Photo of Vacum lines After removing secondaries 1994 !!

[5ABI VT]

I have to admit this part of the job when pulling the plenum nearly scared me to death. It was a total maze of hoses and it was a contributing factor in me going so slow for sure just because it was a little disheartening thinking about trying to put it all back together :neutral:

I asked several people and thanks to everyone for the input. I just wanted to share a photo and ask if this looks right? and leave it here for anyone looking to do the removal in the future to know how simple it really is (assuming its right :) )

ANyhow, about to put the fuel rails/injectors on tonight and the plenum too. I did do a little rerouting (my secrets out ;) ) that I had intended for a while but I still plan to do a lot of rerouting of vaccum lines etc underhood to get the engine bay looking the way I want. Of course the triple catch can setup wont be easy to hide but I have a few ideas.

SO for the photo.. I tried highlighting all the remaining stuff under the plenum. This is majorly simple now in my mind (as most things after doing it once its all downhill from there) I noticed a few 90 degree bends had cracks and I swapped from some of the removed lines and then on most connections used some adhesive backed shrink wrap with the thought that if there was any vaccum leak the adhesive would fill any cracks etc.

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/hoseslt5sans2nds_zpsee37112d.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/hoseslt5sans2nds_zpsee37112d.jpg.html)

Look right to you guys? Definitely simplifies things under the plenum ! I kept looking for photos thinking there was more :dancing

[Scrrem]

Yeah, that looks about right. That is what I am looking forward to when I get my new motor in (with no secondaries). I have also removed all the air pump sytem stuff too, but sill need to get the secondary vacum pump and lines out. I did break a vacum line going to the criuse control, need to find a way to repair that.
Rich

[secondchance]

I got rid of Evap also.
Mine is a 94 as well.

[Paul Workman]

A LOT less cluttered with the evap and secondaries stuff outta thar!

http://i185.photobucket.com/albums/x220/6PPC_bucket/tech%20files/ZR-1009.jpg (http://s185.photobucket.com/user/6PPC_bucket/media/tech%20files/ZR-1009.jpg.html)

[5ABI VT]

Evap is something that can be tuned out I think ? I'm not sure if I had asked for it to be turned off but I can't really see much of an advantage from not having the line be drawn Into the plenum vs leaving the line to vent open ?

[5ABI VT]

On second thought.. Both of those big lines are eliminated by turning it off. Hmm.. What did you do with the hose ? Vent it at the rear or plug it ?

[Dynomite]

Ya.....But.......it turns out that fixing Secondary Vacuum leaks is pretty simple and only takes a few minutes (that is including removing the Plenum) :D

But you got to have your TB Coolant Blocked at the Injector Housings both sides which is a pretty simple modification.

My secondaries function perfectly and probably will be maintenance free for a long time as there really is not much to go wrong.

I happen to like that Functional Full Power Key which is one of the unique features of ANY ZR-1 :thumbsup:

Same goes with the Charcoal Canisters which I installed new Canisters.

A LOT less cluttered with the evap and secondaries stuff outta thar!

http://i185.photobucket.com/albums/x220/6PPC_bucket/tech%20files/ZR-1009.jpg (http://s185.photobucket.com/user/6PPC_bucket/media/tech%20files/ZR-1009.jpg.html)

[Paul Workman]

Ya.....But.......it turns out that fixing Secondary Vacuum leaks is pretty simple and only takes a few minutes (that is including removing the Plenum) :D

Secondaries? SECONDARIES??? WEE DOAN NEED NO STEEKING SECONDARIES!!

Besides...where would you put them little bastards, anywho? (The ball = 37.5, but the "hole" is tapered. The opening was opened to ≈ 38.0 ish.)

http://i185.photobucket.com/albums/x220/6PPC_bucket/tech%20files/Headporting1.jpg (http://s185.photobucket.com/user/6PPC_bucket/media/tech%20files/Headporting1.jpg.html)


But you got to have your TB Coolant Blocked at the Injector Housings both sides which is a pretty simple modification.

Yep! Chops off a good 20 minutes, waiting for the antifreeze to drain a bit, and then reinstalling it...WITHOUT no steeking air pockets...:mad:

My secondaries function perfectly and probably will be maintenance free for a long time as there really is not much to go wrong.

Randy Travis sang it best (about secondary delete...)

Go on, go on
'Til you've reach the end of the line
'Cause I know you'll pass my way again
It's just a matter of time

Yep...My secondaries work perfectly...NEVER fail...NEVER need servicing...(don't exist, tho I keep the POWER switch around for a conversation piece** :p)

I happen to like that Functional Full Power Key which is one of the unique features of ANY ZR-1 :thumbsup:


Same goes with the Charcoal Canisters which I installed new Canisters.

Mine, being a '90, WAS in the front driver's corner...the corner that got smushed in my little flying (or rather LANDING) episode. Gone forever now!

**Note: The 90s use a mechanical switch with all the lovely advantages (HA!) of contacts and spring tension and dirt which was replaced by a PCM latch in 91+ cars. IF the POWER switch were to open, and shut the secondaries off on a "secondary-delete" car, a serious lean condition would result, as half of the fuel would be shut off. Soooooo.... I hard-wired the dang thing so that the switch function is bypassed: NO chance of the secondaries being shut off by that switch through accident or mechanical reasons, boy-yo-boy! You'd LOVE the throttle response with the 2nd's open all the time, I'll betcha!;)

[Dynomite]

Mine, being a '90, WAS in the front driver's corner...the corner that got smushed in my little flying (or rather LANDING) episode. Gone forever now!

**Note: The 90s use a mechanical switch with all the lovely advantages (HA!) of contacts and spring tension and dirt which was replaced by a PCM latch in 91+ cars. IF the POWER switch were to open, and shut the secondaries off on a "secondary-delete" car, a serious lean condition would result, as half of the fuel would be shut off. Soooooo.... I hard-wired the dang thing so that the switch function is bypassed: NO chance of the secondaries being shut off by that switch through accident or mechanical reasons, boy-yo-boy! You'd LOVE the throttle response with the 2nd's open all the time, I'll betcha!;)

Good Information on the mechanical switch....I have to check that out a bit more as my three 90's apparently have that mechanical type switch.
Oh....did I admit it.....my 91' has NO secondaries so I am with you in that regard ;)

Can I assume when the little Dash says FULL POWER....I am good to go with Full Power and Secondaries Functional (I did notice that fiddling with the Full Power Switch turns that indication light on and off if the switch is not set just right on the 90's)?

I like the little challenge of keeping the secondaries functional on my 90's :dancing

On the 90's my Full Power Switch is NOT just for looks and as for Throttle Response....WOWZA.......on ALL 90's (Same goes for 91') :sign10:

I guess there is more than one way to get rid of the Charcoal Canister on the 90's :D

[Hog]

Question: Why are you guys deleting the TB coolant supply?

I remember the supposedly cooler intake charge, but there was a more relevant reason that I cant remember.

[5ABI VT]

Question: Why are you guys deleting the TB coolant supply?

I remember the supposedly cooler intake charge, but there was a more relevant reason that I cant remember.

I think Paul covered it above. When there's a need to do maintenance or check for leaks etc, plug wires, coils, starter etc.. No need to drain coolant

[Scrrem]

Nice clean look too!!
Rich

[5ABI VT]

Nice clean look too!!
Rich

Very nice !! =D> Im not deleting the coolant lines just yet. when I decide to PC the top end and valve covers a different color then Ill pull the fittings out and weld/fill them so its a clean look.

[Dynomite]

Very nice !! =D> Im not deleting the coolant lines just yet. when I decide to PC the top end and valve covers a different color then Ill pull the fittings out and weld/fill them so its a clean look.

You can leave everything showing the way it is now. The only two fittings you install are two 1/8 inch aluminum NPT Pipe Plugs after tapping the Injector Housings Coolant Ports. Install 1/8 inch NPT allen head pipe plugs (21/64 or 11/32 drill) two each Injector Housing (IH) Coolant as shown.

Photo by Ccmano
http://i287.photobucket.com/albums/ll142/dynomite007/Dynomite2/4babdb09-1279-4cb9-ac66-b755797df488.jpg

Remove Plenum and Block TB Coolant at Injector Housing (LT5 will have TB Coolant Blocked but Undetected and engine appears stock).
This will require you insert a plug in the Coolant Return Line on the Passenger side of the Plenum (the only TB Coolant Hose that requires a hose clamp).

http://i287.photobucket.com/albums/ll142/dynomite007/Dynomite9/9eabe7b5-5f0c-48eb-aa6d-835c16de2400.jpghttp://i287.photobucket.com/albums/ll142/dynomite007/Dynomite9/2e6bf71e-50f5-43f9-8328-194dba854f45.jpg

See Summit Racing 1/8 inch Aluminum Pipe Plugs (http://www.summitracing.com/parts/SUM-G1485R/) for Aluminum Pipe Plugs. When you install the plugs.....keep trying the plugs as you tap to make sure the final installation is flush and use Red Loctite on the plugs..

See Item #4 LT5 Eliminated Systems (http://forums.corvetteforum.com/c4-zr-1-discussion/2942569-tech-info-lt5-eliminated-systems.html)

See Item #3 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)

[WydGlydJim]

Very nice !! =D> Im not deleting the coolant lines just yet. when I decide to PC the top end and valve covers a different color then Ill pull the fittings out and weld/fill them so its a clean look.


What are these valve covers you speak of?
;)

[Dynomite]

What are these valve covers you speak of?
;)

Ha........ya.......you have a point :handshak:
Thought I would add some technical information when we are at it....could be wrong but prolly right.....or left :D

The covers over the valves which some of us call Cam Covers ;)

Which Valve Covers or Cam Covers are NOT interchangeable from engine to engine or left to right :p

The Valve Covers or Cam Covers are apparently line bored in place on the heads for the Cams I am thinking.
Each Valve Cover or Cam Cover having two dowel pins for exact positioning on Each Head.

[5ABI VT]

I seem to be confused with the line at the back of the plrnum. Where does it connect to ? Not the fuel pressure hose or brake booster connection.. There is one that goes straight out the back of the plrnum .

[Mystic ZR-1]

MAP sensor

[5ABI VT]

Thank you ! Was taking my time going over remaining parts and saw it :) just need to hear shrink the hoses and reassembly is almost done !!

[5ABI VT]

There is a something bolted to the plrnum ahead of the ignition module. It has a nipple on it does this connect to anything ?? Pic inc

[5ABI VT]

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/CE9AC191-B16F-404C-8287-89393C2090F1_zpsu1njubag.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/CE9AC191-B16F-404C-8287-89393C2090F1_zpsu1njubag.jpg.html)

[5ABI VT]

Think I found it. Looks like a vaccum line connects to here from the secondary vaccum actuators. Since I've phlled the secondaries and lines.. I'm guessing I should plug it so it would think the vaccum is holding or does it matter ?

[Dynomite]

I think that is the Diagnostic Vacuum Sensor (Manifold Differential Pressure Switch) which is normally under the ECM on 90's and 91's. Apparently that is under the Plenum on the 94?

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/CE9AC191-B16F-404C-8287-89393C2090F1_zpsu1njubag.jpg

Diagnostic Vacuum Sensor (Manifold Differential Pressure Switch) on a 91' located under the ECM
vacuum connection left open with elimination of secondary vacuum system.
http://i287.photobucket.com/albums/ll142/dynomite007/LT5/diagnosticvacuumsensor.jpg

Leave that Diagnostic Vacuum Sensor (Manifold Differential Pressure Switch) Vacuum open (unplugged). The vacuum line from the Drivers Side vacuum canister has a "T" from which a vacuum line was connected to this Diagnostic Vacuum Sensor .

Secondary Vacuum System
http://i287.photobucket.com/albums/ll142/dynomite007/LT5/SecondaryVacuumSys.jpg

The Differential Pressure Switch looks a lot like the MAP (Manifold Absolute Pressure) bolted to the rear of the Plenum having this vacuum line attached.

http://i.ebayimg.com/00/s/Njc1WDkwMA==/$(KGrHqR,!lQE6CCE(KtEBOiK65OWMg~~60_57.JPG

[5ABI VT]

Thanks ! I was wondering if the connection should have vacuum or left open etc. Since there is a nipple left open on the drivers side from secondary removal I was thinking I could route a hose into there if required. Sounds like Ill leave it open.

view a little further back of where its mounted on my 94.

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/62770149-581B-4A7F-ABF5-7AFAE40E71A6_zpsyaridf6e.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/62770149-581B-4A7F-ABF5-7AFAE40E71A6_zpsyaridf6e.jpg.html)

[Dynomite]

Thanks for that photo...good stuff to know...another little difference between model years :handshak:

Thanks ! I was wondering if the connection should have vacuum or left open etc. Since there is a nipple left open on the drivers side from secondary removal I was thinking I could route a hose into there if required. Sounds like Ill leave it open.

view a little further back of where its mounted on my 94.

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/62770149-581B-4A7F-ABF5-7AFAE40E71A6_zpsyaridf6e.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/62770149-581B-4A7F-ABF5-7AFAE40E71A6_zpsyaridf6e.jpg.html)

[5ABI VT]

Thanks for that photo...good stuff to know...another little difference between model years :handshak:

Ill snap a photo of the vaccum line. It looks like a spiral like the evap that goes to the plenum but a smaller diameter.

Im just curious about leaving the connection open... would that not tell the ecm that there is no vaccum ? Would it cause the pump to run non stop? Or is all this removed in the chip when programmed to run with no secondaries? I did ask Marc as well if it was as he did do my chip for secondary removal. Im just curious about its function.

[Dynomite]

Ill snap a photo of the vaccum line. It looks like a spiral like the evap that goes to the plenum but a smaller diameter.

Im just curious about leaving the connection open... would that not tell the ecm that there is no vaccum ? Would it cause the pump to run non stop? Or is all this removed in the chip when programmed to run with no secondaries? I did ask Marc as well if it was as he did do my chip for secondary removal. Im just curious about its function.

Marc Haibeck has mentioned to me and to Paul that port can be just left open. Marc can modify a Chip to account for secondaries eliminated. I think you WILL NEED that chip.

[5ABI VT]

Marc Haibeck has mentioned to me and to Paul that port can be just left open. Marc can modify a Chip to account for secondaries eliminated. I think you WILL NEED that chip.

Oh sorry I just typed it all wrong, I DO have a chip for eliminated secondaries I was just wondering if turning off this sensor was already a part of it.

[Dynomite]

Oh sorry I just typed it all wrong, I DO have a chip for eliminated secondaries I was just wondering if turning off this sensor was already a part of it.

I am not sure if that is required in the chip or just not required to do anything with that open port. I am sure that vacuum port on the Differential Pressure Switch is just left open in any event.

I could plug that vacuum line on my 90' and leave that Differential Pressure Port OPEN and see what happens easy enough since that Differential Pressure Switch is under the ECM :D

This is on my 91' with Secondaries Eliminated. You see the open port on the Differential Pressure Switch.
http://i287.photobucket.com/albums/ll142/dynomite007/LT5/diagnosticvacuumsensor.jpg

[GOLDCYLON]

A LOT less cluttered with the evap and secondaries stuff outta thar!

http://i185.photobucket.com/albums/x220/6PPC_bucket/tech%20files/ZR-1009.jpg (http://s185.photobucket.com/user/6PPC_bucket/media/tech%20files/ZR-1009.jpg.html)

Clean Clean Clean Paul ! :)

[Dynomite]

Ill snap a photo of the vaccum line. It looks like a spiral like the evap that goes to the plenum but a smaller diameter.

Im just curious about leaving the connection open... would that not tell the ecm that there is no vaccum ? Would it cause the pump to run non stop? Or is all this removed in the chip when programmed to run with no secondaries? I did ask Marc as well if it was as he did do my chip for secondary removal. Im just curious about its function.

Yes....a photo of the spiral vacuum line would be great. You got me thinking of the differences in the LT5 by model year which differences are relatively minor but important for those purchasing components. I am starting a list of those LT5 Component Differences by year with photos.

Differences between LT5 Components by Year (http://www.corvetteforum.com/forums/c4-zr-1-discussion/3005470-tech-info-lt5-modifications-rebuild-tricks-500-hp-8.html#post1587653786)


**Note: The 90s use a mechanical switch with all the lovely advantages (HA!) of contacts and spring tension and dirt which was replaced by a PCM latch in 91+ cars. IF the POWER switch were to open, and shut the secondaries off on a "secondary-delete" car, a serious lean condition would result, as half of the fuel would be shut off. Soooooo.... I hard-wired the dang thing so that the switch function is bypassed: NO chance of the secondaries being shut off by that switch through accident or mechanical reasons, boy-yo-boy!


I have to include this also as a change from 90' to 91'.

[5ABI VT]

Yes....a photo of the spiral vacuum line would be great. You got me thinking of the differences in the LT5 by model year which differences are relatively minor but important for those purchasing components. I am starting a list of those LT5 Component Differences by year with photos.

Differences between LT5 Components by Year (http://www.corvetteforum.com/forums/c4-zr-1-discussion/3005470-tech-info-lt5-modifications-rebuild-tricks-500-hp-8.html#post1587653786)



I have to include this also as a change from 90' to 91'.


Here's a photo of the spiral line
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/BB1D7ED2-DE8E-4099-8667-D5ABABEBDEE0_zpsofj1skjx.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/BB1D7ED2-DE8E-4099-8667-D5ABABEBDEE0_zpsofj1skjx.jpg.html)

[Dynomite]

WOW....thanks....and I assume that is a plastic line that fits one end into the rubber "T" near the drivers side Canister vacuum line. The other end I am assuming has a rubber adapter that fits on the line one end and on the nipple of the Differential Pressure Switch? :thumbsup:

And it appears the Evap Purge Canister you have on a 94' I assume behind passenger wheel like on 91'........has a coil of plastic tubing under plenum similar to the Differential Pressure Switch coil of plastic tubing. That coil of plastic tubing for Evap Purge connected under front of Plenum Vacuum source. So....for a 94' a BIG mess under Plenum :D

Here's a photo of the spiral line
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/BB1D7ED2-DE8E-4099-8667-D5ABABEBDEE0_zpsofj1skjx.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/BB1D7ED2-DE8E-4099-8667-D5ABABEBDEE0_zpsofj1skjx.jpg.html)

[5ABI VT]

WOW....thanks....and I assume that is a plastic line that fits one end into the rubber "T" near the drivers side Canister vacuum line. The other end I am assuming has a rubber adapter that fits on the line one end and on the nipple of the Differential Pressure Switch? :thumbsup:

And it appears the Evap Purge Canister you have on a 94' I assume behind passenger wheel like on 91'........has a coil of plastic tubing under plenum similar to the Differential Pressure Switch coil of plastic tubing. That coil of plastic tubing for Evap Purge connected under front of Plenum Vacuum source. So....for a 94' a BIG mess under Plenum :D

Exactly! The evap spiral tubing is much thicker I'll put a side by side photo shortly.