Introduction: New member, new project, first ZR-1!

[Alex0413]

Hi, I've been lurking on this forum for a while and wanted to introduce myself and my car. My name is Alex, and I've been wrenching and building cars for twenty years. Big into Jeeps and Corvettes, last one was a Torch Red C5, that i've dearly missed! I'm very familiar with the LS platform, but this is my first experience with the LT5.

One of my co-workers has had a ZR-1 sitting in his driveway for a coupe of years and i've been talking to him about buying it for the past 6 months. The timing was right for the both of us and we came to an agreement on the car: I was ecstatic and getting back into a Corvette, and such a rare piece of history. Seller was excited about seeing his baby be resurrected, so it was a win-win! He has owned the car for the past 15 years and she has 55K miles. 1990 Red ZR-1. It had developed a miss three years ago, and he changed the injectors and both fuel pumps. It didn't fix the miss. He moved right after and didn't have a place to work on the car, and stopped working on it. She's been sitting and hasn't been started for almost three years. So that's what I know, and here's my plans:

1) Drain fuel
2) clean, test, and inspect fuel pumps
3) change all fluids
4) new AC Delco Coils
5) new AC Delco plug wires
6) new AC Delco spark plugs
7) inspect secondaries - should i disable?
8) inspect vacuum lines
9) Flow test all 16 injectors on flow bench and ensure all are functioning and clean.
10) reassemble plenum with new gaskets
11) Start and pray like hell! :fahne:

Anything else you pros recommend I check or replace in order to resurrect this beauty?

Should I go ahead and delete the secondaries while I have the plenum off?

Any advice or guidance would be appreciated! Will start a build thread soon once I start working on her.

[conesare2seconds]

Welcome.

[efnfast]

Welcome. Glad to hear you rescued her before the mice had her for lunch.
Secondaries: The only reason to keep them is because of their uniqueness. Mine are gone.
Don't forget that the chip will need a reprogram.

[JThomas]

Congratulations, and welcome to the madness! :cheers:

[We Gone]

Welcome.

[EvanZR1]

Secondaries: The only reason to keep them is because of their uniqueness. Mine are gone.
Don't forget that the chip will need a reprogram.

Congrats on finding a ZR-1, you're going to love it! I agree with efnfast, no real reason to keep the secondaries, and good reasons to get rid of them. Both my ZR-1s had them when I bought them, and I had issues with them on the first (had plenum off a couple times to chase vacuum leaks to get them running properly). My current one didn't give me any problems with them, but when I had the 391 motor done, I went ahead and had Pete just completely remove them.

[Alex0413]

Thanks for the warm welcome!

As far as the chip for the secondary delete, this just deletes a CEL, it will still run properly without the Haibeck chip?

What write ups can you steer be towards for a secondary delete? Think I'll just zip tie them open, but need to know what vacuum lines/systems to plug.

This car does have some performance works done so far:

SW Headers
Corsa exhaust
Ported Plenum
Tuned

[Alex0413]

Here's a few pics:

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[Ccmano]

Welcome! Nice find, luv the red plenum.
H
:cheers:

[Ccmano]

For the secondary delete a tune (chip) is an absolute necessity. It will not run correctly otherwise possibly even damaging your engine. Its not just a simple matter of eliminating the SES light. Since your car already has a tune this needs to be discussed with whoever does the new chip. Pull your chip and see who did the tune. My guess is youll find a Marc Haibeck chip. The only people doing tunes these days are Marc Haibeck, Dominic Sorresso, Pete all in the Chicago area. Closer to you theres Steve at Crossed Flags in Magnolia TX. Haibeck does a very good canned or generic tune. The rest are all custom tuners.
H
:cheers:

[Alex0413]

For the planned work, do I only need to order Plenum gaskets? what other gaskets are needed?

[EvanZR1]

As mentioned above, yes you must retune for deleted secondaries. Since Steve is so close to you, you could have him do a dyno tune as well instead of getting a canned/generic tune. Would be a good time to do some long tube headers as well, and maybe some intake porting... :wink:

[billschroeder5842]

Geaux Tigers and Welcome! My family has a graduate from LSU and we all spent a lot of time in Baton Rouge.

You have a car with looks great and a lot of the "correct" performance mods already in place.

[Alex0413]

Geaux Tigers and Welcome! My family has a graduate from LSU and we all spent a lot of time in Baton Rouge.

You have a car with looks great and a lot of the "correct" performance mods already in place.

GEAUX! Hope have a football season this year so we can see what Myles Brennan can do!

Thanks, I can't wait to get her going and drive it like I stole it!

[G8nightman]

It?s a 90? Some gave it a facelift. Welcome.


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[Alex0413]

It?s a 90? Some gave it a facelift. Welcome.


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

Keen eye! It's a '90 that was in a minor fender bender that scraped up the front bumper. So they converted it to the '95 body work. I know that hurts the value, but I like the later bumpers much better, so I was happy about it!

[ghlkal]

Congratulations. That's a great find.


I would also clean in the valley and ensure the "drain line" is clear. You might want to inspect and rebuild the starter solenoid "since you're in there."


Good luck

[DRM500RUBYZR-1]

Congratulations!!!

Welcome to the Registry!

Keep us posted on any difficulty so we can assist, and let us know of your progress.

:cheers:
Marty

[Alex0413]

Thanks for the welcomes! I got her home today, and will start dissecting and inspecting everything on the car! I ordered a factory GM manual for the LT5, for assistance with the plenum removal. Any good tips, tricks, write ups, or recommendations, please let me know!

[Ccmano]

Thanks for the welcomes! I got her home today, and will start dissecting and inspecting everything on the car! I ordered a factory GM manual for the LT5, for assistance with the plenum removal. Any good tips, tricks, write ups, or recommendations, please let me know!

For all practical purposes it?s all in the SOLUTIONS sticky at the top of the Tech section. Heres a short cut...
H
:cheers:

https://www.zr1.net/forum/showthread.php?t=16778

[Alex0413]

For all practical purposes it?s all in the SOLUTIONS sticky at the top of the Tech section. Heres a short cut...
H
:cheers:

https://www.zr1.net/forum/showthread.php?t=16778

Thanks, now that is a wealth of ZR-1 knowledge!

[Alex0413]

Today was the big day: time to get my ZR-1 home! I got a rollback truck to tow her, and drop her right in her new room:

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[Alex0413]

First thing of order: Drain the fuel, and see what the fuel system looks like.

Water had obviously pooled in the fuel area and rusted the fuel cap on. I had to fight it off with channel locks.
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I got the fuel pump assembly unbolted (only broke three bolts..) and wrestled the fuel pump assembly off. Water obviously got into the fuel tank, and rust was in the tank and fuel pump assembly.
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Time to drain the fuel/water/varnish/rust mixture out of the tank that has been marinating..
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There was a lot of crud on the bottom of the tank, once I got all the fuel out, I managed to get my arm in the tank and shop vac most the solids out. Tank isn't too bad, Going to get a bunch of brake cleaner tomorrow and get it much cleaner.
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Questions:

Is the fuel pump assembly/cage a ZR-1 specific piece or C4 generic? be nice to get a new one, but I can go to town with brake cleaner and a metal brush!

Best way to check the fuel pumps while they're out? Just put 12V to them on the bench?

[Alex0413]

Now it was time to move onto the LT-5 and do my first plenum removal. My manual hasn't came in yet, but I dove it and it was pretty easy to get everything off and the plenum off. I propped it up with a 2x4 and called it quits for day 1. Tomorrow I'll get everything off and start putting on new parts :-D

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[lfalzarano]

Thanks for the welcomes! I got her home today, and will start dissecting and inspecting everything on the car! I ordered a factory GM manual for the LT5, for assistance with the plenum removal. Any good tips, tricks, write ups, or recommendations, please let me know!



ZR1Specialist.com sells a CD


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[Ccmano]

Fuel pump/sender assemblies are ZR-1 specific because of the dual pump setup. It?s probably one of the hardest items to find right now. Yours looks serviceable, unless you have rust eating through the main support structure. The pumps can be replaced individually. I would tear it down and try to neutralize the rust, replace both pumps (RockAuto) and clean the sender Rheostat. Worst case Mark Haibeck just wrote an article in the Registry (are you a member?) publication Heart of the Beast on how to convert the standard C4 single pump setup.
H
:cheers:

[Alex0413]

Fuel pump/sender assemblies are ZR-1 specific because of the dual pump setup. It?s probably one of the hardest items to find right now. Yours looks serviceable, unless you have rust eating through the main support structure. The pumps can be replaced individually. I would tear it down and try to neutralize the rust, replace both pumps (RockAuto) and clean the sender Rheostat. Worst case Mark Haibeck just wrote an article in the Registry (are you a member?) publication Heart of the Beast on how to convert the standard C4 single pump setup.
H
:cheers:

I have rust eating through my main support structure and both fuel pumps are toast :( How do I get this article?? Could you please share it? That's the route I'm going to need to go.

[Ccmano]

I have rust eating through my main support structure and both fuel pumps are toast :( How do I get this article?? Could you please share it? That's the route I'm going to need to go.

I just sent you a copy of the article via PM.
Registry members get the quarterly publication as part of membership. You also have access to all past publications and articles. Its one of the perks. The first year is $45. You can sign up here...
https://www.zr1netregistry.com/Home.aspx

Membership includes...
"Keeping the Legend Alive" - The ZR-1 Net Registry facilitates enthusiasts to meet, socialize, learn, enjoy and preserve the heritage of the ZR-1 among the automotive community.

Membership in the ZR-1 Net Registry supports efforts to "Keep the Legend Alive" through the Internet forum; membership events; and our quarterly newsletter, "The Heart of the Beast." These mediums act as a support mechanism to help ZR-1 owners should they encounter any problems with their ZR-1s or have any questions. Membership in the ZR-1 Net Registry enables ZR-1 enthusiasts from all over the world to share facts and information, seek technical help, and collaborate about this truly World Class automobile; the most iconic Corvette GM has ever built. Also, as a prospective ZR-1 owner, the Registry offers help with any question and/or concern you may have about purchasing one of these special Corvettes. We can help make your big decision a little easier by providing details about the different years and options to help in selecting just the right ZR-1. The ZR-1 Net Registry will also be present at numerous Corvette shows and several race track events including the annual ZR-1 Gathering at the National Corvette Museum, now approaching its 16th anniversary.

Benefits of joining the ZR-1 Net Registry include:
Access to members only sections of the website and forums
Special member pricing on apparel and other items in the online store
Electronic Quarterly Newsletter - The Heart of the Beast
Registry T-Shirt
Membership Badge and Lanyard
ZR-1 Net Registry Window Decal
ZR-1 Net Registry Forum special access / features
ZR-1 Net Registry Archives
Access to the ZR-1 Member Registry

[Alex0413]

The fuel system rebuild continues: After LOTS of carb cleaner and my handy little shop vac I managed to get the fuel tank nice and clean!

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Now, At first I thought my fuel sending unit was rusty but salvageable, but after closer inspection I determined it was toast :( It's split at the seam, pumps are both seized, and it's rusted away.

Fortunatley CCMANO shared the article on how to use the L98 sending unit with a Walbro 255, so that's the route i'm going for the fuel pump!

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[Alex0413]

Continuing full speed ahead on my ZR-1 resurrection! I got the plenum off pretty easily so now I had access to my injectors and ignition. I removed all 16 injectors so I could test, clean, and inspect them all. One thing I thought was interesting is that there were Ford FOTE-05A fuel injectors installed.. Is this normally used on the ZR-1? I noticed the resistance on them was much higher than the factory 8ohm, these were in the 40ohm range..

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Next up was to pull the coils and replace the coils and wires with OEM AC Delco parts. I did discover two of the coils were cracked, Could this of been the source of the miss in the engine before it was parked? possibly!

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[Alex0413]

Next up was to test the injectors on the car with my buddies flow bench. The PO changed these injectors three years ago before the car was parked, and it still had a miss after he installed these new injectors.

I found one bad primary and one bad secondary injector. Were they bad when they were installed?.. possibly.. Are these Ford FOTE-05A fuel injectors compatible with this ZR-1?

I can either order a couple of these same injectors and flow match a full set (which would be very cheap to do). Or order the proper ZR-1 injectors..

https://www.youtube.com/watch?v=LYl4H1gCpOE

[G8nightman]

I would replace the injectors get a set of msd coils new wires and plugs


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[Alex0413]

I would replace the injectors get a set of msd coils new wires and plugs


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

I just installed new AC Delco coils and wires, so i'm good to go there. These injectors have low miles, but some are bad. I think I can just replace the two bad injectors, since this set has low mileage. A new set would be optimal, but the $800 price tag stings! I'm not certain they are the correct injectors installed though..

[G8nightman]

Depends how much you think your times is worth. Pulling the plenum a second time won?t be that hard.


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[EvanZR1]

I'd replace the injectors. Yeah it's $800, but you'll know they are good and won't have to pull the plenum a 2nd time to do them again (been there, done that). If you Google FOTE-05A it looks like it's actually a Bosch part, and is listed as a 20lb/hr injector with a 14.4Ohm resistance.

[Alex0413]

I went ahead and ordered new injectors from South Bay injectors. Talked to some people running them in LT5's and they have great reviews. So i'm waiting on parts now in order to put her back together and do the first start!

[Alex0413]

I was waiting on parts all week, and finally had a few things come in: L98 fuel sending unit and my 255 fuel pump. I went forward with Haibeck's single fuel pump conversion, and it was quite simple to do!

The connectors are different, due to the second fuel pump power wire for the LT5. So I swapped the LT5 plug onto my L98 sending unit.
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Installing the fuel pump is very straight forward. I ran the pump #2 power wire through the L98 sending unit by drilling a hole, and making a "Y" with the 1&2 power wires into the fuel pump power wire inside the unit.
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I used solder joint connections on all my wires. They're water proof, and don't come apart like butt connectors.
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[Alex0413]

I also did some routine maintenance while waiting:

Oil and filter change
new serpentine belt
new fuel filter
new battery

Now that I had a cleaned out fuel system, operational fuel pump, and fresh fuel filter, it was time to flush out my fuel lines. I disconnected them at the fuel rail, and rigged a bucket into them so I could flush fresh gas through the system and ensure no garbage would get into my new injectors. I was shocked at how much crap came out of the line with a new fuel filter installed:

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[Alex0413]

Time for an update on my progress, been busy with work!

I got my fuel injectors in and put them on the flow bench to test everything before I installed them in the IH. All the injectors tested within 2%! I went ahead with installing the new injectors. Once installed I pressure up my pumps to test the seal on the O-rings, thank goodness I did:
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An O-ring got pinched, so I pulled one off an old O-ring , bolted the rails back down and tested pressure: Good to Go!

Time to button up the Plenum and put everything back together now I have a fresh ignition and fuel system.

[Alex0413]

Now I had the beautiful LT5 back together with a fresh and clean fuel system, and new AC Delco ignition: It's time to see if she starts! I first pulled the plugs and turned over the engine until I got oil pressure so it was primed, then put the fresh plugs back in and turned the key:

https://www.youtube.com/watch?v=vS1aLlL8FUQ


SHE'S ALIVE!!!!!

[We Gone]

Great job congrats...

[Ccmano]

Nice work, I'm anxious to see how she performs with the fuel pump mod. It's the first, aside from the ones Haibeck has done, I've seen.
H
:cheers:

[-=Jeff=-]

Got a link for the South Bay injectors?

[Alex0413]

So the car is purring like a kitten but, I couldn't drive her because the clutch and brakes weren't functional. I ended up having to replace:

*Clutch mater
*Clutch Slave
*Clutch pressure line
*Brake Master

Once I had all the hydraulics working, I could finally take the car on her maiden voyage! Car drove well, but when I would get into high RPM, it would cut out like it was losing fuel. It did this whether I was in full power mode or not, so I knew it wasn't the secondaries.

First step was to rent a fuel pressure gauge with a long enough hose to tape to my windshield and watch what was happening under load. After one pull it quickly became apparent that the car was running out of fuel in high RPM. A 255 pump can certainly handle the fueling requirements for this car, so what was going on with my new fuel pump? Well, Walbros are sold out due to Covid so I bought a Quantum off Amazon... I've used this brand before, and it was unusually cheaper on Amazon than their website. I must of gotten a knock off or incorrectly sent stock LPH pump! So I ordered the Racetronix 255 with the C4 install kit after some research

The Racetronix C4 install kit is impressive, nice hardware and wiring! I installed it tonight and took the car for a spin after thoroughly warming her up: RUNS LIKE A BAT OUT OF HELL!!!!!! WOW! The engine just screams to redline, and the Corsa exhaust is just music to my ears! I'm head over heels in love with her, and can't wait to get some dry weather and tear up the back roads!

[Alex0413]

Nice work, I'm anxious to see how she performs with the fuel pump mod. It's the first, aside from the ones Haibeck has done, I've seen.
H
:cheers:

Fuel pump mod works awesome, just make sure you use a Walbro or Racetronix 255 pump!

I actually emailed Marc and discussed his mod with him last week (he's a great guy btw!) , and showed him some wiring adapters on Racetronix vs soldering pump #2 into a Y with #1. Marc said soldering them into a Y is the only way they can handle the increased voltage from the aftermarket pumps. I showed him pictures of how I did it, and he said that's the right way to do it! So anyone with trashed double fuel pump senders, is now good to go thanks to Marc Haibeck!

[Alex0413]

Got a link for the South Bay injectors?

Jeff,

Below is the link for South Bay injectors. They are re manufactured and flow tested Bosch injectors. I called the owner and spoke with him, and he said he sells a lot and has never had a set sent back. I tested mine on my buddies flow bench, and they were flawless!

https://www.southbayfuelinjectors.com/fuel-injectors/oem/zr1-chevy-corvette-1990-1992-zr1-fuel-injectors?___SID=U

[Paul Workman]

Fascinating saga! I've been following your progress - not jumping in as you were in good hands throughout, and great to bring her back to life!

As I read through, I just have a couple items:


When replacing plenum gaskets, there are a couple tricks I have found that (for me at least) seem to work well:

I lay the new gaskets on a flat surface and spray the top side (ONLY) with silicone spray (ACE Hardware).
Then I use 3M gasket adhesive between the gasket and the Injector housing around the coolant ports; on both the left and right gasket/injector housings. (perhaps an unnecessary left-over from previous gasket experience I suffered before JERRY'S GASKETS :thumbsup: came to the rescue!=D>)

Good luck with the "refurbished" injectors. As long as they are immune to the effects of alcohol blended fuels, my main concern is mitigated. But, "take this with a grain of salt", once they're up to operating temperature and then the resistance is measure for stock or Accel replacement is in the 12-14Ω range, but resistance in the 8Ω area (again when HOT) was a sure sign of failure. (I'm not familiar with injectors measuring 40Ω initially - seems way out of the normal range - at least for what [most of us] I believe have experienced.) In any case, the range of resistance for good injectors is typically within a couple ohms or so. Failure, on the other hand, is indicated by a significant reduction from the normal resistance (e.g., if the normal resistance range was [say] 12Ω when hot, but a particular injector reads 10Ω or less, trouble was indicated, and by the time they get down to 8Ω [again when hot] they were done!)

I'm unfamiliar with the "Y" wire harness configuration mentioned, along with the L98 fuel pump(s?) scenario. Far as I know it hasn't been written up for the Heart of the Beast quarterly member's newsletter (someone correct me if I'm wrong). But, if you would like to write it up, or even provide me with the details, I'd be happy to draft an article for your review/submission to the "HOTB" quarterly magazine.


Well, with all that said, Welcome to the BROTHERHOOD OF THE BEAST!

P.

[tiegsd]

Next up was to test the injectors on the car with my buddies flow bench. The PO changed these injectors three years ago before the car was parked, and it still had a miss after he installed these new injectors.

I found one bad primary and one bad secondary injector. Were they bad when they were installed?.. possibly.. Are these Ford FOTE-05A fuel injectors compatible with this ZR-1?

I can either order a couple of these same injectors and flow match a full set (which would be very cheap to do). Or order the proper ZR-1 injectors..

https://www.youtube.com/watch?v=LYl4H1gCpOECongrats and welcome! That's a pretty cool test rig.

Sent from my SM-N920V using ZR-1 Net Registry mobile app (http://r.tapatalk.com/byo?rid=90383)

[tiegsd]

Now I had the beautiful LT5 back together with a fresh and clean fuel system, and new AC Delco ignition: It's time to see if she starts! I first pulled the plugs and turned over the engine until I got oil pressure so it was primed, then put the fresh plugs back in and turned the key:

https://www.youtube.com/watch?v=vS1aLlL8FUQ


SHE'S ALIVE!!!!!Nice work!

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[Alex0413]

Thanks! This car sure is addictive to drive! Next up is going to be a full detail, paint correction, and recharge the AC!

[Alex0413]

Fascinating saga! I've been following your progress - not jumping in as you were in good hands throughout, and great to bring her back to life!

As I read through, I just have a couple items:


When replacing plenum gaskets, there are a couple tricks I have found that (for me at least) seem to work well:

I lay the new gaskets on a flat surface and spray the top side (ONLY) with silicone spray (ACE Hardware).
Then I use 3M gasket adhesive between the gasket and the Injector housing around the coolant ports; on both the left and right gasket/injector housings. (perhaps an unnecessary left-over from previous gasket experience I suffered before JERRY'S GASKETS :thumbsup: came to the rescue!=D>)

Good luck with the "refurbished" injectors. As long as they are immune to the effects of alcohol blended fuels, my main concern is mitigated. But, "take this with a grain of salt", once they're up to operating temperature and then the resistance is measure for stock or Accel replacement is in the 12-14Ω range, but resistance in the 8Ω area (again when HOT) was a sure sign of failure. (I'm not familiar with injectors measuring 40Ω initially - seems way out of the normal range - at least for what [most of us] I believe have experienced.) In any case, the range of resistance for good injectors is typically within a couple ohms or so. Failure, on the other hand, is indicated by a significant reduction from the normal resistance (e.g., if the normal resistance range was [say] 12Ω when hot, but a particular injector reads 10Ω or less, trouble was indicated, and by the time they get down to 8Ω [again when hot] they were done!)

I'm unfamiliar with the "Y" wire harness configuration mentioned, along with the L98 fuel pump(s?) scenario. Far as I know it hasn't been written up for the Heart of the Beast quarterly member's newsletter (someone correct me if I'm wrong). But, if you would like to write it up, or even provide me with the details, I'd be happy to draft an article for your review/submission to the "HOTB" quarterly magazine.


Well, with all that said, Welcome to the BROTHERHOOD OF THE BEAST!

P.

Thanks for the tips Paul!

I didn't come up with the single fuel pump mod, that was in HOTB, and written by Haibeck. Converting to an L98 fuel sender with a single 255lph pump works flawlessly!

[ZR2]

Great job. I am in the midst of a plenum pull with new injectors, coils and wires etc. Had a bad coils, so why not. It has been awhile since I pulled a ZR1 plenum, but it has come back to me.....slowly. Now time to put back together.....hopefully no extra bolts!!!!

[Alex0413]

Great job. I am in the midst of a plenum pull with new injectors, coils and wires etc. Had a bad coils, so why not. It has been awhile since I pulled a ZR1 plenum, but it has come back to me.....slowly. Now time to put back together.....hopefully no extra bolts!!!!

It's a straight forward job, you got this!!!

I've been enjoying this car, so much fun to drive!