Rebuilding Top End #3032 (Last 1990 Sold)
 

Well....same ole same ole :p

I am rebuilding the Top End on #3032 the Last 1990 ZR-1 sold to public (57K miles).

Everything removed/restored/replaced on Top End (Plenum, Secondary Vacuum system, HVAC Vacuum, Plugs, Coils, Starter, Crank Case Vent Cover, Alternator, AC Compressor (not disconnected).

This is my standard Top End Restoration.

This time I will leave the Water Pump as there are NO leaks at all and ALL bolts were tight.
1. Replaced Power Steering Pulley with Billet Aluminum Pulley.
2. Replaced Belt Tensioner Pulley with Billet Aluminum Pulley.
3. Replaced Crank Case Vent Cover Gasket (several loose bolts - use Red Loctite).
4. Replaced Aftermarket Spark Plug Wires with LT5 Original Plug Wires.
5. Blocked TB Coolant at Injector Housing (appearance is as stock).
6. TB Coolant Return Line to Coolant Surge Tank Blocked.
7. New Spark Plugs.
8. New Secondary Port Throttle Linkages.
9. New RC Injectors (SL4-205s).
10. New Primary and Secondary Injector "O" rings.
11. New Plenum Gasket (use NO gasket sealant of any kind as there is NO Coolant.....Dry Gasket- NO Loctite).
12. New Crank Case PCV "L" hoses under Plenum.
12. Reconditioned Vacuum Canisters (shined up).
13. Reconditioned Starter Solenoid (wire brush contacts on plunger).
14. This time I had to replace bearing on Solenoid end of starter armature (it was a bit rough).
15. New Radiator Hoses with rounded edge clamps.
16. Checked all Coils for proper and consistent resistance.
17. Reconditioned Coil Plate (shined up).
18. Checked Alternator Bearings and shined up Alternator.
19. Replaced Fuel Line "O" Rings at Connection Rear Passenger Side of Plenum.
20. Replaced Injector Housing Coolant Manifold Gaskets and bolts (Use Heat to remove original Torx bolts).
21. Checked ALL Injector Housing Bolts for tightness (Did NOT remove Injector Housings as there were NO oil leaks).
22. Used light Steel Wool (0000) and Simple Green on Plenum and Cam Covers (Will leave Stock Look without Painting or Powder Coating).
23. Removed cover (six 4mm Torx 20 bolts) and dried out TB Coolant Area above TB. Will Replace this cover with Carter Billet Aluminum (ZR-1).
24. More when I think of it ;) (takes three days......one day to disassemble, clean, and repair broken parts, one day to think, and one day to put back together and fire it up) :D

NOTES:
Everything Degreased and HOT WATER Pressure Washed when TOP END Disasssembled. This included clearing the Valley Vent through Bell Housing.

Oh....LT5 ran great (I thought) but found four bad Injectors (resistance 10 ohms, 10 ohms, 6 ohms, 6 ohms)

Compression checked earlier and ALL Cylinders 215 lbs within 5 lbs.

ALL Fluids were Replaced (Engine Oil, Transmission Oil, Differential Oil, Coolant) and Differential Drain Plug Installed Earlier. Haibeck Chip and Starter Relay were also installed earlier.

Typically I check and locate ALL vacuum leaks on secondary system but this LT5 had NO Vacuum Leaks (Secondary Canisters functioned perfectly BEFORE Start of Top End Restoration).


http://i287.photobucket.com/albums/l...ee08725692.jpg
http://i287.photobucket.com/albums/l...7c449daf31.jpghttp://i287.photobucket.com/albums/l...819a47ec75.jpg

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

Sweet!! You are a passionately OCD documenter. Must be the engineer in you.:cheers:

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

Did turn the key for Vacuum Pump and NO vacuum leaks so must have connected ALL vacuum hoses correctly :D

TB coolant is now blocked but you cannot tell by looking ;)
All new RC SL4-205 injectors and some other stuff :thumbsup:

Fired it up and it ran perfectly ......even with TB Coolant BLOCKED ;)

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

That is why I now will call him the
"Detailed Dyno Documenter"

Or "Triple D" for short:salute:

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

Fired it up and it ran perfectly ......even with TB Coolant BLOCKED ;)

Which by the looks of it....NO ONE can tell TB Coolant Blocked at Injector Housing. And.......those hoses for TB Coolant are brand new WITHOUT Clamps (why have clamps when there is NO Coolant Pressure).

Those RC SL4-205 Injectors run sooooo smooth :p

Again...this three day Top End included one day for disassembly and repair/restoration of parts, one day for thinking, and one day for re-assembly (including a test drive up to 120 mph).

http://i287.photobucket.com/albums/l...ee08725692.jpg
http://i287.photobucket.com/albums/l...7c449daf31.jpghttp://i287.photobucket.com/albums/l...819a47ec75.jpg

Note:

The Nice RC Injectors Red Stencil on corner of rear lift top glass.

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

Hey good job and way to go DDD.

Or should it be 3XD or D3X or TriD

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

http://images.corvetteforum.com/imag...s/toetap05.gif

Need to borrow my camera and tripod there Cliff?

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

Thank you...

I like Triple D ;)

Triple D sounds like something to do with Corvette Babes which is ALL good :D

Thanks for all you do and especially like what you have in your signature :thumbsup:

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

"Triple D sounds like something to do with Corvette Babes which is ALL good"

Like the Triple Dipper?

http://www.urbandictionary.com/defin...riple%20Dipper

OH wrong link - I meant the Triple D available from you local Walmart
No doubt the Vette Babes would like this very much

http://www.walmart.com/ip/Crock-Pot-...Black/21154908

Nickname....D to the Third.....'Just Sayin' (nt)
 

I really appreciate your contributions here and to CF.....Awesome!

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

Wonder if I could get him to teach me how to photo-doc my work?

http://www.thegamingtailgate.com/for...icon-Think.gif

Don't bunch up....!!
 

I (and I'm sure many others) appreciate what you have provided also....

Not a zero-sum game......


However, I do prefer my Cold Steel @ Recon Scout...I carried it for years everywhere I went including trips down the Colorado through Grand Canyon and the Snake through Hell's Canyon...then a tour of Afghanistan with my nephew in Company A, 1/1 Infantry, Big Red One...good knife..

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

Thanks for your work RC!

I didn't get to do anything while wearing green for Reagan. No one would tangle with him...

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

Cliff, you D'man! Ryan and Schrade, you're in good hands here, for sure. Nice to see all the input and knowledge sharing.

Cliff, I've studied your documentation and it's so nice to have this at my fingertips. =D>

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

Thanks.......I will document a couple items (not covered before) regarding this restoration a bit later. For the time being, I just fired it up this weekend and am having some fun :D

I have some new 5/16 inch ID rubber hoses coming for the TB Coolant and PCV as well as the Charcoal Canister. On the TB Coolant I will install the new rubber hoses without any clamps since TB Coolant blocked. May show how I use a Whistler Wireless Inspection Camera 9mm Model IC-3709PX to observe the operation of the secondaries (will show photo of what I see with Camera). With the camera you can see operation of secondaries and observe other components under the Plenum without removing the Plenum. And...........you can look at your pistons and cylinder walls as you like :thumbsup:

http://i287.photobucket.com/albums/l...d5e2147b0a.jpg
http://i287.photobucket.com/albums/l...ee08725692.jpg

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

Great work, as usual, Cliff.

When will you start the building to house all your ZR-1's?

:-D

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

Got that building already :D

http://i287.photobucket.com/albums/l...b3098a90c2.jpg

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

Have you a pic with the door down? - I was curious about what is painted on it.

Re: Rebuilding Top End #3032 (Last 1990 Sold)
 

Snoopy with Woodstock on the gun and the Red Baron ;)

http://i287.photobucket.com/albums/l...8/IMG_2493.jpg