-Solutions- (The Fourth Generation)
-Solutions- ALERT http://www.f-lohmueller.de/pov_tut/a...Chain_35tt.gif The BIG Trick for Photo Album Use on the Registry is..... After you have selected 800 or 400 or other pixels using Paint (or other photo pixel resize software) on your computer and applied to any photo on your computer....and after you have uploaded that photo to your Registry Album of Albums. Once the photo is in your Registry Album (resized by PAINT on your computer) you go to that Album and LEFT Click on the photo....It will then appear the size you PAINTED. You then select and copy the BB Code. Then Paste the BB Code into a post. Another way is to LEFT Click on the photo......It will then appear the size you PAINTED. You then right Click and Select Copy. Left Click on Insert Image in the Post Heading and Paste the Copy in the Insert Image Box. Click on OK and the image will be Inserted where your curser was set before you selected Insert Image. Improvements In Solutions. A significant reorganization of -Solutions- has been accomplished and includes eight continuous posts of regorganized Headings. The reorganization makes it easier to obtain specific technical information as required. Mar 5th 2012 - -Solutions- has been modified considerably in appearance (The Second Generation) by using Link Names for all references. Link Names show up as (Underlined Descriptions) which you can Left Click to upload the reference. Aug 24th 2012 - -Solutions- has been modified considerably in organization (The Third Generation) by reorganizing -Solutions- into 8 Posts with many additional Link Name References. Apr 2013 - -Solutions- has been upgraded (The Fourth Generation) with all thread/post references checked and verified. Some posts in threads had been deleted and/or photos in posts hosting photo web sites not maintaned. Aug 2013 - CF -Solutions- were expanded and made identical to the Registry Forum -Solutions-. Both are being maintained equally :thumbsup: A post on this Forum cannot exceed 30,000 characters. This limitation in post characters required reorganization of -Solutions- posts to meet this requirement. Any word or group of words underlined are left clickable Links. Many who post on this Forum no longer use Photobucket. Many of those original posts using Photobucket have lost the photos. Those posts are gradually being replaced with posts that do show associated photos for clarity. See Solutions on how to copy a functional (with left clickable references) -Solutions- to a WORD Document on your computer. A. Acronyms are often used we are not familiar with...... 1. See Common Forum Acronyms 2. See Complete Automotive Acronym List Ebay Searches and Acronyms B. Using Forum Albums for Posting Photos. Resizing Photos for Forum Posts and Creating Reference Links Using Forum Photo Albums……Resizing photos C. Organization Of Solutions. Post 1 to Post 8 includes an Index (-Solutions-) for all issues related to the C4 ZR1 with LT5 engine as well as the C4 Corvette with L98 engine. The eight posts are orgainzed by category. The Posts References are all shown as clickable Link Names with those posts associated with the C4 Corvette (L98) starting with the word L98. All other posts refer to the ZR1 (LT5). OVERVIEW Post 1. -SOLUTIONS- Overview and Ebay Searches Post 2. ZR1 General Post 3. ZR1 Electrical Post 4. ZR1 Engine Post 5. ZR1 Drive Train Post 6. ZR1 Engine Fuel, Lubrication, Cooling, and Exhaust Post 7. ZR1 Specifications, Restorations, Air, Audio, Lifts, and Road Trips Post 8. ZR1 Engine (LT5) Bolts and Hydraulics Post 9. New Secondary Port Throttle Vacuum System for 1990-1995 Post 10. Phil's (Jagdpanzer) Fuel Pressure Regulator Solution 1. -Solutions- Index Posts are Organization by Function. Engine HEADINGS are arranged from front to back and top to bottom and Drive Train HEADINGS are arranged from Bell Housing to Differential to Wheels for example. 2. All Polls and Key instructions/suggestions (TIPS) are listed in Bold Red under each Heading. 3. ALL VIDEO is listed in Bold Red before Polls and TIPS. 4. Links to Off Forum Information Web Sites are listed in Bold Dark Orange. 5. Links to Other Technical Posts and all Calculation Methods are listed in Bold Blue. 6. Occasionally better or more descriptive Solutions appear in new posts which will replace old Solutions in this index. Occasionally new Solutions are found in old archives which will be added to the -Solutions- index. The latest date of updates for each of the 8 -Solutions- posts can be found at the bottom of each post including this post. 7. All posts referenced in -Solutions- are open posts wherein once directed to that post you can scan the entire thread forward or backward as you like. A few Solutions references will take you to the beginning of a thread if the Solution is a process such as a restoration. 8. All professional service sources , all sources of parts, all Ebay searches for parts, and all sources of lubricants are listed last in Bold Dark Green under each Heading. D. HOW TO CREATE (Links, Photos, Videos, Messages, Posts) Photobucket issues Using Forum Albums for Posted Photos TIPS Registry Forum Albums TIPS How to Post Photos TIPS Old Forum Link TIPS Creating Albums and Hosting Post Photos TIPS Using Albums on various Forums to Host and Post Photos TIPS Creating Albums on various Forums TIPS Converting Pixels to Inches Creating 3D images Resizing Photos for Forum Posts and Creating Reference Links Link Name Signatures Creating Reference Links Posting References and Link Photos How to get to old links Using ImageShack Using Photobucket Using PutFile How to post a video Instant message Random images Show Car Displays If you insert a picture in a Post on this forum as cited above using photobucket and then change your photobucket picture title in any way or delete that picture in photobucket, the picture will also be deleted in the forum Post you pasted it in. Most of the pictures cited in this index have been copied just in case. E. Smilies http://www.corvetteforum.com/forums/...ilies/hide.gif http://www.corvetteforum.com/forums/...es/leaving.gif http://www.corvetteforum.com/forums/...coolgleamA.gif http://www.corvetteforum.com/forums/.../confused5.gif F. SUMMARY Ebay Searches Ebay Corvette Electrical Section 8A Ebay Corvette Ignition Key Ebay radiator Comb Ebay LT5 2902 engine mounts Ebay LT5 2713 engine mounts Ebay LT5 PVC CV913C Ebay LT5 PVC CV769C Ebay LT5 Plug wires Ebay LT5 Service Manual Ebay LT5 Thermostat Ebay LT5 Water pump Ebay Power Antenna Mast Ebay ZR1 Bosch 69225 Fuel Pumps Ebay ZR1 LT5 Ebay ZR1 LT5 Chain Ebay ZR1 LT5 Belt Ebay ZR1 LT5 Bolts Ebay ZR1 LT5 Engine Ebay ZR1 LT5 Gaskets Ebay ZR1 LT5 Plenum Ebay ZR1 LT5 Secondary Ebay ZR1 LT5 Throttle Body Ebay ZR1 Alternator Ebay ZR1 Bose Ebay ZR1 Brake Pads Ebay ZR1 Cat Back Exhaust Ebay ZR1 Clutch Cylinder Ebay ZR1 Coolant Ebay ZR1 Corvette Clutch Ebay ZR1 Radiator Ebay ZR1 Spark Plugs Ebay ZR1 Starter Ebay Autometer 2343 The Ebay search terms are defined to maximize Ebay searches for parts. The Ebay searches located within some Headings in Solutions will allow you to go directly from a specific Heading in Solutions to the related parts search on Ebay. The Ebay search is current and will show the most recent ZR1/LT5 parts available on Ebay. PARTS PHOTOS AND ESTIMATED VALUE Part Estimated Value Post 310 - Parts Estimated Value Last UPDATE of post 1 June, 2024 |
ZR1 Electronics
Post 3 - ZR1 Electronics TRY THESE FIRST Check NO START Fuel or Electrical Issue INFL REST Electrical Connector Tools TIPS Prom Chart TIPS HVAC Diagnostic Codes TIPS Removing the instrument Cluster TIPS Trailering a ZR1 TIPS HVAC Display Parameters TIPS 1991 ZR1 brochure 1990 ZR1 brochure Plugs, Clutches, Other Troubleshooting LT5 ZR1 as a daily driver ZR1 Brochures ZR1 reliability LT5 Block numbers SOLVING GENERAL TECHNICAL ISSUES Tech1 TIPS ALDL Error Code Flasher/Eraser TIPS TPS Voltage Tips Engine Hesitation with Haibeck Chip TIPS Marc Haibeck on LT5 Eliminated Secondaries and Associated Anomalies Check Secondary Operation with Plenum Tipped Up TIPS HVAC Codes TIPS No Start TIPS Central Control Module Diagnostics TIPS Developing miss Cutting out under load Slight miss Engine noise Full power stumble BATTERY AND CHARGING Battery poll Tipping the Plenum to Remove Alternator Alternator Replacement without Pulling Plenum TIPS Alternator TIPS The Battery Disconnect Switch TIPS Quality Power Alternators TIPS Alternator Rubber Boot Replace TIPS How To Replace Battery TIP Battery Connection Wrench TIP Belt Tensioner Pulley Serpentine Belt Path Replacing Battery Cable Bolts Replacing An Alternator SYS light flashing Roll start Removing alternator Ebay ZR1 Alternator Ebay ZR1 LT5 Belt ELECTRICAL CONNECTIONS Manifold Pressure Differential TIPS ECM Pin Connections Failed TIPS AC Delco Connectors TIPS Weatherpack Connectors TIPS No Start Gauge Fuse TIPS Cluster Identification TIPS Window and AC Switch Connections TIPS Cleaning Two Engine Block Ground Connections TIPS Maintaining the Engine Block Ground Connections TIPS Ground Connections TIPS Engine Relays TIPS Secondary Injector Drivers TIPS Wire size capacity chart Sensor connectors TIPS Fuses (1991) Weatherpack connectors Tachometer Wire Sources of connectors ECM (90') pin diagram Instrument panel wiring 90' KEYLESS ENTRY, TACHOMETER, CRUISE VKE-1000 system TIPS VKE-1000 system Installation TIPS Cruise Control Vacuum Release TIPS Cruise Control Vacuum TIPS Tachometer Calibration TIPS Instrument Cluster Differences Use of Trim Pot for Tachometer Calibration TIPS Keyless Entry TIPS Tachometer repair Cruise control diagram IGNITION Power Key Rebuild TIPS Power Keys 90'-95' CMHSL LED, Full Power Key and Alternator Pulley Secondary Injector Relays TIPS DIS Diagnostics TIPS Ignition System Modifications TIPS Ignition Module Connections TIPS Defeating VATS TIPS Injector Fuse Pinched TIPS No Start DIS Plug Ins TIPS DIS Prototype TIPS VATS Ignition Key VATS Time Delay Ignition module location VATS gotcha Full power switch malfunction Full power switch repair/replace Power key rebuild Anti-theft Distributorless Ignition System (DIS) DIS module correct grease What is DIS LT5 ignition system questions Secondary Relay Discussion COILS & PLUGS Antiseize on Spark Plugs TIPS Plug condition Spark Plug Thread Chaser TIPS Coils TIPS Coil Base TIPS Using Timing Light To Check Coils TIPS Waste Spark Ignition TIPS Spark Plug Wire Separators TIPS Weak spark Testing coils Spark plug wire routing Removing #8 Ebay ZR1 Spark Plugs STARTER Diagnosing Starter Long Cranking No Start Electrical Circuit Deterioration Explained Starting Bench Testing TIPS Starting System Schematics TIPS Relay Locations TIPS No Start Gauge Fuse TIPS No Start Diagnostics TIPS Starter Enable Relay TIPS Starter Enable Relay Part Number TIPS Starter Clutch Safety Switch TIPS Intermittent No Start TIPS Starter Electrical Connections TIPS Starter Solenoid TIPS Starter relay modification TIPS Hold starter longer to prevent backfire TIPS Starter Solenoid Rebuild TIPS Starter Relay, Wiring Harness, and Plugs Tricks Clutch Start Switch Linkage No Start Clutch Switch Linkage No start No start cure Starting issues Ebay ZR1 Starter LIGHTS Headlight door motor bushings Video Head Light Parts TIPS Electric Window Switch Lights TIPS Headlight Motor Aluminum Gear TIPS Installing HID Driving Lights TIPS Installing HID Fog Lights TIPS Headlight door motor bushings Headlight motor gear box Backup Tail Light Switch CMHSL LED install on my ZR-1 HID Install HID Tail Lights Headlight Motor Clicking Euro Tail Lights Install HID Head Lights CHMSL LED Installing CHMSL LED CHMSL switch CHMSL Wag Back up lights conversion to 50W SENSORS ALDL Fault Codes TIPS ALDL Fault Code Erasing TIPS INFL REST Connectors Inside Car TIPS INFL REST Codes TIPS Upgraded INFL REST Code Clearing TIPS Changing the Passenger Side O2 Sensor TIPS Using Tech 1 TIPS Service Bulletin for SIR TIPS MAP Sensor Hose Fix TIPS Crankshaft Sensor Testing TIPS Oil Level Sensor TIPS INFL REST FIX TIPS INFLREST" and "SEATBELT Trouble Lights Crank shaft position (93' no start) EVAP Purge Solenoid MAP sensor/hose location 90' MAP sensor hose disconnected Knock sensor testing Knock sensor TPS voltage reading Throttle position sensor voltage Replacing O2 sensors O2 sensor with SW headers CCM Diagnostic Trouble Codes TIPS Marc Haibeck code reading Central Control Module Diagnostics TIPS What is the CCM Reading CCM codes paper clip CCM Code 54 CCM interchangeability Inflatable Restraint diagnostics SRC Marc Haibeck code reading SRC Codes and Clearing SRC TIPS Service Ride Control codes TIPS ABS codes TIPS ECM Diagnostic Trouble Codes TIPS GM Trouble Code Info TIPS Marc Haibeck code reading Closed Loop and Open Loop TIPS ECM Interchangeability TIPS ALDL Pin Out TIPS Electronic Control Module Schematic TIPS Electronic Control Module P/Ns TIPS Electronic Control Module Codes TIPS ECM Repair TIPS GM codes Fuel Trim and Closed/Open Loop Operation ECM Chip and Other Electrical Connectors ZR1 ECM CODES 1990 TO 1992 ECM (90') plug pins printout Reading ECM codes paper clip ALDL plug ECM Repairs ECMs and sensors ECM MODIFICATIONS Megasquirt Manual Megasquirt Chip poll Identification of Stock Chips TIPS Interchangeability of Chips in ECMs TIPS Prom tuning guide Chip Removal Chips Tuning LS1 (411) PCM swap Marc Haibeck (Performance) DIAGNOSING ECM CODES Using Tech 1 TIPS ALDL Error Code Flasher/Eraser TIPS Marc Haibeck code reading Clearing Codes Codes Code 9 Low freon Code 12 normal Code 16 DIS system fault Code 21 Throttle position Code 23 Vehicle speed Code 24 Speed sensor Code 31 Cam sensor Code 32 EGR Code 33 MAP sensor hose Code 41 ECM/CCM error Code 41 Bad ECM Code 41 ECM Troubleshooting Code 42 Electronic Spark Timing (EST) Code 43 knock sensor Code 44 Oxygen Sensor (Left Bank Lean) Code 45 Oxygen Sensor (Left Bank Rich) See ECM Code #52 Item #3. ZR1 ECM CODES 1990- Code 55 Lean 02 Code 56 Vacuum pump Code 61 Vacuum/MAP sensors Code 61 secondary vac solenoid Code 63 Oxygen sensor Code 63 Right Oxygen Sensor Circuit Open Code 64 Right Oxygen Sensor (Right Bank Lean) Code 65 Right Oxygen Sensor (Right Bank Rich) Last UPDATE of post 3 June, 2024 |
ZR1 Engine
Post 4 - ZR1 Engine FRONT COVER AND TIMING CHAINS Belt Tensioner Failures Rebuilding the Belt Tensioner TIPS Front cover shaft seal installation Installing Serpentine Belt Timing chain guide LH picture Timing chains and guides installed Chain guide replacement Timing chain, sprockets and guides Timing chain failure Timing Chain failure explained TORSIONAL DAMPENER Belt Tensioner Pulley Rebuilding Belt Tensioner Pulley TIPS Harmonic Balancer Failure TIPS Harmonic Balancer Pin Pulling Tool ATI torsional dampener Serpentine belt ENGINE LT5 engine Dipstick Restored running engine VIDEO Top End Gaskets TIPS Differences between 90', 91' and 95' Crate Engine Plenums and IHs TIPS LT5 Horsepower and Torque Calculations TIPS Rebuilt exchange engines TIPS Tech Info - LT5 Horsepower and Torque Calculations LT5 Eliminated Systems LT5 Added Systems LT5 New Rebuild Issues LT5 Block (375 vrs 405) Engine mounts Engine mount heat shields LT5 assembly project Block tear down Crankcase ventilation cover Brake Mean Effective Pressure Engine cleaning Ebay ZR1 LT5 Engine ENGINE REMOVAL AND INSTALLATION Jacking engine TIPS Engine removal sequence pictures Engine Installation Engine removal Engine mounts Replacing motor mount covers First engine pull Engine Removal HEADS LT5 Heads TIPS LT5 Valve and Head Reconditioning TIPS Piston CC TIPS Pulling the Engine for Head Work TIPS Birmal or Dunn heads Birmal and Dunn Heads Compression tests Header stud oil leak VALVES AND LIFTERS LT5 Valve and Head Reconditioning TIPS Lifters Resurfacing TIPS Lifters TIPS Tech Info - LT5 New Rebuild Issues (Lifters, Camshafts, and Valves) Lifters Valve Stem Clearance Measurement Tool Valve Stem Clearance Measurements For Regrind Camshafts using Mellings JB 2236 Lifter Valve Stem Clearance Measurements For Stock Camshafts using Mellings JB 2236 Lifters L98 Valve Adjustment JB2236 THROTTLE BODY AND AIR INTAKE Air Filter Installation Idle Air Screw TIPS Air Idle Adjustment TIPS Throttle Position Sensor Diagnoses TIPS TB Photos TIPS TB Coolant Discussion TIPS TB Stuck at WOT TIPS Low Idle Speed TIPS Idle Air Control (IAC) cleaning TIPS Stainless Steel Air Box and Air Filter (L98 and LT5) Throttle Body TPS connector tool Throttle Body Blades Sticking Throttle body issues Throttle body adjustment (with ASR) TPS Adjustment Cruise Control Function Issues Ebay ZR1 LT5 Throttle Body PLENUM Push Connect Flare Fittings TIPS Eliminating EGR on 93'-95' LT5s TIPS Difference between 90' and Later Plenums TIPS The 10 Minute Plenum Removal TIPS Removing Pressed In Fittings from Plenum TIPS Removing The Plenum to Change Fuel Injectors TIPS Plenum pull TIPS Plenum Removal Simplified TIPS LT5 IH, Fuel Rails, Plenum Install Tricks Under the Plenum TIPS Removing Plenum (including the 10 minute Plenum Removal) Plenum pull questons Plenum pull tools and parts Plenum pull parts Under the plenum Plenum bolts install INJECTOR HOUSING Injector housing coolant manifold removal (heat) TIPS Adapting 91' IH to 90' Heads (item #6) TIPS Injector and Secondary failure signs TIPS Coolant Temperature Sensors TIPS 91 Injector Housing modifications for 90 Heads TIPS Secondary actuator check pdf PCV Differences between 90 and 91 Injector Housings Non operating secondaries Oil in injector housing Oil catch can source INJECTORS Changing Fuel Injectors TIPS Bad injector/burnt valves TIPS Secondary Injector Drivers TIPS Checking Injector Resistance with Plenum in Place TIPS RC Injectors Fuel injector testing electrical Fuel injector testing pressurized Bad injectors SECONDARIES Secondary Injector Relays TIPS Having an Operational Secondary Full Power Switch TIPS What Conditions Allow/Cause Secondaries to Open TIPS Secondary Functional Test and Reconditioning the Secondary Actuators TIPS Secondary Failure at 5K rpm Removing Secondary Shafts Engine In Car TIPS Secondary Canister Installation FACTS TIPS Removing Secondaries TIPS Removing Secondary Vacuum System Questions TIPS Secondary Canister Installation TIPS Secondary Removal TIPS Secondary actuator operation VIDEO Secondary Vacuum Reservoir Source TIPS Secondary port vacuum diagnosis TIPS Eliminated Secondary Throttles/shafts Tricks Secondary vaccum system removal Secondaries removed picture Remove secondary throttle plates and shafts Dorman plug for removed secondary throttle shafts Secondary failure Upsidedown Secondaries Secondary cannister failure Ebay ZR1 LT5 Secondary VACUUM SYSTEM New Secondary Port Throttle Vacuum System Vacuum Pump Fuse TIPS Vacuum Systems 90' and 91' (Secondary and Cruize/HVAC) TIPS Checking for Vacuum Leaks TIPS Failed Vacuum Check Valve TIPS Finding Vacuum Leak TIPS Condition of Secondary Vacuum System TIPS Vacuum Pump Taken Apart TIPS Differential Pressure Switch Function TIPS Secondary Vacuum Removal TIPS HVAC, Brake Booster, and Purge Vacuum Leaks TIPS Secondary Vacuum Reservoir Source TIPS Vacuum testing Secondary port vacuum diagnosis Secondary diagnosis Vacuum solenoid Cruise Control Vacuum Cruise Control Inoperable Diagnostics Secondary vacuum diagram Vacuum pump malfunction Non operating secondaries Vacuum pump vendor Vacuum solenoid conversion Check valve under plenum CAM COVERS Removing and Painting Cam Covers TIPS Removing Cam Cover Bolts the Hard Way TIPS Chain guide maintenance TIPS Ticking Sound Under The Cam Covers TIPS Cam Cover Filters Cam Cover Installation Tricks Removing cam cover bolts Cam cover bolt removal tools Cam cover dowty washers Cam cover sealant A136 CAMSHAFT Leaky Camshaft Sensor Twisted Camshaft Valve Stem Clearance Measurements Camshaft Timing Rookie Camshaft Installation Camshaft Regrinds, Lifters, Valves, and Camshaft Timing Camshaft Sensor TIPS Cam position sensor oil leak Camshaft follower design Camshaft timing tools Custom cams Camshaft plugs Reground camshafts (2500 miles) Regrind camshafts Camshaft specs CAMSHAFT BOLTS, CLAMPS, RETAINERS Installing camshaft bolts TIPS Camshaft Sprocket Bolts TIPS Camshaft Billet Retainers TIPS Camshaft replacement retainers Locking down the camshaft bolts CHAIN TENSIONERS AND GUIDES Chain Guide Replacement TIPS Upper Chain Guide Failures TIPS Secondary Chain Guide Rattle TIPS Timing Chain Guide Wear TIPS Resetting timing chain tensioner TIPS Secondary Chain Guide Rattle TIPS PCV system and Timing Chain Wear Strips Installing chain guides Always reset chain tensioners Chain tensioner unloader Updated chain tensioner RH Camshaft chain guide wear Timing chain guide bolts New style chain tensioner RH Chain Tensioner housing Upgraded chain tensioner housing impressions Chain guide wear strips Upgraded RH chain tensioner housing CAMSHAFT TIMING USING PINS Camshaft timing event picture CAMSHAFT TIMING USING DEGREE WHEEL Camshaft timing TIPS Dial gage holder TIPS LT5 Camshaft Specifications and Camshaft Timing Tricks Camshaft Timing Tech Info - LT5 Summary of Camshaft Timing from Start to Finish Tech Info - LT5 Timing Diagrams Tech Info - LT5 Camshaft Timing and Timing Chain Calculations Setting/Installing the Chain Tensioners and Timing Chain Tricks Camshaft timing optimum deg Cam timing First attempt at camshaft timing ENGINE LOWER END Lower End Rebuild TIPS Lower End Bolt Torque TIPS Lower End Basics TIPS Reuse of Main Bearing Cap Bolts TIPS Engine Liners Priming Lubrication System Rebuilding Lower End Connecting Rods Main Bearing Cap Bolts Last UPDATE of post 4 June, 2024 |
ZR1 Drive Train
Post 5 - ZR1 Drive Train FLYWHEEL Flywheel poll Duel Mass Flywheel Installation Aluminum Flywheel HP Gains are Dynamic Only TIPS Dynamic HP TIPS Flywheel Trim Weights TIPS Replacing Trim Weights in DMFW Fidanza and Components Flywheel check Fidanza (flywheel/clutch plate) Unsprung clutch with Fidanza Sprung clutch with Fidanza Pressure plate bolts Pressure plate bolt guide Dual mass flywheel purpose Balancing New Flywheel balancing CLUTCH Clutch Hydraulic Line Clutch Plate TIPS Clutch Switch TIPS RAM Clutch Review TIPS Clutch Fork Pivot Stud Allen Head Size TIPS Clutch Kit TIPS Clutch Fork Failure Issues TIPS Clutch Fork Clutch FAQ Clutch Start Switch Clutch Start Switch Modifications Using a L98 Pressure Plate on an LT5 Clutch pressure plate wear pattern Clutch replacement issues Carolina Stage 2 Spec stage 3 & sprung hub Spec stage 3 picture Clutch safety switch Clutch switch bypass Correct Center Force clutch disc Unsprung clutch with roller bearing Pilot Clutch hydraulic hose restriction Power Torque Systems Ebay ZR1 Corvette Clutch CLUTCH MASTER/SLAVE Clutch slave issues Clutch Master Cylinder Clutch Master and Clutch Slave Rebuild TIPS Clutch Fluid Contaminated TIPS Getting the Air Out of the Clutch Hydraulics TIPS Master/slave replacement Bleeding the clutch slave Power Torque Systems Ebay ZR1 Clutch Cylinder TRANSMISSION Rockland Standard Gear Throwout Bearing and Pilot Bearing TIPS Pilot Bearing Failure TIPS Removing Transmission Plugs TIPS Zf S6-40 Parts TIPS Pilot Bearing Depth TIPS Rebuild or Replace TIPS Speeds At Shift Points TIPS Speeds At RPMs TIPS Throwout Bearing Source TIPS Transmission Fill/Drain Plug Source TIPS Transmission Removal/Install TIPS ZF S6-40 Transmission specifications Pilot Bearing ZR-1 Transmission Install and Lift Tricks Vibration Issues Diagnosis Throwout Bearings C4 beam plates Reverse Lamp Switch ZFdoc and Reverse Gear Siezures ZF S6-40 Transimission pictures Transmission install locater pins Allen wrench for fill plugs ZF Shifter modifications Shift light Shift light install Gear rattle Pilot bearing replace Pilot bearing removal tool Shift light ZF Doc (Transmission) TRANSMISSION OIL Zf S6-40 Oil TIPS Castrol Edge Comparisons TIPS Castrol TWS 10W-60 (Transmission) DRIVE SHAFT (INCLUDING HALF SHAFT) Sharp Clicking Rear Axle Half Shaft U-Joints TIPS Universal Joints TIPS Rear Spline Rust TIPS C4 Beam Plates TIPS Align drive train TIPS Align drive train sketch TIPS Align "C" Beam TIPS Half Shaft TIPS Universal Joints Source Loose Axle Nuts Driveshaft vibration "C" Beam removal and install "C" Beam removal pictures C4 Beam Plates explained Half shaft noise U-Joints C4 Beam Plates DIFFERENTIAL Clutch and Differential Upgrade TIPS Differential Gear Ratio TIPS Jeep D44 4.10 Gears LT5 Added Systems (Differential Case Drain) Clicking and rust on Spindle Shaft TIPS LT5 Engine and Differential Lubrication Discussion TIPS Dana 44HD TIPS Going from 3:45 to 4:10 Differential Differential case drain Less intrusive differential case drain Differential removal Differential fluid change 4.10 gears pictures Viper gears Viper Parts Dana 44 WHEELS Wheels C4 Corvette Wheel Alignment and Wilwood 6 Piston Brakes C4 Corvette Wheel Information TIPS Advanced Street Alignment TIPS Front End Alignment TIPS A-Mold Identification TIPS Rear Axle Nut Torque TIPS Reproduction wheel issues TIPS Toe, caster, camber TIPS Wheel Repair TIPS Wheel Bearings TIPS Wheel Technical Information Wheel Rim modifications Wheel spacers Dymag wheels Rear wheel bearing removal Rear wheel bearing Wheel alignment street 89-93 Wheel Toe in Adjusting rear wheel Camber & Toe In Aftermarket Wheel considerations Wheel Offset Calculator Ebay ZR1 SKF BR930024 Rear Wheel Hub & Bearing TIRES Tire Dimensions ASR 92'-95' TIPS Original Tire Pressure Gauge TIPS Tire Pressure Gauge TIPS Nitto Drag Radials Usage TIPS Tires and Selective Ride Control 315 vrs 335 What is ASR Tire sensor Tires Drag Radial test AFS Wheels Discount Tire BRAKES C4 ABS TIPS Brake Pad TIPS Rebuilt Master Brake Cylinders TIPS Brake System Myths TIPS LT5 Final Inspection including Brake Tricks ABS Code - Definition ABS relay (89'-91' Zs) modification Rear caliper rebuild Caliper rebuild part numbers ABS light on ABS system Brake fluid facts ABS wiring issue Ebay ZR1 Brake Pads BRAKE UPGRADES Basic Brake Upgrade TIPS C6 Z06 Upgrade TIPS Brake brackets C4 to C5/C6 conversion Brake adapters installation Brakes That Will Stop a Freight Train ZR-1 (90' and 91') Wilwood Rotors and C4 to C5-Z06 Conversion Brake upgrade MovIt MoveIt Pictures C5/C6 Brake installation on 90' ZR1 C6 Calipers on 94' ZR1 Installed Baer 6P brakes SUSPENSION Bilstein Shock Designations TIPS No Flex Frame Stiffener TIPS Bilstein Shock Applications TIPS Selective Ride Control Solution TIPS Bilstein Shock Applications and Self Alignment TIPS Bilstein Shock Actuator Part Numbers TIPS Service Ride Control Codes TIPS FX-3 shock Rebuild TIPS Revalving and Painting Bilsteins TIPS Clearing Service Ride Control Codes TIPS Disconnect Ride Control TIPS FX-3 Performance TIPS Rear Shocks Replace TIPS Front Shock Change TIPS Rear Shock Change TIPS FX3 Selective Rid Control TIPS FX3 Actuator Rebuild TIPS eshocks Bilstein Shocks Bilstein Shock Gear Differences DRM Coil Overs Rear suspension pictures Coil over technology Coil over installation Coil over springs Coil over rear top brackets Rear suspension Rear coil over DRM coil over pictures Banski kit Vansteel coil overs BUSHINGS, BRACES, SRC Rubber Bushing Kit New bushings on rear cam rods VIDEO Ball Joint Replace Set Up TIPS Camber brace Lower A Arm bushings Upper and Lower A-Arm Bushings Replacing all bushings Rubber bushing kit C4 Frame brace Service ride control time out Service ride control codes STEERING 90-95 Power Steering Pumps Are ZR-1 Specific Power Steering Pump Repair Kit Replacing Power Steering Pump TIPS Make Your Own Power Steering Lines TIPS Sources of Fittings for Power Steering Lines TIPS Loose steering column TIPS Dimmer Switch TIPS Replacing tie rods Tie rod dust boots Rubber bushing kit Tilt Steering column wobbling Removing air bag TurnOne Last UPDATE of post 5 June, 2024 |
ZR1 Engine Fuel, Lubrication, Cooling, and Exhaust
Post 6 - ZR1 Engine Fuel, Lubrication, Cooling, and Exhaust FUEL DELIVERY Replacing Fuel Pumps Fuel Pump Removal Ohm Injectors HOT TIPS Fuel Pump Testing TIPS Fuel Pump Install TIPS Fuel Tank Gasket and Boot TIPS Fuel Pump Jumper TIPS Least Expensive Fuel Pumps TIPS Fuel Pump Option TIPS Difference between 90' and 91' Evap Purge TIPS Fuel Injector Resistance Plenum In Place TIPS Primary Fuel Pump Failure TIPS Changing Fuel Injectors TIPS Fuel pump test connector TIPS Fuel Pump Testing TIPS Fuel Pump replacement using Bosch 69225 TIPS Fuel Pump Bypass Switch TIPS Fuel Injector Offset TIPS L98 Disabling DFCO One more fuel pump source Fuel pump sender Fuel pump replace Fuel filter Cranks but no start Changing fuel filter New fuel pump pictures Old fuel pump pictures Fuel pump fuses Viton seals for ethanol blends Charcoal canister replace Charcoal canister differences (90' and 91') Fuel Delivery (Ethanol) FUEL PRESSURE The Improved LT5 Fuel Pressure Regulator Fuel Pressure Driving TIPS Fuel pump test connector TIPS Fuel Pressure Drop TIPS Delphi Fuel Pressure Regulator TIPS Checking Fuel Pumps #1 and #2 TIPS Checking fuel pressure key and engine off TIPS Checking fuel pressure TIPS Prevention of Fuel Dripping From Disconnected Fuel Lines TIPS Fuel pressure regulator source Hot wire fuel pump Cleaning fuel rails Fuel rail pressure ENGINE LUBRICATION SYSTEM Pre Lube ??? Change oil light reset VIDEO Oil Temperature Control Valve The Importance of ZDDP Debate Billet Aluminum Oil Cooler Adapter TIPS SS Braided Oil Cooler Hoses and Fittings Oil leaks TIPS The most common but most unrecognized oil leak TIPS LT5 Engine and Differential Lubrication Discussion TIPS Engine Lubrication System Functional Discussion TIPS Remove Oil Pan Engine In Car TIPS Oil Cooler Drain Plug TIPS Oil Pans and Gaskets Differences TIPS Engine Oil Prime TIPS Dual Oil Filters TIPS Oil Consumption TIPS Engine Pre Installation Lubrication System Tricks LT5 Lubrication Tricks OPRV Cover Plate Oil Cooler Connections Leaks Oil pick up "O" ring thickness 1 Oil pick up "O" ring thickness 2 Installing New Oil Pan Gasket New Oil Pan Gasket and Bolts Oil pan gasket Magnetic oil pan drain plug Pre Lube Change oil light reset proceedure OIL PRESSURE Gauge Oil Pressure Sensor Calibration TIPS Removing Oil Pressure Switch TIPS Oil Pressure Sensors TIPS Engine Oil Pressure/Temperature Sensors TIPS Oil pressure sensor location Low oil pressure Oil pressure switch removal Sensor Oil leak Mechanical oil pressure gauge ENGINE OIL, OIL FILTER, DIP STICK Oil poll Oil filter poll Changing Oil TIPS Oil Level Sensors TIPS Engine Oil Methology TIPS ZDDP TIPS Elite Engineering Oil Catch Can Oil Dipstick Handle Replacement TIPS L98 Oil Cooler Housing Modifications for Headers L98 Reset Change Oil Light Engine Oils Changing Engine Oil Oil Catch Can Photo Oil Level On Dipstick SS Dip stick Tube Valvoline racing oil ZDP and cam wear ZDDP and lifter wear FRAM TG3985 oil filter Oil drain using MityVac Dip stick tube seal Dip stick bracket Amsoil 10W-30 ZDDP Amsoil 10W-40 (Engine) All about motor oil WATER PUMP The Coolant Bypass Plug and Air Locked Water Pump TIPS Water Pump Replace TIPS Electric water pump TIPS Air Locked Water Pump TIPS Air Locked Water Pump With TB Coolant Blocked TIPS Preventing Air Locked Water Pump L98 Water Pump Fit L98 Removed the Frisbee Randy Woods thermostat Leaking water pump fix Water pump gasket sealant Rebuilt water pump Water pump bolt lengths Ebay LT5 Water pump ENGINE COOLANT Antifreeze poll Coolant TIPS Coolant Characteristics (Mix, Pressure, Elevation) TIPS GM 1825M Coolants TIPS Refilling with coolant Eliminated IH Housing and Throttle Body (TB) Coolant system Coolant Selection Summary NOT Dexcool Coolant system service Coolant refill techniques Coolant temperature display COOLANT SYSTEM, HOSES, LEAKS Thermostat and Engine Cooling LT5 Cooling and Radiators TIPS Tool Comparison for Removing Original Coolant Hose Clamps TIPS Removing Original Coolant Hose Clamps TIPS Thermostat and Thermostat Housing TIPS 180 deg Thermostat vrs 160 deg Thermostat TIPS Gates Power Grip Clamps TIPS Replacing Coolant Hoses TIPS Getting the Air Out Simplified TIPS Thermostat Housing TIPS Stant thermostats TIPS Leaking Heater Hose TIPS Heater Hose TIPS Water Pump Replace TIPS Digital Coolant Temperatures TIPS Engine Temperatures TIPS Coolant Temperature Sensors TIPS Thermostat rubber seal install TIPS Hoses TIPS 1/8 inch allen head aluminum pipe plugs Coolant Hoses and Preventing The Air Locked Water Pump Filling With Coolant (TB Coolant Eliminated) LT5 Thermostat operation LT5 Radiator and Exhaust Install Tricks Using HVAC Display for Engine Coolant Temperature Water Pump, Coolant Temperatures, and Coolant Radiator Debree Screens Getting The Air Out of the Coolant System TB Coolant Discussion Thermostat housings Replacing Thermostat or Lower Radiator Hose Thermostat modifications Hot only at idle TB Coolant elimination discussion SAMCO hoses picture Injector housing coolant leak Ebay LT5 Thermostat Ebay ZR1 Coolant RADIATOR AND FANS Radiator Rubber Mounts TIPS Installing a Ron Davis Radiator and Testing Keeping the LT5 Cool and Radiator Debris Screens Fans On All The Time TIPS Radiator Cooling Fans Operation TIPS Primary Cooling Fan Operation Criteria TIPS Radiator Drain TIPS NOS Fan with Shroud TIPS Fans controlled by AC TIPS Make Your Own Debree Screen TIPS Fans Operational Check Fan Relays Replacing radiator Replacing radiator shroud Removing radiator shroud Cooling fan inputs Debris screens Ebay ZR1 Radiator CA SMOG CA SMOG TIPS Passed CA SMOG Finally passed CA SMOG Failed CA SMOG Passed CA Emissions Approved by CA SMOG Nazi's Finally passed emissions CA Smog Nazi's can kiss.... More SMOG problems Another 91' fails CA Emissions Gross polluter ZR-1 Can't pass CA SMOG POSITIVE CRANKCASE VENTILATION PCV System TIPS PCV valves sources TIPS MAP Hose TIPS PCV connector & MAP sensor PCV system PCV source Crankcase Ventilation PCV and Cam Cover Vents Difference between 90' and 91' heads Cam cover vent material Cam cover SS vent material EXHAUST SYSTEMS Exhaust Manifold Bolts Catalyst failure Eliminating the Air Pump TIPS Passing CA emissions TIPS OBX Cat Back Exhaust TIPS Corsa exhaust Functional/Non-functional Exhaust SW Headers ZR1CORVOR and SW Exhaust ZR1CHAMSW Tricks L98 Air Pump Elimination L98 Air Pump Elimination Details Exhaust System Replace with Headers Exhaust Headers Locking Bolt Tricks Removing Exhaust System L98 Installing SW Headers Performance Exhaust systems Ebay ZR1 Cat Back Exhaust HEADERS Header Install Video Header Gaskets and Bolts TIPS Installed SW Headers/Exhaust Photos TIPS Installing SW Headers TIPS L98 and LT5 Exhaust System Header Bolts Headers install tricks Header stud oil leak Dip stick bracket Stainless Works Headers flex transition Stainless 304 vrs 409 Last UPDATE of post 6 June, 2024 |
ZR1 Specifications, Restorations, Air, Audio, Lifts, and Road Trips
Post 7 - ZR1 Specifications, Restorations, Air, Bose Audio, Lifts NUTS, BOLTS, HOSE & FITTINGS Removing Broken Off Bolts Interior Screws/nuts, and Magnetic Sockets TIPS Stainless Braided Hose and Fittings Loctite 262 Camshaft sprocket bolts Stainless steel bolts Stainless fittings Ebay ZR1 LT5 Bolts GASKETS & SEALANTS Permatex Super 300 Usage TIPS Anti Seize usage TIPS Antiseize on Spark Plugs TIPS Finding and Fixing oil leaks TIPS Reusable Gaskets TIPS O Rings sizes Gaskets Gaskets and sealants Head gasket source Perma bond A136 Ebay ZR1 LT5 Gaskets ZR-1 The FBI Gang TIPS ZR1 quarter mile King of the hill ZR1 memoir #1 ZR1 memoir #2 ZR1 Saga #1 ZR1 Saga Vets Day ZR1 CDs RPO LT5/CCM/Intro to LT5/ABS ZR1 magazines LT5 Training Videos/Tech Guides LT5 Training Videos/Tech Guides Covers LT5 ENGINE PHOTOS AND SPECIFICATONS LT5 specifications LT5 92' and 95' crate engines Overhead picture LT5 LT5 photos LT5 picture RESTORATIONS & TRANSFORMATIONS Craigs 95' Transformation TIPS Restoration-of-steel-blue-91 TIPS Typical Top End Restoration TIPS Locobob Interior Restoration TIPS 1990 LT5 Top End Restoration TIPS ZR-1/LT5 and L98 Restoration Options Cleaning the Valley TIPS Restoration 90' ZR1 continued TIPS High miler TIPS High miler update Restoration 90' ZR1 Restoration 92' ZR1 Restoring the girl Rebuild 1991 Engine cleaning Show Car Displays BLING Billet Aluminum Oil Cooler Adapter TIPS Billet Aluminum Dipstick Handle TIPS Carbon Fiber Interior Trim TIPS Carter Bling TIPS Metal Polish Bling TIPS Carter200 Bling Chrome billet tail light louvers Carter throttle body cover bling Carter LT5 various caps bling Carter center caps bling Carter Brembo bling Carter air bling Shift knob bling POWDER COATING Throttle body Top end refinishing Emblems How to powder coat Sunset Powder Coating Precision Powder Coating PORTING (PLENUM, INJECTOR HOUSING, HEADS, HEADERS) Locobob the Porting Guy TIPS Porting effects Porting examples Head porting details Head porting pictures Matched porting LT5 porting Head porting (Dynomite) Head porting Dyno numbers INTERIOR Suede Headliner TIPS Floor Mats TIPS 95' seats in 91' TIPS Window and AC Switch Connections TIPS Courtesy Light restore TIPS Interior Restoration TIPS Interior Trim Color Touch Up TIPS Swappable Interior Panels Interior Carpet Glued Headliner Repair Seat Repair Headliner Repair Seatbelt Solutions Interior Door panel removal Door panel repair Brey-Krause harness bar How to clean ZR-1 carpet Removing center console Lumbar pump repair Removing carpet stains Interior Carpet replace Steering wheel recondition Dynamat Ebay Hood Insulation Retainer AIR CONDITIONER & HEATER Heater Core Replacement AC Control Module Removal Fans Do Not Shut Off TIPS Climate Control Button Repair HVAC Codes Replacing the Heater Core and Heater Hose Connection Removal of Heater Core Without Removing Dash TIPS Removal of Heater Core TIPS Blower Control Module TIPS Cannot control AC Fan speed HVAC/Climate Control Button Contact TIPS AC Normal Low and High Side Pressures TIPS AC Compressor Not Turning On TIPS Solution to Evaporator Core Leaks TIPS Heater Coolant Flow and Fittings TIPS Air Compressor Part Numbers and Sources TIPS AC Under Hood Fuse TIPS R12 vrs R134a and recharging R12 HVAC Codes HVAC Code Discussion AC and Fan Operation Blower Control Module Air Compressor Not Working Radio and Air issues Replacing heater core Coolant heater core replace AC Evaporator core plugged AC compressor clutch repair R12 vrs R134a Blower motors Cleaning evaporator core BOSE AUDIO SYSTEM Bose Replacement Speakers Radio Antenna Electrical Schematic C4 Audio Antennae Mast Repair Factory Car Stereo Repair Bose Speaker Amp Alternatives TIPS Antenna Mast Repair TIPS Antenna Delete TIPS Antenna Grommet TIPS CDM Removal TIPS Satellite Radio TIPS Bose System including speakers removal videos Antenna Mast Antenna mast instructions Bose Power Antenna Bezel Antenna Mast Part Number Bose Speaker Amp Options TIPS Amp Capacators Repair/upgrade Speaker amps on Ebay Radio antenna Antenna manual control Bose speaker amplifiers AVIC Z3 Installed Avic D3 install Double DIN Antenna Parts Doc Don's (Radio) Ebay ZR1 Bose EXTERIOR Roof Panels Windshield poll Windshield delamination poll Safelite Windshield Install TIPS Windshields Windshield Removal TIPS Windshield wipers TIPS Windshield Replacement TIPS Windshield trim moulding/weatherstrip removal & reinstall TIPS Windshield Wiper Blades TIPS Jack in Zipper Tire Bag inside Black Plastic Bag TIPS Car Cover TIPS Weather stripping Source TIPS Hood Support Source TIPS Engine cleaning TIPS Targa Tops TIPS Melrose Targa Tops TIPS Window Tinting TIPS Hood Latch Receptacle Drain TIPS How to Replace the Wiper Motor Paint Spider Cracks Paint Chip Repair Hood Release Windshield delamination Top glass recondition Repainting the Z Windshield molding 90' Window seals Weather stripping Detailing spray Heat and sound barrier insulation Fiberglass repair Cleaning and polishing Corvette Paint Codes Hood detailing Door ajar switch TRIM Shift and radio surround trim color LIFTS Lifting the ZR1 TIPS Wooden Lift TIPS Lifting and Towing the ZR-1 Using KwikLift KwikLift Adapter Bendpak 4 post HD-9ST Twin post lift ROAD TRIPS Road Trip to Yellowstone Road Trip to Death Valley and the Grand Canyon Purple Zr-1 Road Trip To Utah Road Trip Back To Alaska Tools and Spare Parts for Long Road Trip Road Trip to Glacier NP Road Trip Southwest and San Diego Road Trip Vets on Lexington Road Trip to Canada ZR-1 Pick Up Story Yellowstone and Pacific Norwest Purple ZR1 Road Trip Coast To Coast Purple ZR1 Road Trip West Virginia Trip Florida Trip Alaska Trip Canada Trip CA Redwood Trip CA or Bust Trip Gatlinburg Tenn Trip LAST BUT NOT LEAST Winter Storage Made Simple LT5 Registry Archive TIPS BG 2012 Photos Supercar Cruize to Payson Cell phones and driving in CA Something easy becomes a mpia Always be nice to others Trying to please everyone Kludged and Ripped Instant History Polar Bears The GARAGE The SHED What is Acceleration CCM and CHP Guns and Jerks SCAMS...Beware!! Last UPDATE of post 7 June, 2024 |
ZR1 Engine (LT5) Bolts and Hydraulics
ZR1 Engine (LT5) Bolts and Hydraulics https://cimg5.ibsrv.net/gimg/www.cor...72f51747ee.jpg https://cimg6.ibsrv.net/gimg/www.cor...e50286bb95.jpg LT5 Bolt Charts with suggested bolt torque, loctite and antiseize application information are included above. The free chart from Jerry's Gaskets which provided the basic LT5 component bolt sizes has been considerably modified into two charts above. The charts have been organized by function. If you could only use one Tool....use the Metric Flex Head Ratchet on LT5 Nuts and Bolts. https://cimg8.ibsrv.net/gimg/www.cor...761d2df977.jpg Hydraulic Fitting Size comparison AN (Army and Navy).....-2.........-3...........-4.........-5.........-6..........-8........-10.......-12 Tube OD (Hose ID).......1/8".......3/16"...... 1/4".......5/16".....3/8".......1/2"......5/8"......3/4" SAE thread size...........5/16-24..3/8-24.....7/16-20..1/2-20...9/16-18..3/4-16...7/8-14..1-1/16-12 Pipe thread size (NPT)..............1/8-27.....1/4-18................3/8-18....1/2-14..............3/4-14 Metric Pipe Thread Fine........10-1.5........12-1.5....14-1.5.....16-1.5....18-1.5.....20-1.5 1/8 inch NPT Drill is 21/64 or 11/32 inch. Aluminum Allen Head 1/8 inch pipe plugs found here. Speedway Motors Aluminum Stat-O-Seal washers with molded Buna-N inner seals are much more reliable than the more common steel stat-o-seals. If the rubber portion fails to make contact all around the port, the aluminum will act as a crush washer, providing a reliable metal to metal seal. Use them to seal screws, bolts or plumbing fittings. The Buna-N seal is resistant to petroleum fuels and oils. Pegasus Auto Racing Stat-O-Seal Inside Diameters vs. Outside Diameters ID Size...#6 (0.138")..#10 (3/16")...1/4"..5/16"...3/8"..7/16"..1/2"..9/16"..5/8"...3/4"...7/8"..1.00" OD Size............ .38".......... .44".. .50".. .60"... .66".. .76"... .88"...1.06"..1.19".1.32"..1.51".1.76" SS Braided Oil Cooler Hoses and Fittings 1. Tools. One 10 inch cresent wrench (Box Wrench is best), One vice, Air compressor, Angle Grinder (with Cut Off wheel). The best tool for cutting the SS Braided Hose is a Small Angle Grinder (with Cut Off wheel) which does not fray the SS braids on the hose ends. It is also best to use an appropriate size Box Wrench on the Hose Fittings (box end) to minimize leaving marks on the fittings. I use Aeroquip Reusable Fittings and SS Braided hose from Summit Racing. https://cimg3.ibsrv.net/gimg/www.cor...e9246160ff.jpg To remove existing 12AN x 3/4 NPT fittings from the Oil Filter Housing use a 1 inch box wrench (combination box/open end) with the box end on the fitting interlocked with a 3/4 inch box wrench on the other end. This will provide the leverage/torque without excessive horizontal pressure to remove the fittings. I use permatex when installing the New 10AN x 3/4 inch NPT fittings into the Oil Filter Adapter (lower fitting first). Let the ZR-1 sit over night before removing the existing Oil Cooler Hoses to minimize oil spilling. Use of 10AN Hose/Fittings I use all 10AN Aeroquip Reusable Fittings and 10AN Hose....The 10AN SS Braided hose I use has ID of 9/16 inch and the 12 AN SS Braided Hose has ID 5/8 inch. As it turns out.....the 12AN hose with 5/8 inch ID is identical to stock Oil Cooler Hose having ID of 5/8 inch. Also I noted the ID Fittings on the stock Oil Cooler Hoses on the Oil Cooler end where the tubing is located is less ID than the SS Braided 10AN Oil Lines. The Stock Oil Cooler hoses have 6 inches of steel tubing on Oil Cooler end that are identical in ID (9/16 inch) to SS Braided 10AN. Further, the Stock Oil Cooler hoses are 17 inches long as compared to 13 inches long for SS Braided Oil Cooler Hoses. The Oil Filter Adapter end of the Stock Oil Cooler hoses is only about 1/2 inch ID at the fittings. Which if you add all that up I would say the total head loss in the stock Oil Cooler hoses is about identical to the SS Braided 10AN with Aeroquip 10AN Fittings. 2. Measuring SS Braided Hose Length. A. Follow Step #3 below and make up one end of each SS Braided Hose (cut longer than required to reach the Oil Cooler Adapter) with the 45 degree Aeroquip Reusable Hose Ends. B. Install and snug up but not tight the 45 degree Aeroquip 10AN Hose ends onto the 10AN x 3/4 inch NPT fittings installed into the Oil Filter Adapter. C. Take the free SS Braided Hose ends curved freely around the radiator housing as they would look in the final installation. Mark the SS Braided Free Hose Ends along Red Line A and Red Line B as shown. D. Cut these Hose Ends about 1/4 inch longer than that mark. E. Install the 90 degree Aeroquip 10AN hose ends as in step #3 below. F. After installation of all four 10AN Aeroquip hose ends is complete, install the 90 degree hose ends on the Oil Cooler Adapter. G. Tighten the 10AN Fittings into the Oil Cooler Adapter (18mm x 1.5 or 6AN Straight Fittings). H. Tighten the 10AN 90 degree Aeroquip Fittings onto the 10AN male fittings of the Oil Cooler Adapter at the angles shown by CD and EF. Make sure there is a small gap between the bottom 10AN 90 Degree Fitting and the AC Line and the two 10AN 90 degree fittings (top and bottom) I. Install the other end of the SS Braided Hoses 45 degree Aeroquip Fittings onto the respective Oil Filter Adapter male fittings and tighten. J. Now making sure the "O" rings are in place on the Oil Cooler Adapter (I use Permatex on the adapter "O" ring face), position and the adapter on the face of the Oil Cooler and insert the 6mm x 1.0 x 35 mm SS Allen head bolt with SS washer into the Oil Cooler Adapter and tighten the bolt. No modification of the Fiberglass Radiator Housing is required since the Oil Cooler Adapter is installed on the Oil Cooler AFTER the fittings are connected and tightened on the Oil Cooler Adapter. https://cimg9.ibsrv.net/gimg/www.cor...116746b126.jpg 3. General SS Hose Assembly with Re-Usable Fittings. A. Place SS Braided hose in vice and cut SS Braided hose to length using Angle Grinder with Cut Off wheel. Angle grinder is preferred since minimal SS wires are left free of the cut. B. Make sure NO SS Braided wires enter the hose end and make sure ALL loose SS Braided wires are ground flush with end of hose. Keep the hose in the vice with about 2 inches on the free end out of the vice. (Clean the inside of the hose end Cut Off before going further with Cotton Cue Tip . C. Take the AN reusable hose fitting and unscrew the male part from the female part. The other end of the male part will have an NPT pipe thread or "O" ring seal thread size (AN) as desired. D. Take the AN reusable hose fitting female part and screw/push onto the SS Braided hose (counterclockwise) by hand pushing onto the hose as you rotate the female hose fitting counterclockwise. Aeroquip Nickel Plated Aluminum Reusable Fittings are not threaded but ARE serrated requiring a push onto the hose only. Make sure ALL SS Braids are inside the hose fitting just pushed onto the hose. E. Screw/push the AN female reusable hose fitting onto the hose fitting such that the hose is at a depth into the female fitting as defined by the lines on the female fitting surface. F. Lubricate the inside diameter of the SS Braided hose with oil through the end of the female fitting. G. Insert the male reusable hose fitting into the lubricated hose through the end of the female fitting. H. Push the male fitting into the hose as you rotate the male fitting clockwise using a cresent wrench (Box Wrench preferred). Once the threads are caught, continue rotating the male fitting into the hose untill approximately 1/16 inch space is left between the hexigon of the male fitting and female fitting. I. Install the second hydraulic reusable hose fitting on the other end of the hose as per steps 2 through 8 above. J. Last...but not least....take an air hose (Air Compressor) and blow the hose clear to make sure you have a clean assembly (if the SS Braided hose is not too long look through the hose end to end for any debree). You now have a SS Braided hydraulic hose with fittings good for maybe 2,000 psi hydraulic pressure more or less. 4. Parts Required for SS Braided Oil Cooler Lines with Re-Usable Fittings. The SS Oil Cooler Lines are very easy to make up in SS Braided hose using Aeroquip reusable fittings and SS Braided hose available from Summit Racing. The Aeroquip Fittings are Swivel so self aligning when installing. A. Use two 10 AN Stainless Steel Braided hose B. use two Aeroquip Reusable Hose Ends, 90 Degree, -10 AN Hose to Female -10 AN, Aluminum, Nickel Plated C. Use two Aeroquip Reusable Hose Ends, 45 Degree, -10 AN Hose to Female -10 AN, Aluminum, Nickel Plated D. On the Oil Filter Adapter remove the 12 AN Flare fittings Trick to Remove the 12 AN Flare Fittings and use two 10AN Flare to 3/4 inch NPT E. Oil Cooler Adapter With the secondchance design use one "O" ring on each 10 AN Flare fitting with 18x1.5 metric thread. With the Jeffvette design use one Stat-O-Seal, 5/8 in Inside Diameter, Aluminum with O-Ring on each 10 AN to 3/8" BSPP Straight Adapter. F. One 6mm x 1.0 x 35 mm SS Allen head bolt G. One 6 mm SS washer H. Two "O" rings for the Aluminum adapter manifold to oil cooler interface. The first seven items can be found at Summit Racing. Secondchance Design of Oil Cooler Adapter..................Jeffvette Design of Oil Cooler Adapter https://cimg1.ibsrv.net/gimg/www.cor...f9f7575df1.jpghttps://cimg6.ibsrv.net/gimg/www.cor...a49b3b5f9d.jpg https://cimg8.ibsrv.net/gimg/www.cor...96b42bc558.jpg https://cimg9.ibsrv.net/gimg/www.cor...e2fdfbaf37.jpg I have never had one of these hydraulic lines with Aeroquip Reusable Fittings leak and they are much much tougher than original crimped fittings and easily replaced or adjusted if you want to at some point make them longer or shorter (the fittings are reusable and swivel). And......you will find a much better routing of the lines if you make them yourself by looking at the routing of the existing Hydraulic Lines. The Aeroquip Reusable Fittings come in all sizes and angles to fit any situation. You can make your own oil cooler lines as shown here and Power Steering Lines or any other hydraulic line you might need on the ZR-1. As an aside, I use the similar Aeroquip reusable fittings and Aeroquip 1509 hydraulic hose on all my farm implements and tractors. I make up all my implement hydraulic lines often replacing relatively new lines that come with the implements with my own lines that are much more dependable under extreme usage. We are talking hydraulic pressures over 2,000 psi on the hydraulics of some of these implements when the cylinders reach the stops. Once you experiment with making your own hydraulic lines with some using SS Braided hose you will never look back at buying ready made hydraulic lines again. All you need is a vice, hand grinder (or even a hack saw will work), and a couple box wrenches of appropriate size. Oh...and an air compressor to blow clean the lines after assembly. https://cimg0.ibsrv.net/gimg/www.cor...0586d8386a.jpg See SS Braided Oil Cooler Hoses and Fittings Last UPDATE of post 8 Sep, 2023 |
New Secondary Port Throttle Vacuum System for 1990-1995
New Secondary Port Throttle Vacuum System for 1990-1995.
See.......Post 234 - Installation of New Secondary Port Vacuum System hoses This complete NEW vacuum system designed for the 93'-95' can be installed on a 1990-1995 ZR-1. For 1990-1992 this can be accomplished by substituting the longer Manifold Differential Pressure vacuum line on the original 1990-1992 ZR-1 Vacuum System for the shorter curled MDP Vacuum line in the New 93'-95' Secondary Port Throttle Vacuum System. The New vacuum system connectors are New soft rubber and easy to disconnect connectors which are very tight (just twist the plastic tube back and forth and they will let loose). The Original hard rubber connectors are impossible to disconnect without cutting the connector lengthwise (with razor blade) to remove the plastic tube. https://cimg1.ibsrv.net/gimg/www.cor...da8458b135.jpg The Tee (T) was moved and a 1 inch long 1/8" Fuel Line PCV/EEC (SAE 30R7 obtained at O'Reillys) was used as a splice where the T was located. The Stock MDP Vacuum Line was used and added to the New Secondary Vacuum System. I replaced the stock L fitting with the New L fitting removed when T was re-installed for the Drivers Side Secondary Canister. In this case I also used the Stock line with New L fitting from the check valve to the Vacuum Pump line as that Stock line was just a bit longer https://cimg3.ibsrv.net/gimg/www.cor...14c9b96567.jpg Went for a test drive with the 1990 and ALL is perfect :thumbsup: https://cimg1.ibsrv.net/gimg/www.cor...2d8a0934e3.jpg These New Secondary Vacuum Systems for 93'-95 which can easily be modified for 1990-1992s are offered on Ebay for $100 but one can buy them with an offer for less :D New Secondary Vacuum System https://cimg4.ibsrv.net/gimg/www.cor...189605ba83.jpg Last UPDATE of post 9 Oct, 2022 |
Phil's (Jagdpanzer) Fuel Pressure Regulator Solution
Phil's (Jagdpanzer) Fuel Pressure Regulator Solution:cheers: :thumbsup:
1990 ZR-1 #72 with the IFPR https://cimg9.ibsrv.net/gimg/www.cor...5b8b5e3d3f.jpghttps://cimg2.ibsrv.net/gimg/www.cor...ed552e4baa.jpg https://cimg5.ibsrv.net/gimg/www.cor...33d4017b7.jpeg https://cimg0.ibsrv.net/gimg/www.cor...2722289df2.jpg I see no issues for long term use as I have now tested three IFPR (2-1990 and 1-1995) with over 300 operating miles. It will now be so easy to change out Delphi FPR removing failed Delphi (may never fail once installed) or change out the Dephi (for higher pressure or lower pressure Dephi) from the Modified Stock FPR Housing which take only a couple minutes (release fuel pressure in Fuel Rails first). I have installed one Prototype IFPR and two Production IFPR with the same results.....NO LEAKS and PERFECT Performance under ALL Driving Conditions. The Delphi FP10016 is NOT modified in this Application......there are five items that come with the Delphi FP10016 (Plastic Adapter, Screen and snap ring with two additional sliders) that Phil does NOT use. Phil has eliminated the plastic ring, the screen and the snap ring and is using the "O" rings. See The Improved LT5 Fuel Pressure Regulator Pulling the Plenum for most is a BIG deal and most often the Plenum is Pulled to fix a No Start Situation, an Alternator or to replace Injectors. I would say if you recondition your Starter and/or install a reconditioned Alternator or New Injectors... then also install the Improved Fuel Pressure Regulator at the same time :thumbsup: Post 281 - The Improved LT5 Fuel Pressure Regulator Post 282 Changing Out Improved Fuel Pressure Regulator (IFPR) Last UPDATE of post 10 Feb, 2024 |
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