Winter Projects One Year Later>>>

[ZR1Vette]

After I acquired my ZR-1 in December 2007, I embarked on the first round of winter projects starting in Jan 2008... this was the view for a couple months back then>>
http://i17.photobucket.com/albums/b79/MRBLU/ZR1onlift1108.jpg
Well, now one year later it is time for round two of winter projects so afamilar view>>
http://i17.photobucket.com/albums/b79/MRBLU/ZR1withMINI.jpg

I had to replace the upper control arm (right side) due to a blown ball joint seal... in fact the entire seal was torn and smashed
Here is the old and new control arms>>
http://i17.photobucket.com/albums/b79/MRBLU/ZR1newandoldcontrolarms.jpg
Job was really a lot easier than expected...the C4/ZR-1 shop manuals are really coming in handy...very specific torque specs required.

For anybody having to do this...just remove the center wheel well cover and strut actuator and you have easy access to the control arm nuts-to- frame and once removed control arm easily removes>>
http://i17.photobucket.com/albums/b79/MRBLU/ZR1FrontRightsuspension.jpg

Next job was to switch out brake pads and rotors... in last year's winter projects I installed EBC ceramic pads and EBC sport rotors.. well, I just did not like the feel so went back to OEM rotors (zinc coated) and my pads of choice- Porterfield R4S..

http://i17.photobucket.com/albums/b79/MRBLU/ZR1newrotorsr10209.jpg
http://i17.photobucket.com/albums/b79/MRBLU/ZR1rearbrakescomplete.jpg

Next project are injectors etc....Phil and Dave have volunteered to come over and "hold my hand" being a newbie at removing the plenum. Also,decided to replace the tires... the GS-D3s are 7+ years old with very little mileage, but they are showing the aged induced hardening.

I think that is enough for this year's round ;-)

[32valvZ]

Great pics
:cheers:

[Jagdpanzer]

Michael
Hate having to be to one to break it to you pal, but the finish on your exhaust pipe just before it connects to muffler is starting to dull a little.
Otherwise it's looking fabulous.

[RedSled]

Looks good as always Michael!

- Keith '90 Red/Red #1383

[Aurora40]

Looks good! Any idea how that happened with the balljoint? Let me know if you need any help with the injectors, though it sounds like you've got it covered. :)

[HIZNHRZ]

Michael, car looks great as usual. I'm wondering if I could invite myself over to watch changing out your injectors. I've been under my plenum twice now, once with help and once solo, and the process is still not something that I'm confident with. I figure the more I either do it or watch it happening the better.

[ZR1Vette]

Looks good! Any idea how that happened with the balljoint? Let me know if you need any help with the injectors, though it sounds like you've got it covered. :)

The cotter pin for the slotted upper control arm ball stud had clear evidence of being removed and reinstalled....not sure why, but clearly the reason for the ball joint grease cover failure was whoever did the work way over torqued the nut (spec is 33 flbs and bet the nut was somewhere north of 60 flbs) and caused the cover to fail.
Since the new control arm install will be interesting to see if alignment is still correct (used the same number and in same locations alignment shims).

[ZR1Vette]

Michael, car looks great as usual. I'm wondering if I could invite myself over to watch changing out your injectors. I've been under my plenum twice now, once with help and once solo, and the process is still not something that I'm confident with. I figure the more I either do it or watch it happening the better.

Absolutely invited...in fact the more the merrier... make it another ZR-1 gathering (I will supply food and drink)... just need to lock in a date...looks like sometime soon after Jan 17 (Maryland ZR-1 gathering)

[ZZZZZR1]

Absolutely invited...in fact the more the merrier... make it another ZR-1 gathering (I will supply food and drink)... just need to lock in a date...looks like sometime soon after Jan 17 (Maryland ZR-1 gathering)

Jan 18th? Or the next weekend?

[tomtom72]

Man that car is soooo cherry!:thumbsup::worship:

Kind of doing the same project....sort of, 4 new arms from corvette recycling. I figure that while I'm in the neighborhood I should do the bar ends & mounts, outter tie rod ends and the rack mounts....figure OEM parts for that stuff too; any opinions on that choice? I was thinking poly stuff...I don't feel like taking apart the new arms to toss new bushings in the can...:redface:...too cheap...:mrgreen:

My b-joint & tie-rod covers came blown up as std equipment. I let'em live on borrowed time long enough. I figured that someone tried to grease'em without hanging the front end...just lazy I guess?

The plenum pull is a nice excersise to do as it lets ya see all our stuff & how it all "connects". I came away with a better understanding....I'm a muscle memory type learner:o......one thing...a long torx set, T-15(?) or a pack of three at sears or autozone for the plenum. The outside plenum bolt on the even bank @ the fire wall (last bolt so to speak right below the fuel line block?). Loosen the 2 bolts in that block enough so you can swivel the fuel lines or you may not get a good seat with the torx bit on that last rear plenum bolt....my fuel lines were in the way & the torx went on cocked.

:cheers:
Tom

[ZR1Vette]

Tom..
Wow.. you will be the suspension guru when you finish... this is what I upgraded to poly due to wanting a little more 'firm' ride>>>
http://i17.photobucket.com/albums/b79/MRBLU/ZR1rearsuspensiondetail.jpg

The rest of my ZR suspension (other than the now replace upper control arm) looks in very excellent condition)

Thanks for the plenum tips... obviously I have a lot to go on the learning curve on pulling the beast...

[tomtom72]

Hey Mike any time, that's what I value highly about our group....free exchange of info. Jeffvette has great write ups with picts at this link:

http://www.pnwzr1.net/

and this at CAC is also very helpful:Oh forgot, you do have a Helm FSM?

http://www.corvetteactioncenter.com/forums/zr-1-general-technical-discussion/14272-1990-1995-zr-1-secondary-port-vacuum-diagnosis.html

And there are a few threads here that talk about doing a p-pull. Even doing it alone as a first timer it really is straight forward.....just a lot of stuff to discon to get to where ya need to get to to do the injectors. I would just say a word about all the other stuff under there....if it don't look good, change it out. If for no other reason than the "while we're here" rule. I will say this, after you do it once you will be able to get the plenum off in about 1/2 an hour the next time...and it will be like swapping an intake on an old sbc, only with more stuff & bolts...:mrgreen:

:cheers:
tom

[Aurora40]

The plenum pull is a nice excersise to do as it lets ya see all our stuff & how it all "connects". I came away with a better understanding....I'm a muscle memory type learner:o......one thing...a long torx set, T-15(?) or a pack of three at sears or autozone for the plenum. The outside plenum bolt on the even bank @ the fire wall (last bolt so to speak right below the fuel line block?). Loosen the 2 bolts in that block enough so you can swivel the fuel lines or you may not get a good seat with the torx bit on that last rear plenum bolt....my fuel lines were in the way & the torx went on cocked.
I believe it's a T-45. I also had that fuel block cocked plenum bolt thing. Stupid FSM doesn't say anything about moving the fuel line, so I didn't. Had to get the IH helicoiled to fix it... Next time I have to do it, I'll have some nice Jagdpanzer o-rings on hand to do the fuel line right vs re-using those ancient ones. :cheers:

[tomtom72]

I believe it's a T-45. I also had that fuel block cocked plenum bolt thing. Stupid FSM doesn't say anything about moving the fuel line, so I didn't. Had to get the IH helicoiled to fix it... Next time I have to do it, I'll have some nice Jagdpanzer o-rings on hand to do the fuel line right vs re-using those ancient ones. :cheers:

Yes it is a T45 I was guessing & my memory failed me....again! I was glad that bolt was one of my finger tight ones as I was scared to move the block on the take apart phase:sign10:....all because the FSM was silent on that. Going back on I figured I wasn't gonna ruin the bolt with the T/Q wrench, so I just loosened that block enough to get the both lines to give me some deflection, just enough to get the torx on straight & with a good firm bite. I may be wrong...again with the memory....but I think that my whiteracing plenum set came with those O-rings.....I should go look! But no leaks and I pulled the plenum twice doing the same "just loose enough" thing.

[ZR1Vette]

Thanks for all the info... yes I have the shop manuals which have become the focus of a lot of my time :cheers:

Plenum Torx screws are T40 (if that is what you are talking about)...for the ones that is in the narrow space between the runners the roof removal tool works for them...damn starting to sound like an expert which is dangerous :mrgreen:

[tomtom72]

Thanks for all the info... yes I have the shop manuals which have become the focus of a lot of my time :cheers:

Plenum Torx screws are T40 (if that is what you are talking about)...for the ones that is in the narrow space between the runners the roof removal tool works for them...damn starting to sound like an expert which is dangerous :mrgreen:

Mike....No don't use the roof tool. Jeffvette admonished me about that! I got mine, extra long say about 3 or 4 inches long, in a three pack at autozone. I know sears sells the same three pack or separately if you like. In a pinch, out on the road it's a good emergency tool, but I do remember Jeff telling us all not to use it for this application in place of the store bought long Torx bit.

:o sorry don't mean to be so loud about this......but Obewann-jeffvette-sensi says [-X on the roof tool.:mrgreen:

:cheers:
Tom

[ZR1Vette]

Oh no... I went astray from the force...bad grasshopper. Now have seen light and will amend my ways a visit great source of power... Sears Hardware :-D

[tomtom72]

Oh no... I went astray from the force...bad grasshopper. Now have seen light and will amend my ways a visit great source of power... Sears Hardware :-D

:sign10: Thanks for not taking me the wrong way on this!:thumbsup:

:cheers:
tom

[ZR1Vette]

Today many of the special 'tools' came in for my winter projects, so I am demoNstrating I am not a total novice at this stuff :mrgreen: I can always learn which I love to do>>
Many of you will recognize each tool, but the subtle one is the print out for the 'extended reach torx wrench' [SK] which I am now getting (thanks to Tom..really I mean 'thanks')
http://i17.photobucket.com/albums/b79/MRBLU/ZR1tools.jpg

Love staging things like this

[xlr8nflorida]

Great photos!

[Z51JEFF]

Today many of the special 'tools' came in for my winter projects, so I am demostrating I am not a total novice at this stuff :mrgreen: I can always learn which I love to do>>
Many of you will recognize each tool, but the subtle is the print out for the 'extended reach torx wrench' [SK] which I am now getting (thanks to Tom..really I mean 'thanks')
http://i17.photobucket.com/albums/b79/MRBLU/ZR1tools.jpg

Love staging things like this

If your going to do the plenum pull might want to get the Haibeck DVD on system checks as the thing goes back together.I got it and didnt think I would need it but watched it anyway.It gave me piece of mind knowing everything worked before the plenum went back together.

[tomtom72]

OOOOOOH new toys! I love presents! :mrgreen: :dancing

Hey Mike, I just thought of this so I'll pass it along. My OEM injectors were stuck in pretty well, age I guess. I remember Jeff saying that you pull all the injectors and the rail at the same time. If you remember or know what the "Club" was/is....steering wheel lock bar, remember? Well that and a well placed block of wood as a fulcrum & lever and it works as a great pry bar.

The long piece that slips into the lock end is the "tool" of choice. The "U" at the end of it fits the fuel rail like it was made for it....who knew? The wood block, wraped in a M/F towel ofcourse, sits on the cam cover and gently pry. I started in the middle and worked to the ends, trying to keep an alternating left/right/left pattern.

I remember seeing this "technique" either at Jeffvette's PNW site or at CAC.

:cheers:
tom

[ZR1Vette]

Thanks Tom...continued good info (I don't have access to 'The Club' so I will improvise a substitute). Jeff... thanks for the pointer..will order the DVD today. I think I be ready! :pray