Removal of 1992 ZR-1 Engine Wiring Harness. - ZR-1 Net Registry Forums

rebelz · 04-05-2018

Could someone please help me by explaining how to remove the engine wiring harness at the connector on the firewall on a 1992 ZR-1. I've tried releasing the latches, but it still doesn't want to budge. I can't seem to find the information in the FSM either. I find the section for the harness, but not how to release that connection. I sure don't want to damage the connector.
Thanks

WVZR-1 · 04-05-2018

This isn't from the '92 FSM but all C4 C100 'bulk-head' connectors are assembled similarly. There's a 1/4" hex-head screw that holds everything together. I don't believe the spec was ever changed to Metric.

The screw location should be obvious in the image. It's sometimes difficult find in the actual car. Lots of sealant. The DOT in the connector on the right is screw location and the O in the left is the threaded receptacle.

8A-202-12 in your FSM should look similar to what's on the left in this image.

The 'forward lamp' section needs to be removed before you can release the engine harness. The forward lamp connector acts as a retainer for the engine harness bulk-head. Image reflects retention.

C100 C4.jpg

rebelz · 04-06-2018

Thanks for the reply - I'll look at it in the morning first thing. I looked tonight. I found it. Back to work tomorrow on it. A few minutes later... Thank you very much, I love this ZR-1 site. I have yet to fail to find the information I need, and I pass that on whenever I can give information.

rebelz · 04-16-2018

Just an update on rebuild progress starting in June 2015. Other than this question, and a couple of others, I haven't posted a whole lot. This is my '92 Z that the engine harness caught file destroying it, and some light to moderate damage in other places along the way.
The engine harness is in and all hooked up. I'm finishing all the other related installs and hookups. Top end refinishing, Complete secondary port checks replacing all that is needed etc. Lumbar and cervical spine problems have hindered the work tremendously. But pain pills willing, I'm within days of having everything back together.
The most important thing to pass along was diagnosed by Mark Haibeck over the phone right after the original problem. By questions and phone answers he pinpointed what happened in under 20 questions. I am very impressed with Marks knowledge of these vehicles. In my book, he is at the top of the heap.
It boils down to: do not remove the plastic shielding on the fuel inlet and return lines that connect to the fuel rails. Later model cars do not have the plastic. I did not remove it, it was done by someone who owned the car before me. The only other Z I had ever seen in person was a friends '94. They don't have the shielding so mine looked normal in comparison. It looks cool with the braided SS hoses, but those lines run directly over a 12 volt always live wire connecting to the blower control module. in time they can rub the shielding from the red insulated wire, causing a spark, or however many sparks it takes to melt the fuel line through. As you all know: spark, raw fuel, always hot wire equals "Very Bad" results.
Our only saving grace is that the fire melted through the passenger side hood release cable. I was unable to release the hood on the passenger side. I always carry fire extinguishers in all my vehicles, so holding up the driver's side as far as I could, my wife emptied the Halon extinguisher at the point of flame. We were able to put the fire out. Had I been able to open the hood, the oxygen-starved fire would have no doubt become a raging inferno, probably with an explosive force enough to have hurt or killed one or both of us.
A very public thank you to Mark for diagnosing the problem so the information can be passed to others, so that no one has to deal with the work, cost etc. More importantly physical harm or worse. Maybe someone could write up something for the sticky list to point out the danger.

Ccmano · 04-16-2018

Glad to hear everything is working out. Just in time for the summer driving season in AK I suspect. Mark is an invaluable resource for all of us. Without him we would all still be in the dark (ages) on these cars.

Best of luck
H

Z51JEFF · 04-16-2018

Great info on the source of the fire,I never would have thought of that. Thanks for the info.

04-05-2018	#1
rebelz Join Date: Jul 2007 Location: Anchorage, AK Posts: 106	Removal of 1992 ZR-1 Engine Wiring Harness. Could someone please help me by explaining how to remove the engine wiring harness at the connector on the firewall on a 1992 ZR-1. I've tried releasing the latches, but it still doesn't want to budge. I can't seem to find the information in the FSM either. I find the section for the harness, but not how to release that connection. I sure don't want to damage the connector. Thanks __________________ REBelZ '92 ZR-1 Yellow/Black #031

04-05-2018	#2
WVZR-1 Join Date: Oct 2004 Posts: 1,890	Re: Removal of 1992 ZR-1 Engine Wiring Harness. This isn't from the '92 FSM but all C4 C100 'bulk-head' connectors are assembled similarly. There's a 1/4" hex-head screw that holds everything together. I don't believe the spec was ever changed to Metric. The screw location should be obvious in the image. It's sometimes difficult find in the actual car. Lots of sealant. The DOT in the connector on the right is screw location and the O in the left is the threaded receptacle. 8A-202-12 in your FSM should look similar to what's on the left in this image. The 'forward lamp' section needs to be removed before you can release the engine harness. The forward lamp connector acts as a retainer for the engine harness bulk-head. Image reflects retention. C100 C4.jpg Last edited by WVZR-1; 04-05-2018 at 05:16 PM.

04-06-2018	#3
rebelz Join Date: Jul 2007 Location: Anchorage, AK Posts: 106	Re: Removal of 1992 ZR-1 Engine Wiring Harness. Thanks for the reply - I'll look at it in the morning first thing. I looked tonight. I found it. Back to work tomorrow on it. A few minutes later... Thank you very much, I love this ZR-1 site. I have yet to fail to find the information I need, and I pass that on whenever I can give information. __________________ REBelZ '92 ZR-1 Yellow/Black #031 Last edited by rebelz; 04-06-2018 at 12:25 AM.

04-16-2018	#4
rebelz Join Date: Jul 2007 Location: Anchorage, AK Posts: 106	Re: Removal of 1992 ZR-1 Engine Wiring Harness. Just an update on rebuild progress starting in June 2015. Other than this question, and a couple of others, I haven't posted a whole lot. This is my '92 Z that the engine harness caught file destroying it, and some light to moderate damage in other places along the way. The engine harness is in and all hooked up. I'm finishing all the other related installs and hookups. Top end refinishing, Complete secondary port checks replacing all that is needed etc. Lumbar and cervical spine problems have hindered the work tremendously. But pain pills willing, I'm within days of having everything back together. The most important thing to pass along was diagnosed by Mark Haibeck over the phone right after the original problem. By questions and phone answers he pinpointed what happened in under 20 questions. I am very impressed with Marks knowledge of these vehicles. In my book, he is at the top of the heap. It boils down to: do not remove the plastic shielding on the fuel inlet and return lines that connect to the fuel rails. Later model cars do not have the plastic. I did not remove it, it was done by someone who owned the car before me. The only other Z I had ever seen in person was a friends '94. They don't have the shielding so mine looked normal in comparison. It looks cool with the braided SS hoses, but those lines run directly over a 12 volt always live wire connecting to the blower control module. in time they can rub the shielding from the red insulated wire, causing a spark, or however many sparks it takes to melt the fuel line through. As you all know: spark, raw fuel, always hot wire equals "Very Bad" results. Our only saving grace is that the fire melted through the passenger side hood release cable. I was unable to release the hood on the passenger side. I always carry fire extinguishers in all my vehicles, so holding up the driver's side as far as I could, my wife emptied the Halon extinguisher at the point of flame. We were able to put the fire out. Had I been able to open the hood, the oxygen-starved fire would have no doubt become a raging inferno, probably with an explosive force enough to have hurt or killed one or both of us. A very public thank you to Mark for diagnosing the problem so the information can be passed to others, so that no one has to deal with the work, cost etc. More importantly physical harm or worse. Maybe someone could write up something for the sticky list to point out the danger. __________________ REBelZ '92 ZR-1 Yellow/Black #031 Last edited by rebelz; 04-19-2018 at 07:18 PM.

04-16-2018	#5
Ccmano Join Date: Jun 2006 Location: Sparks, NV Posts: 2,852	Re: Removal of 1992 ZR-1 Engine Wiring Harness. Glad to hear everything is working out. Just in time for the summer driving season in AK I suspect. Mark is an invaluable resource for all of us. Without him we would all still be in the dark (ages) on these cars. Best of luck H __________________ 90'ZR-1 #1461 Red/Black Ported Intake, Degreed Cams, OBX Headers & Exhaust, Fidanza FW, Secondary Delete, Custom tune, C6 GS Wheels. Sold 08 C6 Z51 Crystal Red Metallic Sold Vararam Intake, Tune, Sold 05 C6 Z51 Red/Black Sold 90'ZR-1 #1723 Black/Gray Sold but not forgotten 91' Z51 L98 White Vert. My First, you always remember your first. Sold.

04-16-2018	#6
Z51JEFF Join Date: Dec 2007 Location: Fremont,Ca Posts: 3,078	Re: Removal of 1992 ZR-1 Engine Wiring Harness. Great info on the source of the fire,I never would have thought of that. Thanks for the info.