90 ZR-1 #2273 - To be rescued
 

Recently acquired a 1990 black/black ZR-1, which has led me to this rather impressive LT5 community.

Figured I'd share the process of getting the car to those bored enough to read it. :cheers:

The previous owner bought the car at the age of 18, owned it for 4 years, drove it 2000 miles, might have done some less good mods, and sold it to me.
Not sure who actually did the mods though.
Throughout his ownership, the Service Engine Soon light had always been lit, so he never tested the car with the secondaries active.
When I realized he thought the SES light was a service indicator, I started thinking of the purchase more like a rescue mission than a regular car purchase.
Knowing so little about a car this special makes you unqualified to own it. At least that was my thoughts.

When I came to pick up the car, it was standing on a mix of various wheels and seemingly arbitrarily placed spacers on some wheels.
The rear wheels were apparently worn out when he bought it, and had yet to be replaced.
http://imageshack.com/a/img923/9809/Q5oYEU.jpg

Fortunately I had brought my own set of wheels. Winter tyres from a BMW M3.
The positive lead for the battery had been extended with a car stereo lead, attached to the old lead with a hose clamp.
http://imageshack.com/a/img922/7375/LaoOzB.jpg

The only positive mod I've found. To bad he didn't keep the stock setup.
http://imageshack.com/a/img924/272/dMo7bD.jpg

The battery was busted, so I brought a new one with me. When I got there he had removed the old battery,
and during the moments it was removed, he had lost all the bolts to the battery door/lower fender.
Quite a few wheel lug nuts were also missing, and one stud was rotating.

Beforehand he had told me that the slave cylinder was bad, but topped up with fluid, it should last until I got home.
It lasted approx. 5 minutes, and the remaining 375 miles were pretty much carried out in 5th gear (CAGS did not help either).
Might also mention that using 5th gear put the revs in the range of the worst drone one can imagine.
Those who have read my resonator WTB request, can probably tell why. Another little surprise that came with the car.

Usually I'd walk away when met with such overwhelming signs of poor maintenance, but there are just 10-15 ZR-1's in Norway, and this one deserved a better faith.
And besides, one of the main reasons of buying the car, was to have a project to tinker with in the years to come. Can't tinker on a flawless car.

In the end I did however get the car home, and until my own garage is finished, the Z currently resides in my missus little garage, 15 minutes away from the Arctic Circle Raceway, which suits me just fine. :dancing

I've only had the car since October, but been able to fix most of the electrical issues, as well as the clutch.
The latter more of a semi-success, as the slave cylinder provided by Summit Racing (dorman) does not fit.
The hydraulic line and the vent should be 180° apart, but they are probably approx. 80° apart. Does not fit the right way up, and puts quite a bit of strain on the hose.
Will get the '91 slave and hose the next time.
http://imageshack.com/a/img923/3368/q5Y1Gq.jpg

Re: 90 ZR-1 #2273 - To be rescued
 

I assume all here know how a 90 black/black Z looks like, but I also know people like photos, so here's one from the ad,
http://imageshack.com/a/img921/6549/z25TFJ.jpg

And one from it's new (temporary) home,
http://imageshack.com/a/img923/8388/vpQWHC.jpg

Re: 90 ZR-1 #2273 - To be rescued
 

Bless you.

Re: 90 ZR-1 #2273 - To be rescued
 

Well thank you, Sir.

I got kinda lost in the story-telling so I forgot to ask the question I initially started the post for.

Is it possible to acquire some of the cars history, while it was still in the States? As far as I can tell it was exported in 2005, but Carfax has no history on it.

Re: 90 ZR-1 #2273 - To be rescued
 

I've got to correct my self on this one. Been reading all the tech-archives one the registry front page (quite a few broken links there), where it's mentioned that the original GM slave cylinder for the '90 had the aluminium snap-off bleed nipple, which allows installation in such a tight space. The snap-off bleed screw has been replaced by an extra tall one in steel. Odd no one has told the after marked makers (in this case - Dorman) that they won't fit without the snap of bleed screw.

Clutch Slave Cylinder Installation (1990)

Edit: I see the forum doesn't like use of of the "attachment function", will have to re-post some pictures. ImageShack this time. :)

Re: 90 ZR-1 #2273 - To be rescued
 

Car looks good,it will only look better. How I was advised when installing the new slave cylinder was bolt it up and start pumping the pedal,eventually preassure would build. After about a 1/2 hour of pumping the pedal I broke out the auto bleeder and fineally got the system bleed.

Re: 90 ZR-1 #2273 - To be rescued
 

Thank you!
I bled the slave before installing it (hanging by the hose), and the clutch is somewhat firm after pumping a bit. Not sure I got it all though, so I've ordered another slave cylinder, this time for a 91-95, with the bleed screw pointing down. Would recommend all to get the 91-95 slave and hose for their '90, as I'm quite sure that the hose on the later model is a lot easier to install rather than the long metal pipes on the '90.

I also noticed the following statement in the "ZR-1 Trivia",
Anyone knows what changed in the calipers? Piston? Can one see the difference?

Re: 90 ZR-1 #2273 - To be rescued
 

As far as I know the calipers were all the same for 90-95 and the statement about pedal height makes no sense.

Re: 90 ZR-1 #2273 - To be rescued
 

[emoji106] good luck


Sent from my iPhone using ZR-1 Net Registry

Re: 90 ZR-1 #2273 - To be rescued
 

What boggles the mind is why would anybody do that to a car such a Z and how did an 18 year old kid get ahold of it.

Re: 90 ZR-1 #2273 - To be rescued
 

Thanks, Station.

I'm not sure how he got a hold of it. The kid had 15 cars now, but didn't exactly look as he was made of money. Nor does the "repairs" suggest that there's been a decent cash flow involved.

Re: 90 ZR-1 #2273 - To be rescued
 

Good luck with the resurrection. I'm starting a project myself with another ZR-1, and I hope to have good news to share soon.

Re: 90 ZR-1 #2273 - To be rescued
 

Much appreciated!
Have you got a forum thread on your's?

Re: 90 ZR-1 #2273 - To be rescued
 

Not much to do at work today, so I figured I'd update my little project.
My main plan for my previous 6 weeks at home was mainly to get the car approved, so I could get my licence plate, or at least know what needed to be done to get the approval. No such luck, though.

All I had intended to do before the vehicle inspection was to color match the rear calipers with the fronts, in an attempt to make it less obvious that the fronts aren't stock. :)

Got these re-manufactured ones from Muskegon Brakes, and must say they looked rather decent upon arrival.
http://imagizer.imageshack.us/v2/640...924/ESkIQa.jpg

While waiting for the caliper bracket paint to dry I figured I'd have a look at the passenger seat. The new seat covers are from Corvette America and seems to be of rather decent quality. I replaced only the leather on the passenger side, and both leather, lumbar support and foam on the drivers side. The foam had a good shape compared to the old one, but the internal metal rods weren't always where one hoped they would be, and if they're only off by 1/2", that can call for some improv underway to compensate. The driver side bolster support hinge was also rather loose, so I drilled out the old hinge rivets, and pressed in new 5mm stainless rivets. Side bolster foam is also the only part that's glued to the frame.
Slightly disappointed that the stitching was not white like the original seats, but I'll live with it.

A word of advice, the "Seat installation kit" does not include enough hog rings for two seats. Need 75-100 more to complete both. Not all metal rods are included either, so don't discard the old ones.
http://imagizer.imageshack.us/v2/640...924/kwvbs8.jpg

And of course with the seat out, the center console became readily available. So I dismantled it. Not really to impressed with the parts I got from CorvetteCentral though. The new arm rest was rather decent, but I had to take the cover underneath from the old unit, to preserve the OEM stickers. I also took the light/switch assembly from the old unit, as the new one was of a different, rather noisy type.

The belly of the arm rests.
http://imagizer.imageshack.us/v2/640...922/OnOzss.jpg
New type light w. switch.
http://imagizer.imageshack.us/v2/640...924/R21eRf.jpg

Re: 90 ZR-1 #2273 - To be rescued
 

New center console cover mounting holes didn't match very well with the shifter leather.
http://imagizer.imageshack.us/v2/640...924/ZTUPI2.jpg

Leaving a rather annoying gap if one leave that last bolt out. The paint doesn't really match either.
http://imagizer.imageshack.us/v2/640...924/VYD57X.jpg

With the console out, Climate control unit must also be inspected.
Found a ball of solder on it, otherwise it looked quite good, so I just cleaned it thoroughly, replaced the condensators and re-installed.
http://imagizer.imageshack.us/v2/640...921/T3vP3Z.jpg

Also a good time to have a look at the gear knob, but I must say that I'm rather displeased with the ebay knob I had ordered. Anyone know where I can get a good one? NOS is obviously preferred, but can't seem to find one.
http://imagizer.imageshack.us/v2/640...923/4z6wpi.jpg
The old one seems to have a thicker kind of leather, or some additional fabric glued to the inside of it.
http://imagizer.imageshack.us/v2/640...924/XSAOvm.jpg

Re: 90 ZR-1 #2273 - To be rescued
 

Back to the brakes, I unpacked the Carbotech brake pads they push so hard on CF. Not too impressed with the looks of them, compared to the EBC greenstuff that was installed. One of the "wear indicators" also fell off when I opened the box with the pads. Haven't been able to test the performance though.
http://imagizer.imageshack.us/v2/640...922/8uECFy.jpg
http://imagizer.imageshack.us/v2/640...923/YNxZtw.jpg
The new carbotech pad actually has less meat than the old EBC pads (slight taper on the EBCs).
http://imagizer.imageshack.us/v2/640...923/oqwEcD.jpg

Moving on to clean/check the last corner of the car,
http://imagizer.imageshack.us/v2/640...922/4yTDKt.jpg
Found a nasty surprice when splitting the hub from the disk.
http://imagizer.imageshack.us/v2/640...924/f6F4oI.jpg

The poor disks have been left out of the maintenance schedule and are worn way below minimum. The wear edge on the inside is 2-3mm high on each side, giving 4-6mm total disk wear (I believe 2mm tot. is maximum). The crack is seemingly caused by corrosion originated in the periphery closer to the rim.

Following this, I reupholstered the drivers seat, rented a carpet cleaner to remove 27 year of use from the carpets, and started fault finding on the AC programmer, currently without too many useful results.
With the car re-assembled two days before going back to sea, I went to the workshop where I usually get the vehicle inspection. After seeing the tech drive around with the handbrake on for a while, trying to get the car onto the lift, he comes back to the waiting room telling me the car is too low. They can't lift it, and they can't check it. "And by the way, your rear brakes are hanging a bit".. Very useful people. The next shop I went to couldn't get the car on to the roller for brake testing. "Too low", they say.
The final shop were a bit more positive, saying "Sure, we'll make it work, but our tech is at the dentist, come back next week".

So, all in all, I failed the one thing I set out to do. :cheers:

Re: 90 ZR-1 #2273 - To be rescued
 

Anyone know where to find a bolt for the battery panel hinge?
Bolt "C" on this illustration.

http://www.corvettephotographs.com/c4vettes/battery.GIF

Re: 90 ZR-1 #2273 - To be rescued
 

These can be found at the dealer,if you were closer I've got some extras. I'm sure WVZR-1 will stop by with a part number for the bolt. I forgot your in Norway. I tell you what,if you need something and pay the shipping fees I can help you will the small parts.

Re: 90 ZR-1 #2273 - To be rescued
 

Truly appreciate that, Jeff.
I was kinda hoping to find it at Jerry's or something, so I could just pop it in with a bigger order, but so far no such luck.

Re: 90 ZR-1 #2273 - To be rescued
 

A bit of Filipino motorman art. Not really Z-related, but too nice a piece not to share. :)
http://imagizer.imageshack.us/v2/102...922/AcsDen.jpg

Re: 90 ZR-1 #2273 - To be rescued
 

Sorry I didn't see this earlier. The GM part# for that screw for earlier years is 12338098 and is a T30. I don't know that in later years this was changed to a HEX or not. I might prefer a HEX and maybe I actually changed mine to a HEX when I reassembled. I would think you could do these maybe "everywhere" the dimensions are/were quite popular in all foreign and domestic productions. The spinning washer is certainly desired!

It's an M6.3 X 1.81 x 25 with a "spinning washer"

Another option that might work better considering location is changing the u-nut used to a more conventional M6X1.0 thread and then use a conventional Metric screw. I would think that many of the auto brands sold in ***Sweden use maybe the M6.3 X 1.81 specification but the M6 X 1.0 I'd think for sure. You want the "spinning washer".

What model VW or BMW/AUDI are sold there? Maybe I can scrounge an OEM part number for you.

I'll email you some information.

*** OOPS - Norway

Re: 90 ZR-1 #2273 - To be rescued
 

Thanks! I've replied to your e-mail.
Ordered 20 pcs of ebay. :cheers:

Also added a couple words on the Corvette America leather seat covers in an earlier post, in case anyone were to consider these.

Re: 90 ZR-1 #2273 - To be rescued
 

New wheels received from Steve Jasik!

http://imageshack.us/a/img924/174/jfIk5P.jpg

I'm thinking it'll look more appropriate than the BMW winter rims. :)

Re: 90 ZR-1 #2273 - To be rescued
 

I had heard that BMW wheels would fit.

Re: 90 ZR-1 #2273 - To be rescued
 

BMW wheels fit rather well. You just need hubcentric rings and "wobble nuts". Not something I'd take to the track though.

Next issue was a leaky check-valve on the secondaries, so the plenum was pulled. Wouldn't say it's any harder to do than any other plenum removal job (on euro cars, that is).
It didn't look that bad below, but definitely in need of some cleaning. The crankcase hoses were hard as rocks, but remaining hoses were not bad at all.
http://imagizer.imageshack.us/v2/800...924/0OkIpK.jpg

Removed the starter for overhaul, and to clean the drain.
http://imagizer.imageshack.us/v2/800...923/X2kAW6.jpg

I assume these are the Accel 150821 injectors? They are marked 01D109B and 21 lb/hr.
http://imagizer.imageshack.us/v2/800...923/teS8UP.jpg

Re: 90 ZR-1 #2273 - To be rescued
 

Here's the starter overhaul kit, ordered at advice from WVZR-1.
Part number ND-17-1103
http://imagizer.imageshack.us/v2/800...923/IpJWNz.jpg
It does contain pretty much all you'll need to service the starter, but does not contain the bearings on the crank gear.

http://imagizer.imageshack.us/v2/102...922/IBqdXK.jpg

Didn't look all that bad inside,
http://imagizer.imageshack.us/v2/800...922/Ox1QDO.jpghttp://imagizer.imageshack.us/v2/800...924/9HfF5L.jpghttp://imagizer.imageshack.us/v2/800...924/nvsJUR.jpg

Note, there was nothing wrong with the starter before the service. Just preventive maintenance. Started right up when it all was assembled again.

Re: 90 ZR-1 #2273 - To be rescued
 

Did some TB cleaning as well, where I found no DAG on the sealing surfaces, which might be the cause of my idle issues.

http://imagizer.imageshack.us/v2/800...924/erHmyW.jpg

And this is just to illustrate the sad/cramped surroundings of my miniature garage. And of course because Z's are rather nice to look at and it deserves a picture.

http://imagizer.imageshack.us/v2/800...923/qker5w.jpg

Re: 90 ZR-1 #2273 - To be rescued
 

Nothing like "hands-on" to learn a new (different) vehicle! (Mine isn't named after the Phoenix bird for nothing!) Looks like your ol gal is in good, caring hands now. :cheers:

Re: 90 ZR-1 #2273 - To be rescued
 

Thanks Paul. I saw that news clip from the C4 gathering, pretty neat! =D>

The car's currently wrapped up with all new vacuum hoses/actuators/check-valves, as well as nice, new red spark plug wires (it came with gray ones). Thanks to Jerry's Gaskets and White Racing for supplying the parts. :)
I even got the mandatory carter bling.
http://imagizer.imageshack.us/v2/800...924/Z9nWQa.jpg

The car is now finally approved, and I'm just waiting for my new shiny plates to arrive. About time, as it hasn't been on the road (approved) since 2013.

That doesn't mean the car's finished though. As with all other US car's I've had, the door hinges sag a bit, so I took them of to replace hinge pin/bushings.
http://imagizer.imageshack.us/v2/800...923/RcNyg5.jpg

Took one hinge at the time, with the door closed to avoid it moving. I did however re-adjust the door afterwards, as it wasn't aligned properly. Since the OEM hinge pins are pressed flat after assembly, the new ones were just installed with these toothed retainer washers you can glimpse here.

http://imagizer.imageshack.us/v2/800...923/WJ0UrO.jpg

The lower hinge still had some axial play after replacing pin/bushes (approx. 1mm), so I'm considering to replace the whole hinge if I can find a new one somewhere. Truth be told, I'm not really satisfied with how tight the new hinge/bushes were at all. These came from Corvette Central. But as I do not have any other to compare with, I can't tell whether they're within spec.

http://imagizer.imageshack.us/v2/800...924/sRQttX.jpg

Re: 90 ZR-1 #2273 - To be rescued
 

I also received a new set of discs for my Big Red Porsche brake kit (T295) from Movit. which unfortunately also led to the disappointing discovery that these do not really fit under the Sawblades I just had refurbished. They fit neatly inside the original 90 wheels, but needs an additional 1/4" spacer to clear with the sawblades.

http://imagizer.imageshack.us/v2/800...922/Mmqvjh.jpg

New gaskets recently arrived from Wilcox, but I'm not completely convinced on these yet. The rear hatch rubber gaskets without glued corners is a truly great product, but as I replaced the ones above the doors, attached to the roof, I noticed that the old had these plastic reinforcements molded into them, while the new gaskets do not. The still seal quite well, but I'm not convinced on the longevity.

http://imagizer.imageshack.us/v2/800...922/SGs912.jpg

Now I'm unfortunately back at work in Angola, so not much will happen in the garage for the upcoming 5-6 weeks.

http://imagizer.imageshack.us/v2/800...924/UBWbN3.jpg

Re: 90 ZR-1 #2273 - To be rescued
 

Nice keep up the good work.

Re: 90 ZR-1 #2273 - To be rescued
 

Yes, great work....enjoyed all of the pics.....

Sent from my SM-G935P using ZR-1 Net Registry mobile app

Re: 90 ZR-1 #2273 - To be rescued
 

Wow... you saved this Z from certain death; that's for sure. I'll be watching this thread as it will be great to see the changes progress nursing it back to health. Congrats on your Z!

Re: 90 ZR-1 #2273 - To be rescued
 

Appreciate the feedback, gentlemen.

I've just ordered the Haibeck calibration, and I'm currently considering a new, more interesting set of wheels. Given that the seller doesn't back out of the deal.
I've also started the process of building a new garage for the car, so hopefully it'll soon have a better place to reside. Well, "soon" might be an optimistic choice of words, but at least that project is now ongoing.

During replacement of the complete secondaries system, I found my self lacking the hose from the pump to the sub-plenum system, and of course, that was the one in worst shape. I've tried to E-mail Kurt at White racing, as his kit was supposed to include this hose, but no reply.

The check valve integrated in the reservoir is not sealing perfectly either. Not leaking enough to be an issue in any way, but still annoying. I know Kurt has NOS of these, but as he doesn't seem to read much e-mail these days, it's hard to acquire one.

Re: 90 ZR-1 #2273 - To be rescued
 

Call him on 813-854-4203. Kurt site says it's best to call during business hours and email after hours.


Sent from my iPhone using ZR-1 Net Registry

Re: 90 ZR-1 #2273 - To be rescued
 

I should probably call, but as I am at work in Africa, between the time zone difference and my 12 hr shifts, it's not easy to find a suitable moment.

Re: 90 ZR-1 #2273 - To be rescued
 

Engine bling from Jerrys,

http://imagizer.imageshack.us/v2/800...923/SGMxGR.jpg


http://imagizer.imageshack.us/v2/102...922/BvSG8Y.jpg

I've also gotten the chip from Haibeck, and it sure makes a difference. Car feels much better, and the idle issue have improved. It's still not perfect, so throttle blade sealing is probably the way to go.

Re: 90 ZR-1 #2273 - To be rescued
 

Car's coming along nicely.
http://imagizer.imageshack.us/v2/102...922/rg1iwA.jpg

Re: 90 ZR-1 #2273 - To be rescued
 

Looking good.

Re: 90 ZR-1 #2273 - To be rescued
 

Thanks. I wish I had some better pics of the new wheels, but that'll have to do for now.

Quite happy I finally got the plates as well, even though they don't currently fit very well.

http://imagizer.imageshack.us/v2/102...922/JBW247.jpg

Sent from my MIX using ZR-1 Net Registry mobile app