In car removal of cam covers

[Mystic ZR-1]

Winter project: powder coat top end
Can the left side cam cover be removed and reinstalled
without disconnecting the AC lines to the compressor?
I know about moving the brake master cylinder etc.
Any tips and tricks?
Thanks!

[We Gone]

Yes just unbolt the AC compressor and move it out of the way some say it is easier if you remove the brake bosster also. . On the right if you look close part of the heater box is removable also.

http://imageshack.com/a/img911/1099/9aQ9Sj.jpg

[Mystic ZR-1]

That makes sense, didn't occur to me to just move it out of the way
once the plenum is off. :o
Thanks!

[Dynomite]

Winter project: powder coat top end
Can the left side cam cover be removed and reinstalled
without disconnecting the AC lines to the compressor?
I know about moving the brake master cylinder etc.
Any tips and tricks?
Thanks!

Be careful when you set AC Compressor aside that you do not upset the AC connections to the Dryer.
You do not necessarily need to remove the Brake Master Cylinder but does help to remove the C-Frame from Transmission so you can tilt/lower the engine.

See Item #1 Removing Cam Covers (Engine In Car) for Inspections of Camshafts (http://forums.corvetteforum.com/c4-zr-1-discussion/3005470-tech-info-lt5-modifications-rebuild-tricks-500-hp-4.html#post1581665190)

[BigJohn]

Winter project: powder coat top end
Can the left side cam cover be removed and reinstalled
without disconnecting the AC lines to the compressor?
I know about moving the brake master cylinder etc.
Any tips and tricks?
Thanks!


SAWZALL???????????

:neutral:

[Mystic ZR-1]

SAWZALL???????????

:neutral:

Bring it to breakfast tomorrow AM

[ZRXMAX]

If I were to do it my approach would be to leave to brake booster alone. Your time and fussing around under the dash will be considerable with R & R. Like Clint said... drop the exhaust, drop the C beam and lower the trans enough to gain access to the rear of the motor. Make sure you have a good torx setup and a sure way to apply pressure down on the cam cover bolts before attempting to unscrew them. I would also soak them for hours with the best loosening agent you can come up with... opinions will vary on what to use. Take your time and good luck with it. A nice powder coated engine is a very gratifying project imho.

[BOB HDZ]

I have never done this but got it from a good source. if you take out the motor mount bolt one at a time & jack the motor up with a piece of wood you can access all the torx bolts!!!

[ZRXMAX]

I have never done this but got it from a good source. if you take out the motor mount bolt one at a time & jack the motor up with a piece of wood you can access all the torx bolts!!!
You only have to much room to go up. It seems you might end up pinching some things.

[Paul Workman]

I have never done this but got it from a good source. if you take out the motor mount bolt one at a time & jack the motor up with a piece of wood you can access all the torx bolts!!!

Likewise... I think it was Jeff Flint that recommended that method, but removing the heater shroud cover is required to allow the motor to be tipped toward the right, IIRC. Maybe some day... Bob G has one of the prettiest powder coats I've seen, if you like silver. It looks (to me) like a tiny silver metal flake. Really nice!

[Mystic ZR-1]

Got some of the stuff back from the PCer!
Couldn't resist sticking it together to see how its gonna look!
Cam covers are off without incident! To PCer after
the holidays.

[BigJohn]

What's that Black thing????

[Hib Halverson]

Before you pull those covers, make sure you understand the procedure to properly seal them when you put them back on.

Also, DO NOT let the powder coater coat the underside of the covers. Any change in thickness of the cover will change camshaft being clearance.

The sealing surface of the covers must stay pristine or bearing clearance will be FUBAR.

[Billy Mild]

What method did you use to remove the cam covers?

If I went through all this work I would definitely have my plenum ported while its off.

[Mystic ZR-1]

A good rap with a drift and a hammer to the bolt heads (to get their attention...) and then use of a hand impact with a tight fitting torx socket to break them loose. All came out without buggering up the bolts or snapping any off.
That's some tough thread locker they used at the factory...

[BigJohn]

What method did you use to remove the cam covers?

If I went through all this work I would definitely have my plenum ported while its off.


Why port the plenum and not the heads?

:cry:

[Paul Workman]

Why port the plenum and not the heads?

:cry:

Yup. A top end porting opportunity presents itself. However, to avoid messing up the paint job, it would have been better to port the plenum (and the IHs too perhaps) before the PC'ing was done (in case something has to be welded as result of punching through one (or more) of the plenum/IH runners).

[Billy Mild]

Why port the plenum and not the heads?

:cry:

I thought the heads flowed pretty well from the factory.

[Paul Workman]

I thought the heads flowed pretty well from the factory.

Considering it is possible with a properly tuned motor with top-end porting and free flowing exhaust to get 390 to 400 wheel hp on stock cams - is a pretty good indication there is a LOT more horsepower to be had by letting it breath better.

[Mystic ZR-1]

Cam covers going to the PCer next week.
How do you remove the secondary timing chain
guide strips?
Any special kind of wire to retain the new foam
filters during reassembly?
Thanks!
OBTW: not a single scratch in the guide strips!

[efnfast]

Cam covers going to the PCer next week.
How do you remove the secondary timing chain
guide strips?
Any special kind of wire to retain the new foam
filters during reassembly?
Thanks!
OBTW: not a single scratch in the guide strips!

How many miles on the motor?
And why are you removing the guide strips?

[Mystic ZR-1]

Not many...
Read it here somewhere to remove
them prior to sending them out for PC
That oven is hot 400 degrees...

[efnfast]

I didn't know there where guide strips in the cam covers.

[Mystic ZR-1]

Take off your oil fill cap and peek in the hole,
you can see part of one of them

[efnfast]

I've spent a lot of time rumaging around in various holes. Never looked in the oil fill hole.

[Mystic ZR-1]

This conversation is going south real fast...
:-D

[Mystic ZR-1]

Cam covers going to the PCer next week.
How do you remove the secondary timing chain
guide strips?
Any special kind of wire to retain the new foam
filters during reassembly?
Thanks!
OBTW: not a single scratch in the guide strips!

[Dynomite]

Cam covers going to the PCer next week.
How do you remove the secondary timing chain
guide strips?
Any special kind of wire to retain the new foam
filters during reassembly?
Thanks!
OBTW: not a single scratch in the guide strips!

Cam Cover Chain Guides clip onto a Chain Guide Holder held on by two small screws. Cam Cover Chain Guides (http://www.zr1specialist.com/HAT%20Web/articles/Upper%20Camshaft%20Chain%20Guide%20Facing%20Failur es.pdf)

I switched from Scotch Brite to Marc Haibeck's new Cam Cover Vent filter material Cam Cover Filters (http://www.zr1specialist.com/HAT%20Web/products/cam%20cover%20filter.htm)

I think any kind of wire the size of a regular paper clip would work fine (bend straight a paper clip and cut so about 3/8 inch of the Paper Clip sticks out each side of the Cam Cover Filter Housing). Insert the straightened Paper Clip after the Cam Cover Filters are installed. Then.....bend each end of the wire sticking out of the Cam Cover Filter aluminum sides about 3/8 inch 90 deg so they will not drift out of place.

http://i287.photobucket.com/albums/ll142/dynomite007/Dynomite3/5507ecfb-7c0a-4330-8ba9-278d953a3d45.jpg

Be sure you do NOT loose those two dowel Pins aligning the Cam Covers with the Heads (one each end of the Head)

See Cam Cover Chain Guides, Filters, and A136 (http://www.corvetteforum.com/forums/c4-zr-1-discussion/3005470-tech-info-lt5-modifications-rebuild-tricks-500-hp-9.html#post1588412799)

Now you can delete your redundant Post #20 :D

[Mystic ZR-1]

Thanks!
A few more questions...
The guide strips "pop" off and the chain guide holder has
screws that can't be seen with the strips in place?
What's the best way to "pop" them off?
I just want to be sure before I screw anything up...
Got the new foam from Jerry.
Should I use A136 on the end plugs when reassembling?
A136 on all machined mating surfaces or just around the
edges and plug recesses? (not on o-rings of course...)
Thanks again for the advice!!!!

[Dynomite]

Thanks!
A few more questions...
The guide strips "pop" off and the chain guide holder has
screws that can't be seen with the strips in place? yes
What's the best way to "pop" them off? Lift up on each end or get a small screw driver tip and push out on tabs on each end under guide.
I just want to be sure before I screw anything up... I do that some times experimenting ;)
Got the new foam from Jerry. :thumbsup:
I use A136 on the end plugs when reassembling? you do not have to put anything on the two guide pins.....but YES on the two rubber end plugs each end (applying the A136 on the grooves in the Head and Cam Covers and NOT on the rubber End Plugs themselves)
A136 on all machined mating surfaces or just around the edges and plug recesses? (not on o-rings of course...)
Exactly except I do not apply A136 in the plug recesses where the "O" rings are placed but DID apply A136 around mating surface just outside of each "O" ring.
Thanks again for the advice!!!!

Apply A136 on the Heads (I actually apply A136 to the Head and not the Cam Cover after DEGREASING the surfaces) and in the grooves of the cam cover rubber end caps on both the Head AND Cam Covers

Make sure you clean the grooves and rubber caps completely before applying A136.....and...NOT TOO MUCH A136.....just use finger and smooth out flat on surfaces of Head. And make sure you have the 4 "O" rings in place set in each recess of the Head (one each spark plug hole).

AGAIN.......apply a small bead of A136 in center of mating surfaces on the Head and then smooth that bead out ALMOST to the edges of those surfaces with your finger (very thin surface of A136 ALMOST to the edges of the mating surfaces). You do not want a lot of A136 squeezed out and into the Head area during assembly of the Cam Covers onto the Heads.

When you get the Cam Covers installed, take a paper towel and wipe clean ANY excess A136 that might have squeezed out on each end of the Cam Covers around the rubber end caps and all around each Cam Cover. There should be not much at all squeezed out if you did not overdo the use of A136. ;)

I do NOT apply A136 beyond the bolt hole on each side of each journal making sure I do not end up with A136 messing with the Cam Shafts. In other words....stay away from the Camshafts journals at least 1/4 inch more or less (I keep A136 just outside of the bolt hole edge) each side of each Journal.

http://i287.photobucket.com/albums/ll142/dynomite007/A%20Engine%20LT5/SCamshafts3_zps5fa9bb0a.jpg

I think I actually did everything above on the Cam Covers and NOT the Heads one time but definitely do not apply A136 on BOTH. Either the Heads OR Cam Covers but not on BOTH. Except where the Rubber End Caps are involved (apply A136 in BOTH Heads and Cam Cover Grooves that take the Rubber End Caps). :D

Cam Covers (Filters and Wear Strips) (http://forums.corvetteforum.com/c4-zr-1-discussion/3005470-tech-info-lt5-modifications-rebuild-tricks-500-hp-5.html#post1581825192)

See Cam Cover Chain Guides, Filters, and A136 (http://www.corvetteforum.com/forums/c4-zr-1-discussion/3005470-tech-info-lt5-modifications-rebuild-tricks-500-hp-9.html#post1588412799)

[BigJohn]

I got some dumb questions, but I think I'll ask Mike Z!!!!

[Dynomite]

I got some dumb questions, but I think I'll ask Mike Z!!!!

Just ask the questions here and I WILL NOT post.
I will just observe :D
Who is Mike Z? ;)

[BigJohn]

Just ask the questions here and I WILL NOT post.
I will just observe :D
Who is Mike Z? ;)

GM Callaway Cars!;)

[Mystic ZR-1]

Big John
The only dumb question is one that's not asked!
:dancing
Doug

[Mystic ZR-1]

OK...
The p/s guide strip popped right off 'cause you
can get behind it with a screw stick through the oil fill hole.
Not so on the d/s. Any suggestions (except from Big John) :dancing
on how to get it off without destroying it?
Looks like they used a bit of sealant on the underside
of the strip, what kind? Locktite 262 on the screws when reinstalling?

[A26B]

OK...
................................
Not so on the d/s. Any suggestions (except from Big John) :dancing
on how to get it off without destroying it?
Looks like they used a bit of sealant on the underside
of the strip, what kind? Locktite 262 on the screws when reinstalling?

Don't laugh too hard...... I use a big nail. like a 10 penny. Clamp the nail body with vise grips. Then, just hook the head of the nail on the underside of the end of the facing, then pull out & up at the same time. Pops right off for me.

Yes, Loctite 262 on the 2 Guide screw/bolts.

[Mystic ZR-1]

Jerry
Thanks!
I'll try that in the AM. Sounds like it'll work just fine.

[Dynomite]

OK...
The p/s guide strip popped right off 'cause you
can get behind it with a screw stick through the oil fill hole.
Not so on the d/s. Any suggestions on how to get it off without destroying it?
Looks like they used a bit of sealant on the underside
of the strip, what kind? Locktite 262 on the screws when reinstalling?

Well....if the Passenger side popped right off most likely they are not glued on the metal strip too tight.....I have not heard of those guide strips being glued on the metal strips in any way :p

Like Jerry says.....get under the plastic guide somehow and pry out on the clip if you can. Use RED Loctite on the two screws when you re-install the metal holder strips. Then clip on the plastic guides making sure you did not damage the clips in any way when you removed them.

And yes...prolly best to remove those metal holder strips before PC as the heat may change the original Loctite used on the two screws of each strip.
You can then use fresh red Loctite like Jerry suggests on the two screws when you reinstall the metal holder strips after PC.

Jerry has the Cam Cover Chain Guide Facings as well as the Metal Holder Strips Cam Cover Chain Guide Facings (http://www.jerrysgaskets.com/facing-top-guide-cam-cover-used-90-95-6d1/)

[Mystic ZR-1]

Had to go out to the garage tonite on a different mission.
Couldn't resist trying your suggestions...
Never got to that different mission, it can wait.
Came right off! Thanks guys!
What looks like a small dab of sealer on the back of the strips
is locktite that must have oozed out on original assembly
back in May of 1990.

[BigJohn]

Don't forget to check the oil in the BMW!

[Mystic ZR-1]

Don't forget to check the oil in the BMW!

Now John, that's good advice!

[Dynomite]

Don't forget to check the oil in the BMW!
Engine Oil? :thumbsup:

Have a Great New Year John :cheers:

Take some photos after the PCing is complete and especially after the Cam Covers are Re-Installed Mystic ZR-1

And a Great New Year to ALL :handshak:

Oh....almost forgot.....Are you using Jerry's SS Allen Head Bolt Sets when you re-install (they go great with a New Powder Coating)?

Plenum (http://www.jerrysgaskets.com/bolt-set-intake-plenum-stainless-steel-90-95-9b4/)
Cam Cover Front (http://www.jerrysgaskets.com/bolt-set-cam-cover-front-stainless-steel-90-95-2e4/)
Cam Cover (http://www.jerrysgaskets.com/bolt-set-cam-cover-stainless-steel-90-95-2d3/)
Coolant Manifolds (http://www.jerrysgaskets.com/bolt-set-coolant-outlet-pipes-stainless-steel-90-95-2e4/)

[Mystic ZR-1]

The Bride's 3 Series has a small oil leak at the oil filter housing.
I don't do Bimmers...
Jerry's SS bolts are part of the plan, they'll look great with
the bright red covers!

[Mystic ZR-1]

Getting there...
PCing all done!

[efnfast]

Getting there...
PCing all done!

BABY, that looks good!

[USAZR1]

Oh Yeah,you do nice work!

[nelson007]

Looks great.

Nelson

[Dynomite]

Getting there...
PCing all done!

Great Job :thumbsup:

The Red Trim makes you a member of the Red Stripe Club :D
XfireZ51, Dynomite and now you.

I am doing another Top End Red Stripe today ;)

http://i287.photobucket.com/albums/ll142/dynomite007/A%20Corvette%20LT5%2090/37cdb647-2dda-449e-8d0d-57905f95ecfd.jpg

Is that Red Stripe around the Air Horn Painted or taped stencil?

http://i287.photobucket.com/albums/ll142/dynomite007/Dynomite9/192c7622-c7bf-4ebb-b4e1-16e41182b4ec.png

[We Gone]

Looks great, can't wait to see the finished pics.

[Mystic ZR-1]

[QUOTE=Dynomite;218323]Great Job :thumbsup:

The Red Trim makes you a member of the Red Stripe Club :D
XfireZ51, Dynomite and now you.

I am doing another Top End Red Stripe today ;)


Is that Red Stripe around the Air Horn Painted or taped stencil?

Dom's plenum was the inspiration, thanks Dom!
The airhorn stripe is just vinyl pinstripe tape to see what it would look like,
probably won't stay.

[BigJohn]

Is that the correct color Red?

[Dynomite]

Is that the correct color Red?

In this regard....ANY color is the correct color :p
I use Torch Red or Regal Red and both are correct for the LT5 Plenum Red Stripe ;)

[BigJohn]

I guess, I will need to see it live; looks kind of light or pink on this monitor!!!

[Mystic ZR-1]

John
You're looking thru bloodshot eyes again...
The red matches the rest of the car "Bright Red"
GM was pretty clever when they came up with that name...
D. :dancing

[BigJohn]

Gee, I slept in today; Got up at 03:45!!!

[efnfast]

That throttle body plate show up yet? Looking for some assembled pic's!

[efnfast]

What's the latest? Been busy shoveling?

[Mystic ZR-1]

About 20 inches of snow here in the Miami of New England, hard to tell due to drifting from the 40 knot winds!
The Z and all the PCed parts are awaiting in the garage... (which had a 4 foot drift in front of it!)
GO PATS!!!!!!!!!!!

[BigJohn]

About 20 inches of snow here in the Miami of New England, hard to tell due to drifting from the 40 knot winds!
The Z and all the PCed parts are awaiting in the garage... (which had a 4 foot drift in front of it!)
GO PATS!!!!!!!!!!!

It took me two and one half hours to clear my brothers drive from street to garage doors. I put all the snow in front of the vacant house next door.

:rolleyes:

[Z06scentair]

What's this snow everyone's talking about?

We got a sprinkling on rain here today.

[Mystic ZR-1]

It took me two and one half hours to clear my brothers drive from street to garage doors. I put all the snow in front of the vacant house next door.

:rolleyes:

Which plow truck were you using or was it just a shovel? ;)

Breakfast Saturday 0830 Goodies Rt2 NS ... If you're plowed out that is...

[Mystic ZR-1]

My Bride's getting sick of the cam covers being on display on the dining room table
for the last month or so... I don' t understand, they're beautiful? At least she doesn't have to look at the plenum etc too, I removed them from the DR table to the garage so we could have Xmas dinner a while back. No, the cam covers didn't share Xmas dinner, they were still at the PCer.
I guess I'll slog thru the snow out to the garage soon and start putting things back together.
I'm sick of Winter and being on a 1st name basis with my snowblower and snow shovel! :cry:

[efnfast]

You could have to deal with my driveway.

[Mystic ZR-1]

You could have to deal with my driveway.

There's always a bright side! ;)
Well, maybe not for you in this case...
:cry:

[efnfast]

68" snow blower man!!

[tomtom72]

68" snow blower man!!

:notworthy Now that's what I'm talkin' about!


Doug, what it be lookin like for a reassembly date? Sometime in March sound good to you? Did you put the top end back on yet?

:cheers:
Tom

[Mystic ZR-1]

Port side cam cover went on today with no issues, Starboard side tomorrow! Saving most of the rest for when Tom Tom comes back, he fits under the dash better than I do to rehook the brake master cylinder and booster etc, Thanks Tom! :cheers:
It's gonna look great!
Had to quit procrastinating so I borrowed an extra propane heater and the garage can be made "toasty" now!
The propane heater works great along with the kerosene heater, even with the windows cracked! Garage started at 24 and was up to 80 in an hour or so! Ran a small electric space heater under the oil pan all last nite so the motor was warm in the morning, don't feel comfortable about torquing on a 24 degree motor.

Bride's happy! The cam covers are off the dining room table!
Well, actually only one, the other will be off the table tomorrow morning...

[edram454]

missing the cold. out winter is over in miami. 83 today and sunny.

[efnfast]

missing the cold. out winter is over in miami. 83 today and sunny.
Come on up, it's 10 out this morning. At least it's 10 above. 22 below the other morning.

[WARP TEN]

missing the cold. out winter is over in miami. 83 today and sunny.

Miss you too, Ed. Wish you were here. Minus 2 this morning. --Bob

[BigJohn]

missing the cold. out winter is over in miami. 83 today and sunny.

Cool, did you get the new car???

:-D

[edram454]

Miss you too, Ed. Wish you were here. Minus 2 this morning. --Bob

You guys are soldiers. I dont know how you stand it so cold for so long. I have never lived in a cold climate. I have worked in some very cold places -6, 0, etc.. in my travels but never day to day living. Let me tell you, the dog days of summer in Miami are just as grinding as your frigid days up there. I dont know what is worse?

ed ramos #3028:confused:

[efnfast]

The heat is worse. These days, 30 is t shirt weather

[Gunny]

Consider relocating to the north Georgia mountains ...

A/C rarely needed in the summers
Winters usually mild (just enough snow to be enjoyable)
Spring is delightful
Fall foliage is outstanding (have to go to New England to see better)

Almost forgot ... exceptional mountain roads that are perfect for the ZR-1

[Mystic ZR-1]

Gunny
You're right about the roads!
One of my fondest memories is chasing you around
on them during MR2!
More snow here in the Miami of New England
tomorrow nite...:mad:

[efnfast]

Hey Doug, I generated 107 KW of solar electricity today. (yea for me)

[Mystic ZR-1]

Well it's all back together!
Looks great and it actually runs!
Big thanks to Tom Tom, Big John, Rod (ZR-1 owners)
and Flyin Brian (C6 Z06) for help putting it
back together! That's TomTom on the plenum...
Now if Winter would just go away...

[efnfast]

Wow, that looks great Doug!

[tomtom72]

Well, at least the photo doesn't show me with a case of "plumber's butt"! :sign10:

Oh, you're welcome Doug! Glad to be of assistance.:handshak:

[Dynomite]

Well, at least the photo doesn't show me with a case of "plumber's butt"! :sign10:

Oh, you're welcome Doug! Glad to be of assistance.:handshak:
I have removed Plenums but never sat on one :D
Great job Tom :thumbsup: