.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/02F71DA1-7537-4E70-9A0B-56D1C661C048_zpsp9pdjp48.jpg.html)
Noticeable amount pooled up at the back. Will be installing catch can(s) before reassembly. Will take some pics in daylight tomorrow.

[5ABI VT]

Oil in the plenum..
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/64F31415-02E8-4D63-B91B-DA1A882C7591_zpsxajssrix.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/64F31415-02E8-4D63-B91B-DA1A882C7591_zpsxajssrix.jpg.html)

[5ABI VT]

Not sure if I read anything about it when removing the secondary vacuum system.. there was a connection to the bottom of the plenum. Does this need to be plugged or .. ?

[XfireZ51]

You have a 94. Are you talking about the Differential Pressure Sensor under the plenum?

[tf95ZR1]

VERY CLEAN!
Engine & workbench
Who's doing your porting?
I also had a puddle of oil in my airhorn.

[PhillipsLT5]

VERY CLEAN!
Engine & workbench
Who's doing your porting?
I also had a puddle of oil in my airhorn.

I know, you better start cleaning, LOL
Really, Very Nice!

[mike100]

about par for the course on the plenum oil.

[5ABI VT]

You have a 94. Are you talking about the Differential Pressure Sensor under the plenum?

That sounds like it. Is it for the secondary vaccum ?

I'm having Pete do the port work.

Thx :) I just finished painting this half of the garage and putting up the cabinets and work benches up/together along with the lighting. It's why it took so long to start the pull and it feels so nice to have a better place to work :)

I didn't have any oil in the air horn maybe just faint residue. The one grommet on the passenger side wasn't fully seated inside the injector housing and not sure if a slight leak would affect much .

Hoping to pull the injector housings tonight !

[XfireZ51]

That sounds like it. Is it for the secondary vaccum ?

I'm having Pete do the port work.

Thx :) I just finished painting this half of the garage and putting up the cabinets and work benches up/together along with the lighting. It's why it took so long to start the pull and it feels so nice to have a better place to work :)

I didn't have any oil in the air horn maybe just faint residue. The one grommet on the passenger side wasn't fully seated inside the injector housing and not sure if a slight leak would affect much .

Hoping to pull the injector housings tonight !

Yes. Its the Differential MAP sensor. Tells the ECM there's enough pressure differential for the secondaries to activate. Once the secondaries are un-installed, Pete will make the necessary calibration change bypassing it.
That sensor is located under the ECM in earlier model years.

[5ABI VT]

Yes. Its the Differential MAP sensor. Tells the ECM there's enough pressure differential for the secondaries to activate. Once the secondaries are un-installed, Pete will make the necessary calibration change bypassing it.
That sensor is located under the ECM in earlier model years.

Makes sense now thanks !

This is what my VW needs lol!
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/837572AB-F7B0-4376-9E06-BC134641C496_zpsga1hckjn.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/837572AB-F7B0-4376-9E06-BC134641C496_zpsga1hckjn.jpg.html)

[5ABI VT]

Hmm removed the fuel lines at the rail. Removed the 4 bolts that hold down the rail. Do the injectors need to be unclipped from the rails or should the rails and injectors pull out of the plenum ?

[5ABI VT]

Well theres 1 crack I found. Possible leak my secondary pump cycled every 5-7 seconds key on.

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/F33F741B-0443-48D5-B95C-96D20F1389F2_zps3wfwxuer.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/F33F741B-0443-48D5-B95C-96D20F1389F2_zps3wfwxuer.jpg.html)

Is this hard line part of the secondary system? Its routed with the passenger side fuel injector harness :dontknow:
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/CB24D700-FDB7-48EA-930C-E451F5FA30DA_zps7bwgtlj5.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/CB24D700-FDB7-48EA-930C-E451F5FA30DA_zps7bwgtlj5.jpg.html)

[batchman]

Hmm removed the fuel lines at the rail. Removed the 4 bolts that hold down the rail. Do the injectors need to be unclipped from the rails or should the rails and injectors pull out of the plenum ?

Looks like I'm a 1/2 day ahead of you!

I hoped to pull them all out together but 8 is too much. The electrical plugs push & hold base of U clip toward the center of the engine and wiggle plug up. For the fuel connection push legs of U clip toward the center of the engine and remove. The rail will still be hard to pull up, for me some injectors "came with" and some stayed behind.

Have fun with the IH o-rings, I think that's been the most time consuming part for me so far.

Cheers,
- Jeff

[5ABI VT]

I guess I spoke too soon last night I searched on this forum and found that it just needed a bit of help. I covered a pRy bar with some chassis tape etc and they all slid out nicely.

I had a ton of oil in the round area. Really really happy to be eliminating the secondaries. There's deposits on the secondary valves and I can't wait to get this motor up to temp to clean them up :)

Question though, what can I use to clean the secondary valves in the heads ? Obviously getting anything down there past the valves is a concern.

Secondary injectors are covered. O rings will be replaced a few are cracked and many are hard. Will replace uppers and lowers.
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7B7C4FD2-BE8C-4F46-91F3-784221DD8C28_zps4fj56pnp.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7B7C4FD2-BE8C-4F46-91F3-784221DD8C28_zps4fj56pnp.jpg.html)
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/FD5424DD-AADF-45D8-BDBE-46FE465F9900_zpsukbvddqj.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/FD5424DD-AADF-45D8-BDBE-46FE465F9900_zpsukbvddqj.jpg.html)

[5ABI VT]

I'll take better pics, but should there be any sign of machining/porting or grinding in the runner behind the valve ? Valve guides are untouched and the size difference is obvious without measuring so they haven't been opened up but I believe I see signs of a little work behind the valves ?

[Schrade]

Good snappics.

I tried to work loose the rails with the INJ's attached, but it's harder that way. INJ's on the end popped out of the rail when I pulled them photo here (http://www.zr1.net/forum/showpost.php?p=185343&postcount=43), and here (http://www.zr1.net/forum/showpost.php?p=185345&postcount=45)....

I don't think you'll damage anything if you do, just work SLOWLY.

Shooting lots of pics and write-up stuff is good for sequencing your work. Putting bolts back in holes with the part out of the way is good too. Takes more time, but you won't loose stuff. Maybe clean EVERY part as you pull it too. Dirty parts stack up pretty quick; too easy to blow 'em off, and do a hasty clean-up at re-assembly. Sometimes you can get away with it. But you never know what the problem is if you took shortcuts.

Your stuff looks pretty clean tho'...


ed.:
and on those IH O-rings - those ESPECIALLY are tough gettin' in, like batch said, and they'll go in twisted too. Maybe after you get them in, with plenty of oil, try to spin them inside the IH, to make sure they're seated without a twist. Seatin' the rail on top of the INJ's is hard enough. I got them in right the first time, but when I had to do it again, I sheared off a piece on #8 ring, because fuel had rinse off the oil from the ring. Dry O's grab better than GSD3's!!!

[5ABI VT]

I haven't taken a closer look at where the o rings seat.. Is there a groove in the injector housing where they seat or do they seat on the injector and are just slid into the IHs? I'm assuming there's one seating it to the rail and one to the IH per injector ? Maybe I'm just confusing myself uh reading too many threads !

Definitely plan to clean all the bolts and pieces on re-assembly. Everything Is relatively clean except in the valley. The top end was off not too long ago for the pc refinish that's most likely why the cleanliness . I have msd coils I picked up as spare but I'm debating on leaving well enough alone for now. Even having thoughts of new injectors.. The 'while you're in there' bug can get expensive real fast !

[Schrade]

I haven't taken a closer look at where the o rings seat.. Is there a groove in the injector housing where they seat or do they seat on the injector and are just slid into the IHs? I'm assuming there's one seating it to the rail and one to the IH per injector ? Maybe I'm just confusing myself uh reading too many threads !

Definitely plan to clean all the bolts and pieces on re-assembly. Everything Is relatively clean except in the valley. The top end was off not too long ago for the pc refinish that's most likely why the cleanliness . I have msd coils I picked up as spare but I'm debating on leaving well enough alone for now. Even having thoughts of new injectors.. The 'while you're in there' bug can get expensive real fast !

I'm pretty sure that there's a groove in the IH INJ port for the primaries (secondaries???), which is what holds the O in place when you yank the rail, and the INJ's come out behind it

Got gaskets in from Jerry - thanks!

Setting the primary [?] O's...

A drop of Trans-X into the groove...

https://lh3.googleusercontent.com/-knTMU7tysrA/UnVmMWHgbDI/AAAAAAAACB0/e41NPAOVKAY/s1280/HPIM7357c.JPG

After setting the O's, I wanted to set the INJ's, and rock them in the ports to make sure they weren't twisted / bound in the grooves.

Put some oil in the ports (can't wrench on a motor without busting knuckles ( or almost slicing off some fingertips OUCH ) ):

https://lh6.googleusercontent.com/-37vYeGx_epo/UnVoYV1flYI/AAAAAAAACCA/TQsLxkuJ74g/s1280/HPIM7358.JPG

and on the INJ shafts

https://lh5.googleusercontent.com/-gFdEh7fHMzM/UnVpWp2N3zI/AAAAAAAACCI/SKo2Lkm762o/s1280/HPIM7359.JPG

Then I tried to sink the rail into the IH. WASN'T happenin' the way I like (with LT1)...

Gonna' have to sink the INJ's into the IH individually, and then drop the rails ONTO the INJ's...........................

[5ABI VT]

How about assembling the rails on the injector housings off the motor and placing it all on as one unit? Or possibly disconnecting the crossover pipe (probably need another o ring ? - boy this never ends lol). Just thinking aloud.

If I may ask for a picture request.... Does anyone have any photos of the runner down the primaries in the head? Basically the angle looking at the back of the valve ?

[Schrade]

I got one shot while serving eviction notice on a moth:

So I go out to assess work and cover the ports, and there's a moth on the secondary valve. I go for his wing, and he decides it's time to bounce the joint....

right into the open primary, with the valve on the intake.

Mr moth; meet Mr. Shop-Vac

http://www.zr1.net/forum/attachment.php?attachmentid=2958&stc=1&d=1382145239

http://www.wallpapersgalaxy.com/wp-content/uploads/2009/07/smiley-face-wallpaper-008-300x225.jpg

and now he's gone into the cylinder All he needs now is butter, cause he's toast. At least it wasn't a clam...



There's probably a few other shots in the TE thread (link below); have at it...

[A26B]

I haven't taken a closer look at where the o rings seat.. Is there a groove in the injector housing where they seat or do they seat on the injector and are just slid into the IHs? I'm assuming there's one seating it to the rail and one to the IH per injector ? Maybe I'm just confusing myself uh reading too many threads !

Definitely plan to clean all the bolts and pieces on re-assembly. Everything Is relatively clean except in the valley. The top end was off not too long ago for the pc refinish that's most likely why the cleanliness . I have msd coils I picked up as spare but I'm debating on leaving well enough alone for now. Even having thoughts of new injectors.. The 'while you're in there' bug can get expensive real fast !

For 93~95
Top & bottom injector o-ring seals are the same. There is no receiver area in the injector housing.

To install after new O-rings are on the injectors, just lube the o-rings lightly with a little motor oil on your fingers. Install all the injectors in the rails first. It's easier to put the clips on. Then line up with the injector housings, press down & wiggle until the rail brackets are down on the injector housings & bolt them in place.

[A26B]

Looks like you need to "exercise" your secondaries more! Have some fun with that thing. The greatest travesty is to have to discard tires because of age.... that still have tread on them. :dancing

[batchman]

Install all the injectors in the rails first. It's easier to put the clips on. Then line up with the injector housings, press down & wiggle until the rail brackets are down on the injector housings & bolt them in place.

Jerry - that post was *just* in time for me - thanks!
- Jeff
(pondering what I've forgotten before flopping the top back on)

[5ABI VT]

The secondaries get too much exercise from me :) most likely deposits from relaxed driving from previous owners.

What are the stock sizes for primary and secondary ports ?

[A26B]

What are the stock sizes for primary and secondary ports ?

Injector Housing; Cylinder Head side
Primary = 32mm
Secondary = 36.5mm

[5ABI VT]

Well I'm not sure if I'm disappointed I won't be making more power or if I saved some $$$.. But it looks to me like this top end has been ported already. Ports on plenum are the same size, one end of the ih are the same size and you can see where it stopped in the IH.. Cylinder head side of the IH are what look to be stock sizes with secondaries larger than primaries. Going to buy a caliper tool to measure.. Pics to come

[LGAFF]

94 primaries are 33-34 at the top of the IH.....you can tell if its ported, it would be smooth in the runner vs cast

[5ABI VT]

Are primaries and secondaries both 34mm ? I feel a little relieved as they are 34mm or slightly over depending on where I put the digital caliper I just picked up. Primary and secondary ports are 34mm at the top

[5ABI VT]

Ok so here are some measurements ...

Plenum ports all appear the same size. About 34.3-34.5mm give or take.

Injector housing TOP side. I double checked .. The side mating to the plenum. 34.3 - 34.5 mm on all.

Now here's the interesting part ... The cylinder head side (bottom) of the injector housings ... The primaries are 33-33.6mm

The secondary ports are as measured across ..

37.4 36.85 37.4 36.91

Not quite sure how this happened or if it's supposed to be like this but these are the largest port sizes.


Going to measure the cylinder head now...

[5ABI VT]

At the heads . Primaries are 33. Secondaries 36.5. Give or take a few this caliper tool isn't the most accurate or steady. Pics coming right now ..

[5ABI VT]

Here's a few of various plenum/IH .

Can see some machining and a stop line here assuming this Might be from the 93-5 program?
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/3F571881-A25B-4C0E-B3F0-1D2C140EA2D2_zpsymdumv4a.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/3F571881-A25B-4C0E-B3F0-1D2C140EA2D2_zpsymdumv4a.jpg.html)
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/AF5A9037-FD4B-41BB-9264-7E3311D79CF6_zps6ss63yq9.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/AF5A9037-FD4B-41BB-9264-7E3311D79CF6_zps6ss63yq9.jpg.html)
Plenum
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/B5AF069D-E9B4-4DBF-B7AF-EEF3605EEC1F_zpsrts8857g.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/B5AF069D-E9B4-4DBF-B7AF-EEF3605EEC1F_zpsrts8857g.jpg.html)

[5ABI VT]

Perhaps I confused myself when reading up on primary /secondary sizes etc thinking that they were those sizes from the plenum down to the head? I still find it odd that they are large at the head on the IH/cyl head. Can't be a bad thing I guess once opened up.

Plenum measurements :
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/3E6DCA73-259F-4546-A062-DD092F9C2B79_zpstjmyazqn.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/3E6DCA73-259F-4546-A062-DD092F9C2B79_zpstjmyazqn.jpg.html)
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/941D96D8-0BF4-40B2-A1DD-73676D1B5D15_zpsv1dgwem6.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/941D96D8-0BF4-40B2-A1DD-73676D1B5D15_zpsv1dgwem6.jpg.html)

Injector housing top
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/521D4CA4-0EF8-4B6A-894E-8AA76EA10B30_zpseptdkbqn.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/521D4CA4-0EF8-4B6A-894E-8AA76EA10B30_zpseptdkbqn.jpg.html)
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/61220F3F-1121-4131-B8F6-784C18E60658_zpsqc8did38.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/61220F3F-1121-4131-B8F6-784C18E60658_zpsqc8did38.jpg.html)

[5ABI VT]

Injector housings bottom /cylinder head side
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7A7D3C65-C298-4B8C-AD90-B21553C5F1A6_zpskwogiljm.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7A7D3C65-C298-4B8C-AD90-B21553C5F1A6_zpskwogiljm.jpg.html)
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/B37AC0ED-24E8-4790-A2E0-A804EB13FE67_zpsgghw5xmh.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/B37AC0ED-24E8-4790-A2E0-A804EB13FE67_zpsgghw5xmh.jpg.html)
And the head.

Primary
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/C3B16296-019C-475B-98D7-88878904EB49_zps3raa9qdr.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/C3B16296-019C-475B-98D7-88878904EB49_zps3raa9qdr.jpg.html)
Secondary
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/F4B02370-7E6C-4630-B781-F2AAFAD90328_zpsz4cnhjei.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/F4B02370-7E6C-4630-B781-F2AAFAD90328_zpsz4cnhjei.jpg.html)

[5ABI VT]

Injector Housing; Cylinder Head side
Primary = 32mm
Secondary = 36.5mm

I must have missed this. I feel better now. Isn't it odd that the runners would start small and open up at the head or is it designed that way for air speed/swirl or all that fancy stuff ?

[LGAFF]

Those are stock

[5ABI VT]

Those are stock

Really happy to hear it! Lack of knowledge on my end that the sizes varied at different points.

The cylinder heads however.. Have definitely been altered. Just got some better photos now of the drivers side. Relieved that the work had been done on both heads so they're equal. I'm
Not sure why someone would do head work and not have done the plenum/IH. My only guess is at some point before sale possibly the ported versions were removed for a set of stockers.

I don't know if the factory heads have any casting material around the valves? Or valve guides (not sure of the exact term) but if there was it's completely removed on all runners. Just the metal of the guide and valve are coming into the runner and it looks like most of the material around the back of the valve has been worked on. How much I don't know. Hopefully it had a positive impact and will only help when the top end is ported. She does run strong now and it's good to know I'll be picking up some ponies after all :)

[5ABI VT]

Here's a primary on the drivers side..
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/9488D8BA-DC22-47E0-8FD5-AE4B3EF4F25E_zps5mchlgqs.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/9488D8BA-DC22-47E0-8FD5-AE4B3EF4F25E_zps5mchlgqs.jpg.html)
Shot down at that valve in the runner
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7CAE0735-A0A1-4809-AED8-624CC0E794A3_zpsh291novd.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7CAE0735-A0A1-4809-AED8-624CC0E794A3_zpsh291novd.jpg.html)
Down the secondary .. Ugh .. Good riddance that this won't happen in the future. Unless I idle a lot !
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/CD95ED26-660A-4BDD-A430-E40525586096_zps1qgcy7rv.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/CD95ED26-660A-4BDD-A430-E40525586096_zps1qgcy7rv.jpg.html)
Another primary
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/095A3E54-B214-4D8A-A49A-513FAAA023E5_zpstygnvprj.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/095A3E54-B214-4D8A-A49A-513FAAA023E5_zpstygnvprj.jpg.html)

[LGAFF]

Those are ported....I would measure them with a telescoping gauge....a lot of the older porting is just cleanup....


http://www.harborfreight.com/6-piece-telescoping-gauge-set-5649.html

[Jagdpanzer]

From what I can see in the photos the head, injector housings and plenum ports appear to be the same as when they left the factory. I have a untouched set off a 94 motor setting on the bench and they look the same as yours. What you are seeing in the head ports is the minor machine work they performed to help reach the 405 hp rating on the later 93-95 motors.

[5ABI VT]

From what I can see in the photos the head, injector housings and plenum ports appear to be the same as when they left the factory. I have a untouched set off a 94 motor setting on the bench and they look the same as yours. What you are seeing in the head ports is the minor machine work they performed to help reach the 405 hp rating on the later 93-95 motors.

i can see that the machining at the top of the head being from the factory as its machined quite nicely and evenly. Further down however it looks to me like someone used a porting tool and was doing some clean up. Thats what it looks like to me anyways. Ive searched for hours to find some photos of a factory head/runner to compare and no such luck.

[LGAFF]

90-92 heads definitely do not have that type of machining....I would be surprised they would go into the bowl like that

[5ABI VT]

heres the only photo I dug up.. fromt he big 427 build thread. Looks to me like I can see some valve guide 'boss' there.. if that's the correct term for it. On mine there are grinding marks around that area looking like theyve been removed.
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/portingLT5headsArrows_zps94d6d936.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/portingLT5headsArrows_zps94d6d936.jpg.html)
Mine
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7CAE0735-A0A1-4809-AED8-624CC0E794A3_zpsh291novd.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7CAE0735-A0A1-4809-AED8-624CC0E794A3_zpsh291novd.jpg.html)

Unless it was part of the 93+ program not sure. To what extent was that enlarging done? More reading for me... =D>

[5ABI VT]

Moving on then .. Now to the hard part.. How to package this :o. Debating on shipping the injector housings seperately. Should shed some weight and prevent too much moving around ? Debating on just driving down to Chicago to drop these off in person !

[XfireZ51]

Moving on then .. Now to the hard part.. How to package this :o. Debating on shipping the injector housings seperately. Should shed some weight and prevent too much moving around ? Debating on just driving down to Chicago to drop these off in person !

If you come down to Chicago, you get pizza too!

[5ABI VT]

What is this hard vaccum line for ? Its connected with the Pass side injector wiring harness. Im excited to just start ripping everything out secondary related... but want to make sure nothing is for anything important.

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/CB24D700-FDB7-48EA-930C-E451F5FA30DA_zps7bwgtlj5.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/CB24D700-FDB7-48EA-930C-E451F5FA30DA_zps7bwgtlj5.jpg.html)

[5ABI VT]

Only box I have that is fairly strong .. Not sure if there's enough room on the sides to protect the plenum. Maybe I'm over thinking this a little but shipping is scaring me. Free pizza is really making me lean towards driving it down...!

The box was for coilovers which were really heavy . Going to grab my foam and things and see what I can come up with ..

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/8B6A2201-6418-42D5-95A9-D3D10C4F3D76_zpscp1ard4t.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/8B6A2201-6418-42D5-95A9-D3D10C4F3D76_zpscp1ard4t.jpg.html)

[Schrade]

We love to look at snappics, but getting Q's answered is another story, huh ABI? (I had that problem in my TE re-work thread).

---------------------------------------------------------------------------------------------
That vac line goes to the HVAC Control.

(maybe do some vac line integrity tests while you're there; some more of that @ post #410 +/- in the TE thread)

Comes off vac junction here (can't remember if it's 'C', or 'A' tho')

https://lh5.googleusercontent.com/-ubDVOvfK_Bc/Uo6j-4sTljI/AAAAAAAAC-A/ilD7OARQQUQ/s1280/HPIM7568.JPG

Sometimes the best way to get a response is not to ask a question, but rather to make a declaration of something that you know is wrong. Web nazi's will come out from behind their keyboards like flies to *fertilizer* http://www.zr1.net/forum/images/icons/icon10.gif

[XfireZ51]

What is this hard vaccum line for ? Its connected with the Pass side injector wiring harness. Im excited to just start ripping everything out secondary related... but want to make sure nothing is for anything important.

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/CB24D700-FDB7-48EA-930C-E451F5FA30DA_zps7bwgtlj5.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/CB24D700-FDB7-48EA-930C-E451F5FA30DA_zps7bwgtlj5.jpg.html)


Cruise Control

[5ABI VT]

We love to look at snappics, but getting Q's answered is another story, huh ABI? (I had that problem in my TE re-work thread).

---------------------------------------------------------------------------------------------
That vac line goes to the HVAC Control.

(maybe do some vac line integrity tests while you're there; some more of that @ post #410 +/- in the TE thread)

Comes off vac junction here (can't remember if it's 'C', or 'A' tho')

https://lh5.googleusercontent.com/-ubDVOvfK_Bc/Uo6j-4sTljI/AAAAAAAAC-A/ilD7OARQQUQ/s1280/HPIM7568.JPG

Sometimes the best way to get a response is not to ask a question, but rather to make a declaration of something that you know is wrong. Web nazi's will come out from behind their keyboards like flies to *fertilizer* http://www.zr1.net/forum/images/icons/icon10.gif


LoL I noticed that when Ive gone through that thread several times ! I agree with what you said though and I think I need to just go one step at a time. Going to focus on shipping this plenum first and then remove the secondaries and then worry about whats left for vaccum items.

The one thing that is confusing me is the fact that many of the threads with pics and info are earlier year cars. I believe I see what looks to be the evap purge solenoid beside the coils. I also have what looks to be a knock sensor or something else bolted under the plenum beside the dis module.

one step at a time I guess ! and btw that thread of yours is fantastic !

[USAZR1]

Only box I have that is fairly strong .. Not sure if there's enough room on the sides to protect the plenum. Maybe I'm over thinking this a little but shipping is scaring me. Free pizza is really making me lean towards driving it down...!

The box was for coilovers which were really heavy . Going to grab my foam and things and see what I can come up with ..

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/8B6A2201-6418-42D5-95A9-D3D10C4F3D76_zpscp1ard4t.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/8B6A2201-6418-42D5-95A9-D3D10C4F3D76_zpscp1ard4t.jpg.html)


I would NOT use that box,Mike. Need more packing room to adequately protect the runners. Do you have "U-Haul" centers up there? If so,they sell a huge variety of shipping containers.

I shipped a plenum & IH's in the same box,to Bob DeMarco a few months ago w/o problems. IIRC,the weight was around 30lbs.

[WVZR-1]

That box will do well for the 'first' of the double box. If you wrapped it well in that box and then used 3/4" or 1" Styrofoam sheet on all six sides of it inside of another box you would be probably fine. I'd center it lengthwise in that box and fill the ends, paper is a great packaging product. For the second box if you've a smaller LCD flat panel of a recent purchase or check some local stores they're quite substantial. 1" Styrofoam is the preferred here I'd say.

An auto dealership generally has some really good packaging hanging around in either the parts dept. or the body shop. If you've some relationships at one or a few I'd use them.

I'd consider two boxes total for the ship. For the IH's I'd find a box suitable for each one and box them and then package them in a single larger box that is as well packaged as the plenum will be.

If you could find an appropriate box then the three singles inside of a single if well packed would do likely as well like Clint mentioned.

[5ABI VT]

Appreciate the input I'll google uhaul I'm pretty sure they are around here. Here's a photo of some high impact foam I was planning to use on the sides to give it a tight fit. I still plan to add lots of styrofoam and bubble wrap as well..

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/81DED801-579B-4F5D-B477-57E661E98E99_zpsvlafelsx.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/81DED801-579B-4F5D-B477-57E661E98E99_zpsvlafelsx.jpg.html)

Folded ..
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/C9416D46-3E43-4975-9604-99A5D4D93BFE_zpst2sb2kz0.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/C9416D46-3E43-4975-9604-99A5D4D93BFE_zpst2sb2kz0.jpg.html)

[5ABI VT]

Getting the materials together. Will see how well I can stuff this thing. Definitely going to send the injector housings in a seperate box.
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/64B0FCCA-28C9-48EC-9BCA-3E56D4CB315E_zps9s5yvffm.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/64B0FCCA-28C9-48EC-9BCA-3E56D4CB315E_zps9s5yvffm.jpg.html)

[Hog]

That plenum looks amazing, the "keynote" of the LT5's visual appeal.

[5ABI VT]

Definitely one of the most appealing engines to date. I love popping the good and seeing peoples faces when they see it :) priceless. It's something I think gm let down c6z owners when they had Rubbermaid design the cover on the ls9 and even put a window on it.

Anyhow.. Ran out of tape for now.. Will get some more from work. The high impact foam surrounds the runners and top and bottom. The front and back will have 6+ inches of foam stuffed in there to protect those sides. Preparing myself for he worst and I feel better now knowing I can always get it repaired and then polish the whole thing and smoothen the runners.

Generally a ton of styrofoam front and back... Just test fitting.
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/03516D2D-99B5-4B57-8918-B940299B1E30_zpsuzpfpebi.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/03516D2D-99B5-4B57-8918-B940299B1E30_zpsuzpfpebi.jpg.html)

Foam wrapped around the runners and folded below and above for protection. Ran out of tape here but it will be wrapped up better with more styrofoam to fit. Then I'll add some thick pieces front and back and wrap that way as well.

I'm planning to head over the border to pick up more parts etc on Thursday I'm thinking it will be a lot cheaper to ship from there than here in canada so hopefully I'll get it wrapped up tomorrow. Injector housings I'm not too worried about I have lots of foam that should swallow them up good.

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/FC7ECBB7-664A-40CB-9BD1-C0E3E8D7EE18_zpsc8uqvoke.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/FC7ECBB7-664A-40CB-9BD1-C0E3E8D7EE18_zpsc8uqvoke.jpg.html)

[Schrade]

Looks fine. Like Dave said, for FIRST box - use tape to EXTREMELY compress that Black styro, AND compress first box, then cushion THAT box inside second box. Then the load from handling hits on outside box gets spread evenly on inside box. ;)

(owned a courier & delivery for 21 years - junk car parts, human organs, office supplies, US Bulk Mail, etc., ... http://www.zr1.net/forum/images/icons/icon12.gif )

[5ABI VT]

Looks fine. Like Dave said, for FIRST box - use tape to EXTREMELY compress that Black styro, AND compress first box, then cushion THAT box inside second box. Then the load from handling hits on outside box gets spread evenly on inside box. ;)

(owned a courier & delivery for 21 years - junk car parts, human organs, office supplies, US Bulk Mail, etc., ... http://www.zr1.net/forum/images/icons/icon12.gif )

Much appreciated ! Plan to really tighten things up.. but finding a box bigger than this one.. Not exactly sure where to look:confused: Will look up uhaul etc now while Im at work.. Still considering the drive... a hell of a drive just to drop stuff off lol. the suspension box is fairly thick I was thinking it would be enough lined with enough Styrofoam on all sides. I believe the suspension weighed in around 56 lbs when it came in.

[5ABI VT]

seperate box.
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/64B0FCCA-28C9-48EC-9BCA-3E56D4CB315E_zps9s5yvffm.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/64B0FCCA-28C9-48EC-9BCA-3E56D4CB315E_zps9s5yvffm.jpg.html)

I spoke to soon.. I do have those giant white boxes in the pic above that were for the rolling workbenches I built. ive been using the Styrofoam from them. I can cut them down to size.. and put a few inches of Styrofoam sheets on every side of the first box and double box it. I see the logic in the double box now it would definitely help and couldn't hurt. :cheers:

[XfireZ51]

How about using a Rubbermaid container?

[WVZR-1]

How about using a Rubbermaid container?

That's what I've used for shipping the last 3 differentials that I've shipped but I'd think for these parts the cardboard box and Styrofoam works better. If you used a 'tote' you still have to do the same packaging of the single pieces and I actually use a 'tote' inside of the same sized 'tote' with a couple inches trimmed from the top of the inner one. I retain the lid to the tote with a combination of threaded fasteners and seal the perimeter with cable ties. I've used a single tote also with the fold-over lid and used bolts and u-nuts for the flaps and at the handles as well as cable ties.

It could certainly work.

[Schrade]

LoL I noticed that when Ive gone through that thread several times ! I agree with what you said though and I think I need to just go one step at a time. Going to focus on shipping this plenum first and then remove the secondaries and then worry about whats left for vaccum items.

The one thing that is confusing me is the fact that many of the threads with pics and info are earlier year cars. I believe I see what looks to be the evap purge solenoid beside the coils. I also have what looks to be a knock sensor or something else bolted under the plenum beside the dis module.

one step at a time I guess ! and btw that thread of yours is fantastic !

can't compete with Cliff tho'; he's the Forum Archivist! http://www.zr1.net/forum/images/icons/icon12.gif

[LGAFF]

When Kinsler shipped my items they sprayed expanding foam into a bag and put on top of the plenum, and a bag under and it surrounded the plenum. I am guessing this process is probably a shipping kit or system they bought....but it worked very well, even for the cylinder head.

[5ABI VT]

A tip for anyone looking to do their top end. Shipping the thing is MUCH harder than the entire job !!:)

[5ABI VT]

Got some tape and more foam to cover the front and back. Can easily flip this thing around the floor while taping with no worry.
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/2153A86E-12BD-4FAC-9368-DA48B06DA03F_zps34mssduk.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/2153A86E-12BD-4FAC-9368-DA48B06DA03F_zps34mssduk.jpg.html)

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/EAFE3660-B770-4E5F-89E3-2FCBCA8F21C0_zpswh2obyo8.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/EAFE3660-B770-4E5F-89E3-2FCBCA8F21C0_zpswh2obyo8.jpg.html)

Not really sure why I bought these .. Spares I guess but I'm tempted to use them because they look so much nicer . What's the opinion on msd coils vs stockers ?
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/6F7799BA-AB8B-49DB-A0C1-05AC6271D46C_zpsfbthtykh.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/6F7799BA-AB8B-49DB-A0C1-05AC6271D46C_zpsfbthtykh.jpg.html)

[Dynomite]

Not really sure why I bought these .. Spares I guess but I'm tempted to use them because they look so much nicer . What's the opinion on msd coils vs stockers ?
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/6F7799BA-AB8B-49DB-A0C1-05AC6271D46C_zpsfbthtykh.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/6F7799BA-AB8B-49DB-A0C1-05AC6271D46C_zpsfbthtykh.jpg.html)

I use them on a 90' and they ARE purty. ;)

Then i covered them up with the Plenum.
But.......with TB coolant blocked at injector housing I can remove plenum in 10 min and look at them :D

[FU]

Put some more tape on it :cheers:

[5ABI VT]

Put some more tape on it :cheers:

Lol I plan to.. but realized that tomorrow ill be crossing the border and depending on the officer I may have to pull over and they'll tear all the packaging off and I'll have to redo it anyways. I did find a box that better fit the plenum.. but its very thin, this coilover box is clearly a beefed up cardboard and I think Im going to stick with it. Will check the recycling at work today for more boxes. I still want to double box it as suggested. We do have some Large plastic bins at work that would be perfect.. Ill be asking if I can take one home with me.

[5ABI VT]

I use them on a 90' and they ARE purty. ;)

Then i covered them up with the Plenum.
But.......with TB coolant blocked at injector housing I can remove plenum in 10 min and look at them :D

Having mine plugged at the His too :) Just a thought... HAd an idea to mount a cpu case fan under the plenum blowing air towards the coils and out the back.. Or do you think there would be sufficient flow under there?

[Dynomite]

Having mine plugged at the His too :) Just a thought... HAd an idea to mount a cpu case fan under the plenum blowing air towards the coils and out the back.. Or do you think there would be sufficient flow under there?

Do not think that would help cool engine much as you are just moving hot air around ;)

Good for you on TB block and doing it the right way (blocking at Injector Housing). No one has to know if you leave TB hoses in place. Just have to put a plug on other end going to coolant reservoir but you can leave it look stock :thumbsup:

[Schrade]

Having mine plugged at the His too :) Just a thought... HAd an idea to mount a cpu case fan under the plenum blowing air towards the coils and out the back.. Or do you think there would be sufficient flow under there?

I've considered this too. I got a tower fan, couple HD fans, etc...

ANY air movement is better than NO air movement.

MORE air movement is better than air movement.

Especially for the IG Module...

[5ABI VT]

I've considered this too. I got a tower fan, couple HD fans, etc...

ANY air movement is better than NO air movement.

MORE air movement is better than air movement.

Especially for the IG Module...

Pretty much what I'm thinking. It can only get hotter under there and a fan or 2 might create some air movement under there . Like a computer cup that uses paste air flow is critical . The module isn't needing Requiring that much cooling but it does use paste.. Which tells me it can get hot anything that might help keep it cooler is a good thing. CPU fans come in various sizes and looks now and don't draw much power either. Something else to add to the list .. With the coolant blocked off I think it will be fun to play with the idea over the winter.

Happy with the packaging .. Got some foam and cut it to shape and they're surrounded good.
Test fit
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7337C7CC-C2EA-423E-80A8-CBDA03B4F2B2_zpsk05tqhnw.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7337C7CC-C2EA-423E-80A8-CBDA03B4F2B2_zpsk05tqhnw.jpg.html)

Bubble wrapped and added a few sheets on all sides with the foam..
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/F984864A-90EE-4ED6-86E9-A9E4705468C6_zps1g5le7xd.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/F984864A-90EE-4ED6-86E9-A9E4705468C6_zps1g5le7xd.jpg.html)


On my way to ship everything . Will start pulling the exhaust tonight to get ready for the clutch /lt flywheel install !

[5ABI VT]

Everything is out. Insured for 2k on the plenum and 500 I think for injector housings. least if they get lost itll put a dent in what I would have to pay to make a new billet manifold =D> Maybe NRE can build me one.. but I don't feel like giving up my kidneys just yet.

Anyways I wanted to post up a closer pic of the bowl area. Do you guys agree this isn't part of the factory 93+ upgrade?

Ive dremeled a set of wheels before to look the way I wanted.. sure looks hand done to me.
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/5BFDA3B1-A6C7-4150-A38C-6732B623707D_zpshi2goieo.png (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/5BFDA3B1-A6C7-4150-A38C-6732B623707D_zpshi2goieo.png.html)

[Jagdpanzer]

Looks about the same as this one off a 94 which has neever been touch since leaving the factory.
http://i540.photobucket.com/albums/gg333/pwasinger/94LT5Intakerunnerbowl_zps24199efb.jpg

[5ABI VT]

Looks about the same as this one off a 94 which has neever been touch since leaving the factory.
http://i540.photobucket.com/albums/gg333/pwasinger/94LT5Intakerunnerbowl_zps24199efb.jpg

That makes me feel better. Just surprised it's so rough .surely a machine didn't do the work ?

[Jagdpanzer]

That makes me feel better. Just surprised it's so rough .surely a machine didn't do the work ?
I always wondered where Fred Flintstone ended up after his TV show ended.

[5ABI VT]

I always wondered where Fred Flintstone ended up after his TV show ended.

Ahaha :) my faith has been restored .. I guess I do just have a fast one ! Now it's clean up time in the valley and time to remove the secondaries . Yesterday I was in buffalo and searched several auto parts stores for a black oil filter .. No luck. I guess I'll just order them off eBay. Did pick up a 2000lb trans jack.. This thing will surely help with the trans.

[5ABI VT]

Just wanted to ask about 1 line in particular but figured while I was on the photo I may as well ask about a few just for clarification.

1. Coolant
2. ?? (evap?)
3. PCV
4. PCV vacuum
5. ?? (secondaries?)
6. Coolant
7. ?? No idea here.
8. ?? Don't even recall this on my motor but thought I'd ask since I saw it in the pic :p

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/HighresLT5_zps265c95c5.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/HighresLT5_zps265c95c5.jpg.html)

[secondchance]

Just wanted to ask about 1 line in particular but figured while I was on the photo I may as well ask about a few just for clarification.

1. Coolant
2. ?? (evap?)
3. PCV
4. PCV vacuum
5. ?? (secondaries?)
6. Coolant
7. ?? No idea here.
8. ?? Don't even recall this on my motor but thought I'd ask since I saw it in the pic :p

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/HighresLT5_zps265c95c5.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/HighresLT5_zps265c95c5.jpg.html)

5ABI VT,

If I remember correct from your corvetteforum thread, you have a 94 or a 95. Picture above is of an early car. 94 and 95s are configured slightly different on the driver side.
On later cars 7, I believe, is a vacuum line that connects to a "T" splitting to vacuum reservoir (black plastic ball) and the other side to cruise control servo. I will check later but I don't recall seeing 8 on my 94.

[5ABI VT]

Finally got back in the garage and spent the first 2 hours searching for a 7mm wrench and then buying one :/. Needed it to pull the secondary linkage off. Started cleaning up and it looks like the ac compressor needs to move to get the vent cover off so I might just leave it as is and wipe what I can. Got the linkages off easy just need to pull the bearings/bushings out and plug them which I'll do tomorrow after cleaning up the gunk.

My biggest concern is the snake pit of vaccum lines still. There looks to be 2 solenoids here anyone know which is the evap ? The one on the left had a small maze of vaccum lines that in praying I don't have to reuse .

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/99304D79-CD72-4085-B801-460FAF5C0400_zpsjpkjt9ax.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/99304D79-CD72-4085-B801-460FAF5C0400_zpsjpkjt9ax.jpg.html)

[5ABI VT]

Started the clean up a bit just using water for now. What are your guys thoughts on cleaning the plenum before install ? Was thinking blow, brush and power wash

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/02C317B7-0A3B-4C15-A148-E3E6180BA25B_zpsxg2fmbjz.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/02C317B7-0A3B-4C15-A148-E3E6180BA25B_zpsxg2fmbjz.jpg.html)

[5ABI VT]

Wiping wiping wiping .. Before I get any further ... I noticed something .. When pulling the bell housing I remember some bolts being hard to reach .. After I pulled the coil packs there are easily accessible bolts on the bell housing from the top . Maybe it's a good thing I decided to do both at the same time !
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7753D4CD-D22A-4219-841F-990C11706D83_zpszxbctqwn.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7753D4CD-D22A-4219-841F-990C11706D83_zpszxbctqwn.jpg.html)

[XfireZ51]

[QUOTE=5ABI VT;212888]Wiping wiping wiping .. Before I get any further ... I noticed something .. When pulling the bell housing I remember some bolts being hard to reach .. After I pulled the coil packs there are easily accessible bolts on the bell housing from the top . Maybe it's a good thing I decided to do both at the same time !


Yes that's called the rule of "While you are there you may as well...".
Basically the rule states that you take advantage of doing one or more things since they are already adjacent to the initial thing you started out to do in the first place.

[Dynomite]

Wiping wiping wiping .. Before I get any further ... I noticed something .. When pulling the bell housing I remember some bolts being hard to reach .. After I pulled the coil packs there are easily accessible bolts on the bell housing from the top . Maybe it's a good thing I decided to do both at the same time !

Rather than wipe I would HOT pressure wash Using Degreaser first.


Yes that's called the rule of "While you are there you may as well...".
Basically the rule states that you take advantage of doing one or more things since they are already adjacent to the initial thing you started out to do in the first place.

"While you are there you may as well..." :thumbsup:
Everyone should follow that rule ;)
Goes right along with my Standard Top End Restoration which usually takes three days. One day to remove, fix, and modify stuff (including a steam cleaning), One day to think and let it dry out, and one day to put it back together and take it for a ride :D

That fits right in with getting Gaskets and stuff from Jerry which usually takes only two days from time of placed order :sign10:

Minimum Restoration of a 1990 ZR-1 (http://forums.corvetteforum.com/c4-zr-1-discussion/3005470-tech-info-lt5-modifications-rebuild-tricks-500-hp-7.html#post1585219749)

[Schrade]

Wiping wiping wiping .. Before I get any further ... I noticed something .. When pulling the bell housing I remember some bolts being hard to reach .. After I pulled the coil packs there are easily accessible bolts on the bell housing from the top . Maybe it's a good thing I decided to do both at the same time !
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7753D4CD-D22A-4219-841F-990C11706D83_zpszxbctqwn.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7753D4CD-D22A-4219-841F-990C11706D83_zpszxbctqwn.jpg.html)

Grounding straps? Back of the heads?

There's 3 on P side

https://lh4.googleusercontent.com/-X_YkanjZotw/UnCdak995ZI/AAAAAAAAB3w/ik8NCYVcyNY/s1280/HPIM7315.JPG

and 5 on D side (although they're on the coil mounting grid bolt, on '90)

https://lh3.googleusercontent.com/-Qti2P5lIxKw/UnCcMzJTLwI/AAAAAAAAB3c/KrVIQWeBtaY/s1280/HPIM7310c.JPG

Looking good so far there http://www.zr1.net/forum/images/icons/icon14.gif

[5ABI VT]

What are all those ground straps for ? I haven't seen them or are they screwed down onto the bell housing ?

Got the secondary blades out and pulled the shafts out tomorrow I'll get to plugging them and then onto the clutch !

Any thoughts on cleaning the valves or secondary runners ? Obviously don't want to get crud in there but they're pretty gunked up. Fuel may clean them up slightly over time I'm hoping.
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7B8164CA-C655-4690-B5B2-C34CD9E8F2F1_zps82dsdfz7.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/7B8164CA-C655-4690-B5B2-C34CD9E8F2F1_zps82dsdfz7.jpg.html)

[Schrade]

There ARE 2 BRAIDED grounding straps on the bellhousing - 1 / side.

The ones in my hand - on the P side, are on the back end of the head [circled, in your snappic). Good Q - what ARE they? I cannot find them in FSM 8A???

http://www.zr1.net/forum/attachment.php?attachmentid=3796&stc=1&d=1411730580

But the 5x was on the Coil Pac mounting plate, D side back corner. I can't find THEM in FSM either. You didn't see 'em on yours?

Another shot of 'em here:

http://www.zr1.net/forum/attachment.php?attachmentid=3011&stc=1&d=1382397326