Newbie needs help alternator maybe

[QMCMSS]

I think I'm getting electrically screwed. 1991 ZR1 with 51k miles I bought it about a month ago, Symptom, about 2 weeks ago I go to start her up after stopping at the store and I had no as in zero electrical power the car ran fine ten minutes before. Called my buddy to bring my jumper box as I assumed the new battery had gone dead. While waiting for him I give it another try and varoooom the world is wonderful. Probably should have put the meter on it when I got home but things looked good and the voltmeter on the dash indicated I was charging. I used the car a little over the next 2 weeks and everything seemed fine. Went cruising yesterday and made a few stops. Kept a close eye on the voltmeter and everything looked normal throughout the day. Also noticed that my after market sound system was having problems kind of reminded me of a skipping record, hindsight makes me think it was loosing power for a nano second. After my last stop the skipping got worse and the car began to sputter, I think I was running on the battery, a quick look at the dash meter and she indicates trouble only a little more than 8 volts. And of course she shuts down in traffic. Call AAA the car starts with a jump but quickly starts to sputter and I have her towed home. Once she is safely in the garage I open a bottle of bourbon and opt to deal with the problem the next day. So here I am battery voltage was low this morning so I've got her on the charger and will check alternator output after the charge. I'm thinking the alternator died a slow death and I will have to replace it. So after looking at a number of posts it looks like I'm in for my first plenum pull. If my alternator diagnosis is correct while I have the plenum off I wondering what else I should do and what parts do I need to assemble before I get started, again after reading a few posts I'm guessing coils and injector upgrades are in order, also the posts indicate that getting the correct alternator may not be as simple as I wish. Any help or suggestions etc. would be much appreciated.

[Mystic ZR-1]

The alternator can be removed without a plenum pull.
The correct replacement can be obtained along with a lot
.of good advise from Jerrys Gaskets

[batchman]

Perhaps our story will be of help.

Bought 91 ZR-1 and struggled with several electrical issues. Turned out the stereo installer had used an inch adapter in the metric battery. Removed stereo power (this is a race car, still need to remove the stereo "ballast") and replaced the battery, ditched the adapter and used a correct bolt - all is good.

Good luck, I think you'll be back to enjoying a bourbon shortly.
- Jeff

[QMCMSS]

Ok after several cups of coffee reading some more posts and some testing things don't look as dark. Pretty convinced that it's defenitly the alternator . After fully charging the battery voltmeter reads 12.6V with everything off and the engine started right up meter reads 12.2 with the engine running definetly not the 14.5 I would get if the alternator was working dash voltmeter looks like around 10 and the battery red light is on in the instrument status display. So I'm going with alternator. Found a very detailed post on how to, need to learn how to loosen the belt and I'm gonna go for it. Is their a definiteve answer to "where can I buy a replacement.

[QMCMSS]

Trying to tackle alternator removal myself without removing the plenum. Someone wonderful sent me a step by step and I had to skip step 1: Remove the air horn. Followed the remaining steps and the alternator is ready to come out but not until I remove the air horn. I removed 4 torx screws 2 external and on the top of the airhorn and 2 inside the horn on the bottom. The sucker won't budge. Pretty sure their is something else holding it on but can't for the life of me figure or see what it is. Really could use a step by step for air horn removal if it exists. Is there a gasket between the horn and the plenum that could have to much sealant. I looked at trying to pry it loose but don't want to damage the horn or plenum. Just think I'm missing something. Tried tapping it with a rubber mallet but no joy. Hopefully something easy that I just can't see. Thanks in advance for your help.

[We Gone]

Yes there is a gasket it may be just stuck from time, no sealer.

http://www.jerrysgaskets.com/gasket-throttle-body-to-air-horn-90-95-11d6/

[A26B]

There are 4 bolts inside. Disregard the very small hole in the gasket.


http://cdn3.bigcommerce.com/s-nkg90o/products/256/images/544/10067759_R_Air_Horn_to_TB__46923.1413928844.1280.1 280.JPG?c=2

[QMCMSS]

awesome help. I can see the other two will report back on progress. Thanks

[QMCMSS]

It's out new one on the way from Jerry's gaskets. Discovered a small oil leak looks like it's coming from the oil filter housing. Gonna check the forum to see if anyone has a similar issue and how to repair it.

[QMCMSS]

DONE new alternator in thanks for the tips.

[QB93Z]

WELL DONE! Now you are the expert for the next guy that has electrical problems.

I am a retired Submariner. CO-632G, XO-643G, Eng-686, JO-605. What boats did you serve on Master Chief?

Jim Voter

[QMCMSS]

Ahoy Captain, Thanks for the Bravo Zulu, I started on diesels SS337 and SS339, then on to SSN588, SSN591, SSN603, SSN612, and then COB on the Barb SSN596 where I had the honor of serving under John Grossenbacher a name you might be familiar with. Mixed in the somewhere was a tour on Enterprise with a submarine detachment coordinating the use of LA Class SSN's supporting carrier battle groups and a tour at CSSIII. My final tour was CMC at Mare Island where I retired in 98. Thirty years of Summer Camp!:saluting:

[Paul Workman]

Ah! Danged 'sewer pipe sailors'...muckin' up the decks again - fresh outa their 'hot rack' and full of themselves...as Usual! (LOL!)

USS Horne DLG 30

I told Jim, the most sobering photo I ever saw was posted in Sonar Ops, taken of the ship through a periscope during an ASW exercise off San Diego. (You could make out people walking around on the main weather deck. Someone wrote "Sweet Dreams!" on the bottom with a magic marker...(shiver...)). I'm glad now my biggest worry is if my primary pump quits and I don't have a jumper!

[Mystic ZR-1]

Paul, as the Captain and I told you at the NCM:
There's 2 kinds of ships, submarines and targets...
:salute:

[QB93Z]

That is quite a career Master Chief. All boats that were run by real men, working hard to complete their mission. Remember when a Bearing Rate Computer didn't have batteries, it was just two plastic discs? Well Done.

Jim

[QMCMSS]

Thanks again Skipper as COB I developed a great relationship with my CO. I don't know that I could possibly respect anyone more then the Commanding Officer of a nuclear submarine. The day to day decisions and the overwhelming amount of responsibility, and knowledge required was mind blowing. I can't imagine a more challenging or rewarding career opportunity in any line of work. With all sincerity Sir God Bless you and thank you for your service. That said I think I'm gonna take the top off and take the lady for a wild ride in the wine country.

[Z51JEFF]

awesome help. I can see the other two will report back on progress. Thanks

Im in Fremont if you want a hand rebuilding the old ALT. I wouldn't let it go as a core.

[QMCMSS]

Might take you up on it. Never rebuilt one before I got my replacement from Jerrys Gaskets but might be a smart Idea to rebuild the old one for a backup.

[Z51JEFF]

Might take you up on it. Never rebuilt one before I got my replacement from Jerrys Gaskets but might be a smart Idea to rebuild the old one for a backup.

The biggest challenge is getting the 4 bolts in the housing loose without breaking any. I've got the one that came out of my car at 8000 miles with one of the bolts broken, I have no idea as to how to get it out without raping the case.

[jrd1990zr1]

The alternator can be removed without a plenum pull.
The correct replacement can be obtained along with a lot
.of good advise from Jerrys Gaskets


Although it is possible to switch out without pulling the plenum it is far easier to pull the plenum and switch it out. Last year in Carlisle, Mystic, Jim Voter and I changed one out in the hotel parking lot without pulling the plenum. I think it was more difficult this way. I would still be in Carlisle if it wasn't for them.

Good Luck. :handshak:

[BigIke]

EX-NAVY Engineman and Fairbanks Mores Engine mechanic... You had those engines on your sub... :)

[QB93Z]

EX-NAVY Engineman and Fairbanks Mores Engine mechanic... You had those engines on your sub... :)

Yes, we did run FM diesels. On a nuclear submarine, the diesel was one of our backup power sources, about 650 KW if I remember correctly. I spent a lot of hours as a Junior Officer learning how to operate and maintain that engine.

I hope the Phil (jagdpanzer) will chime in, he is an ex-Navy Engineman as well.

Jim

[Mystic ZR-1]

... You had those engines on your sub... :)[/QUOTE]

Only one on SSBN657
Comforting to know it was there!

[lfalzarano]

Now that it is running great, I have a simple question, and maybe you can help me based on your good running car. After the car is warmed up and everything electrical is turned off, set the emergency brake. What does the in dash voltmeter point to on the word "Brake"? Mine looks like it pointing between the "k" and "e". What does your voltmeter read?

Thanks in advance

[We Gone]

Get a meter and check it at the battery.. Should very from around 13 volts at idle to 14 volts + or - .05 when the RPM's come up.

[lfalzarano]

Steve,

Thanks for the advice. Borrowed a Voltmeter and across the battery terminals it was 12.78 and after starting the car the, the Voltmeter read 12.31. It's time to replace the alternator for the second time at 70K miles. I will use Gerry's Gaskets for the AC-Deco REME replacement.

Any suggestions for a ZR-1 wrench in Raleigh, NC?