'92 ZR-1 Repair & Restoration - ZR-1 Net Registry Forums

bdw18_123 · 07-23-2010

7/23/10:

I've started helping out my buddy Evan (eguyett1985 on CF) with the repair and restoration of the 43K mile '92 red/black ZR-1 he bought. He decided to let me do the thread posting and updating on this project.

So now I've got 2 ZR-1 projects to work on!

Here is the link to the initial thread that he posted on CF telling how he acquired this ZR-1:

http://forums.corvetteforum.com/c4-z...-opinions.html

But here is a partial quote of his initial post on CF if you don't want to or can't view the link for some reason:

eguyett1985:
"... The car is Red/Black, 1 owner, both tops, window sticker, etc. Now here's the problem; the car had a minor electrical fire underneath in the trans tunnel, the reverse light switch shorted causing the harness to catch fire briefly which scorched the LH side of the floor next to the transmission and the area of the firewall below the wiper motor. The owner opened the hood right away and put the fire out; the underside of the hood is completely undamaged as is the engine and the interior. The car was fully insured and the body shop and the insurance company were unable to locate a replacement harness over the past year and the car has sat in my friend's shop with a pending lien sale against it until last week when the body shop got title to the car. Unfortunately, the owner sent the insurance company the title he had in his possession 2 weeks earlier and accepted a payout on the car. So now, I have been offered the car with the necessary minor floorpan repair made and the engine and trans on a pallet at a great price; I have located a perfect replacement harness and can put the car back together in short order. ..."

We are not sure exactly how the fire started. Evan mentions in his post in the link above about the reverse light switch causing it (not sure where he got that info), but we are thinking now that it may have started around the VSS sensor since it seems like the fire would have traveled up towards the engine, not back towards the rear (though I guess it could have traveled back along the wire harness a little way). If the fire had started at the reverse switch, I think the shifter/VSS sensor area would not have gotten burned as bad as it did. There was also a patch of something melted onto one of the exhaust pipes near the front by the transmission, so it's also possible that the fire started as a result of the wire harness touching the exhaust.

Now for some pictures!

(The pictures in this post are a bit slow loading, so they may not show up at first. Just be patient, they will load.)

First, a couple of shots of the exterior. Engine bay area has already been degreased and pressure washed(no pics of
that area yet), exterior has also had a quick wash. Overall, this car is in very good condition (other than the dust,
dirt & fire-damaged areas

)

Here are some pictures of the repaired fiberglass area on the driver's side of the transmission tunnel. Evan's body shop
friend did the repair (same guy he bought the car from). The fiberglass didn't completely burn through, it was just
brittle and weak from the fire.

The repaired section is going to be sanded down so it is smoother, then a quick spray of red paint so it blends better
with the surrounding area.

bdw18_123 · 07-23-2010

bdw18_123 · 07-23-2010

bdw18_123 · 07-23-2010

Coil pack mounting plate with new coil pack connector-base and new AC-Delco coil packs.

Update - 11/24/13

Injector housings installed with new gaskets, PCV system hoses & grommets installed and also the two coolant temp sensors with thread sealant into the driver side IH. The FSM says to tighten the bolts to the specified torque value starting from the center and working your way outward.

One thing to remember is that the bolt closest to the front of the car in the passenger IH also holds the bracket for the cam cover vent tube on that side and the small bracket that bolts to the rear of the alternator. They need to be in place under that bolt before you put on the fuel rails because that bolt won't come out fully with the rails bolted down. Also, I waited to torque that bolt until I was ready to install the alternator so I could make sure that the bracket would be in the right place to line up with the bolt hole in the alternator.

Fuel rails assembled with new fuel injectors. The primary and secondary injectors had o-rings on them, but they weren't the brown Viton ones like Evan had already bought from Jerry, so I removed the black ones and installed the Viton ones.

Fuel rail/injectors assembly installed on engine.

Under-plenum vacuum system installed.

bdw18_123 · 07-23-2010

Power steering reservoir & pump assembly installed.

This is a picture showing the routing of the wire harness that goes down the passenger side of the engine. There are two metal tabs that hold the harness, the L-shaped one goes on the outboard bolt on the oil filter adapter assembly (there is a thick washer that has to be under this tab so it can be put in the right position) and the lower, flat one goes on a bolt on the front cover (second from bottom on passenger side). There are diagrams in the FSM that show how this and many other wire harnesses are supposed to be routed.

The O2 sensor harness connector on the passenger side of the engine is very, very difficult to get to if you put the connector in the factory location behind that little metal bracket that is bolted to the front, passenger side of the oil pan (can be partially seen in the below pic). I'm going to leave the O2 sensor connector sitting on the other side of that bracket next to the motor mount (like how it is sitting in the pic) so it will be a little bit easier to get to if needed.

New AC-Delco spark plug wires and new NGK spark plugs installed. There is also a diagram in the FSM to show how the plug wires route to the coils under the plenum.

Alternator & A/C compressor installed. I replaced all the o-rings on the A/C compressor.

A/C & oil cooler lines installed with new o-rings.

bdw18_123 · 07-23-2010

Fuel lines bolted to the rails with new o-rings and stainless hardware (for some reason, these 3 bolts are not included in the stainless hardware kit from Jerry).

New F-tube assembly (looks just like the original GM versions) and new PCV valves from Jerry's Gaskets installed.

As I was about to install the big lower coolant hose from the thermostat assembly to the water pump, I noticed that it had somehow gotten a big cut in it. It didn't go all the way through, but obviously had to be replaced anyway.

Evan got the new Goodyear replacement hose (part number: 66057) that surprisingly is still available from various places online and as a special order from some auto parts stores. It comes with the protective cover on the outside, but not the spring on the inside, so you have to use the one from the original hose. The spring is a little hard to install in the new hose, you have to keep twisting it (in the direction that would tighten the coils of the spring) and pushing it until it is centered in the hose.

New hose installed.

End of update!

bdw18_123 · 07-23-2010

Time to finish off this thread.

The car is pretty much done now, runs and drives excellently. The only things left to do is get the engine lettering airbrushed on & install the new front spoiler. I'll add new pictures of the engine once the lettering is done.

Paint has been polished. The paint is original except for the hood & top of the front bumper, which have been professionally repainted to eliminate scratches/paint chips/etc. The two 'ZR-1' emblems on the hood were also replaced with genuine GM OEM NOS versions because the originals were destroyed during removal to repaint the hood.

The windshield also had to be replaced with a regular C4 version due to very bad delamination across the whole thing. Probably the worst cast of delam I've ever seen, not sure how it got so bad.

Tires are brand new, they are Sumitomo's.

Also, this ZR-1 is up for sale. Evan is going to do a 'for sale' post soon with all the relevant details (which I will re-post here from CF for him).

Now for the pictures:

bdw18_123 · 07-23-2010

bdw18_123 · 07-23-2010

bdw18_123 · 07-23-2010

Engine lettering is done (reposted pics from Evan's post on CF):

[/QUOTE]

07-23-2010	#1
bdw18_123 Join Date: Apr 2009 Location: Prather, CA Posts: 808	'92 ZR-1 Repair & Restoration 7/23/10: I've started helping out my buddy Evan (eguyett1985 on CF) with the repair and restoration of the 43K mile '92 red/black ZR-1 he bought. He decided to let me do the thread posting and updating on this project. So now I've got 2 ZR-1 projects to work on! Here is the link to the initial thread that he posted on CF telling how he acquired this ZR-1: http://forums.corvetteforum.com/c4-z...-opinions.html But here is a partial quote of his initial post on CF if you don't want to or can't view the link for some reason: eguyett1985: "... The car is Red/Black, 1 owner, both tops, window sticker, etc. Now here's the problem; the car had a minor electrical fire underneath in the trans tunnel, the reverse light switch shorted causing the harness to catch fire briefly which scorched the LH side of the floor next to the transmission and the area of the firewall below the wiper motor. The owner opened the hood right away and put the fire out; the underside of the hood is completely undamaged as is the engine and the interior. The car was fully insured and the body shop and the insurance company were unable to locate a replacement harness over the past year and the car has sat in my friend's shop with a pending lien sale against it until last week when the body shop got title to the car. Unfortunately, the owner sent the insurance company the title he had in his possession 2 weeks earlier and accepted a payout on the car. So now, I have been offered the car with the necessary minor floorpan repair made and the engine and trans on a pallet at a great price; I have located a perfect replacement harness and can put the car back together in short order. ..." We are not sure exactly how the fire started. Evan mentions in his post in the link above about the reverse light switch causing it (not sure where he got that info), but we are thinking now that it may have started around the VSS sensor since it seems like the fire would have traveled up towards the engine, not back towards the rear (though I guess it could have traveled back along the wire harness a little way). If the fire had started at the reverse switch, I think the shifter/VSS sensor area would not have gotten burned as bad as it did. There was also a patch of something melted onto one of the exhaust pipes near the front by the transmission, so it's also possible that the fire started as a result of the wire harness touching the exhaust. Now for some pictures! (The pictures in this post are a bit slow loading, so they may not show up at first. Just be patient, they will load.) First, a couple of shots of the exterior. Engine bay area has already been degreased and pressure washed(no pics of that area yet), exterior has also had a quick wash. Overall, this car is in very good condition (other than the dust, dirt & fire-damaged areas ) Here are some pictures of the repaired fiberglass area on the driver's side of the transmission tunnel. Evan's body shop friend did the repair (same guy he bought the car from). The fiberglass didn't completely burn through, it was just brittle and weak from the fire. The repaired section is going to be sanded down so it is smoother, then a quick spray of red paint so it blends better with the surrounding area. __________________ [IMG]http://i13.photobucket.com/albums/a292/bdw18_123/_zr1netforumsigphoto.jpg[/IMG][B] 1990 Corvette ZR-1 [/B][I] White/Flame Red, #2299, mostly stock, 144K miles.[/I] -Cams timed to the '93-'95 405HP LT5 stock timing. -IAT sensor relocated to below front bumper. -Haibeck hoops installed in airduct. -OBX cat-back exhaust. [COLOR=DarkRed][B](SOLD - December 2012 [/B][/COLOR][COLOR=DarkRed][B]:hello:)[/B][/COLOR] 1993 Corvette Coupe Black/Black, 6-speed (SOLD - October 2009 :hello:) Last edited by bdw18_123; 11-17-2013 at 01:45 AM.

07-23-2010	#2
bdw18_123 Join Date: Apr 2009 Location: Prather, CA Posts: 808	__________________ [IMG]http://i13.photobucket.com/albums/a292/bdw18_123/_zr1netforumsigphoto.jpg[/IMG][B] 1990 Corvette ZR-1 [/B][I] White/Flame Red, #2299, mostly stock, 144K miles.[/I] -Cams timed to the '93-'95 405HP LT5 stock timing. -IAT sensor relocated to below front bumper. -Haibeck hoops installed in airduct. -OBX cat-back exhaust. [COLOR=DarkRed][B](SOLD - December 2012 [/B][/COLOR][COLOR=DarkRed][B]:hello:)[/B][/COLOR] 1993 Corvette Coupe Black/Black, 6-speed (SOLD - October 2009 :hello:) Last edited by bdw18_123; 11-10-2013 at 09:32 PM.

07-23-2010	#3
bdw18_123 Join Date: Apr 2009 Location: Prather, CA Posts: 808	__________________ [IMG]http://i13.photobucket.com/albums/a292/bdw18_123/_zr1netforumsigphoto.jpg[/IMG][B] 1990 Corvette ZR-1 [/B][I] White/Flame Red, #2299, mostly stock, 144K miles.[/I] -Cams timed to the '93-'95 405HP LT5 stock timing. -IAT sensor relocated to below front bumper. -Haibeck hoops installed in airduct. -OBX cat-back exhaust. [COLOR=DarkRed][B](SOLD - December 2012 [/B][/COLOR][COLOR=DarkRed][B]:hello:)[/B][/COLOR] 1993 Corvette Coupe Black/Black, 6-speed (SOLD - October 2009 :hello:) Last edited by bdw18_123; 11-24-2013 at 11:20 PM.

07-23-2010	#4
bdw18_123 Join Date: Apr 2009 Location: Prather, CA Posts: 808	Coil pack mounting plate with new coil pack connector-base and new AC-Delco coil packs. Update - 11/24/13 Injector housings installed with new gaskets, PCV system hoses & grommets installed and also the two coolant temp sensors with thread sealant into the driver side IH. The FSM says to tighten the bolts to the specified torque value starting from the center and working your way outward. One thing to remember is that the bolt closest to the front of the car in the passenger IH also holds the bracket for the cam cover vent tube on that side and the small bracket that bolts to the rear of the alternator. They need to be in place under that bolt before you put on the fuel rails because that bolt won't come out fully with the rails bolted down. Also, I waited to torque that bolt until I was ready to install the alternator so I could make sure that the bracket would be in the right place to line up with the bolt hole in the alternator. Fuel rails assembled with new fuel injectors. The primary and secondary injectors had o-rings on them, but they weren't the brown Viton ones like Evan had already bought from Jerry, so I removed the black ones and installed the Viton ones. Fuel rail/injectors assembly installed on engine. Under-plenum vacuum system installed. __________________ [IMG]http://i13.photobucket.com/albums/a292/bdw18_123/_zr1netforumsigphoto.jpg[/IMG][B] 1990 Corvette ZR-1 [/B][I] White/Flame Red, #2299, mostly stock, 144K miles.[/I] -Cams timed to the '93-'95 405HP LT5 stock timing. -IAT sensor relocated to below front bumper. -Haibeck hoops installed in airduct. -OBX cat-back exhaust. [COLOR=DarkRed][B](SOLD - December 2012 [/B][/COLOR][COLOR=DarkRed][B]:hello:)[/B][/COLOR] 1993 Corvette Coupe Black/Black, 6-speed (SOLD - October 2009 :hello:) Last edited by bdw18_123; 11-24-2013 at 11:24 PM.

07-23-2010	#5
bdw18_123 Join Date: Apr 2009 Location: Prather, CA Posts: 808	Power steering reservoir & pump assembly installed. This is a picture showing the routing of the wire harness that goes down the passenger side of the engine. There are two metal tabs that hold the harness, the L-shaped one goes on the outboard bolt on the oil filter adapter assembly (there is a thick washer that has to be under this tab so it can be put in the right position) and the lower, flat one goes on a bolt on the front cover (second from bottom on passenger side). There are diagrams in the FSM that show how this and many other wire harnesses are supposed to be routed. The O2 sensor harness connector on the passenger side of the engine is very, very difficult to get to if you put the connector in the factory location behind that little metal bracket that is bolted to the front, passenger side of the oil pan (can be partially seen in the below pic). I'm going to leave the O2 sensor connector sitting on the other side of that bracket next to the motor mount (like how it is sitting in the pic) so it will be a little bit easier to get to if needed. New AC-Delco spark plug wires and new NGK spark plugs installed. There is also a diagram in the FSM to show how the plug wires route to the coils under the plenum. Alternator & A/C compressor installed. I replaced all the o-rings on the A/C compressor. A/C & oil cooler lines installed with new o-rings. __________________ [IMG]http://i13.photobucket.com/albums/a292/bdw18_123/_zr1netforumsigphoto.jpg[/IMG][B] 1990 Corvette ZR-1 [/B][I] White/Flame Red, #2299, mostly stock, 144K miles.[/I] -Cams timed to the '93-'95 405HP LT5 stock timing. -IAT sensor relocated to below front bumper. -Haibeck hoops installed in airduct. -OBX cat-back exhaust. [COLOR=DarkRed][B](SOLD - December 2012 [/B][/COLOR][COLOR=DarkRed][B]:hello:)[/B][/COLOR] 1993 Corvette Coupe Black/Black, 6-speed (SOLD - October 2009 :hello:) Last edited by bdw18_123; 11-24-2013 at 11:25 PM.

07-23-2010	#7
bdw18_123 Join Date: Apr 2009 Location: Prather, CA Posts: 808	Final Update - 9/3/14 Time to finish off this thread. The car is pretty much done now, runs and drives excellently. The only things left to do is get the engine lettering airbrushed on & install the new front spoiler. I'll add new pictures of the engine once the lettering is done. Paint has been polished. The paint is original except for the hood & top of the front bumper, which have been professionally repainted to eliminate scratches/paint chips/etc. The two 'ZR-1' emblems on the hood were also replaced with genuine GM OEM NOS versions because the originals were destroyed during removal to repaint the hood. The windshield also had to be replaced with a regular C4 version due to very bad delamination across the whole thing. Probably the worst cast of delam I've ever seen, not sure how it got so bad. Tires are brand new, they are Sumitomo's. Also, this ZR-1 is up for sale. Evan is going to do a 'for sale' post soon with all the relevant details (which I will re-post here from CF for him). Now for the pictures: Last edited by bdw18_123; 09-03-2014 at 09:28 PM.