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[Dynomite]

Post 10 - ZR1 Engine (LT5) ZR-1 Lubrication Simplified

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. ZR-1 ALDL and associated Codes
Post 10. ZR-1 Lubrication Simplified

Last UPDATE of post 11 Dec, 2018

[Franke]

Wow. You da man. Very helpful.

[Dynomite]

The Oil Filter Adapter has many important functions. The Oil Filter Adapter is NOT for the sole purpose of holding/adapting the Oil Filter.

The oil paths through the Oil Filter Adapter Housing are describe in Item #5 below.

1. A Discussion of the Functions of the Oil Filter Adapter.
a. Control Oil Temperature. See Related ECM Code #52 Item #3 ZR1 ECM CODES 1990 TO 1992
b. Provide Sensor Feedback to the Instrument Panel.
c. Provide Oil Filtration.
d. Assure proper Oil Flow at any Oil Temperature.
e. Assure proper Oil Flow with contaminated Oil Filters.

The Oil Pressure Regulating Valve situated between the Oil Pump and Oil Filter Adapter controls and maintains Consistent Oil Pressure.

As an aside
2. Oil Pressure Sensor (Dash Gauge) Malfunction I changed out the oil pressure sensor for the dash gauge (top of oil filter) after engine installation. Oil pressure cold was registering 75 lbs. After changing out the oil pressure sensor, oil pressure is registering 55 lbs steady hot or cold and does not increase much with revs.

Oil Filter Adapter Sensors ..............................................Oil Filter Adapter Ports and Sensors


3. LT5 Oil Pressure and Oil Temperature Regulation

a. The Oil Pressure Regulation Valve (OPRV) (just after oil pump) opening pressure is 50-60 psi.



b. The Oil Cooler Bypass Valve on the Oil Filter Adapter allows oil to bypass the open oil cooler at hot temperatures since oil cooler is a bit restrictive. This valve raises the pressure a bit on the flow trying to bypass the oil cooler making sure some oil does go through the oil cooler.
c. The Oil Temperature Control Valve on oil filter housing opens oil flow from the oil cooler. The temperature opening characteristics of this valve are Thermostat-Open-203 degree F, Fully open-266 degree F.
d. The Oil Filter Bypass Valve on oil filter housing allows oil to bypass oil filter if the oil filter becomes to restrictive.
e. Oil pressure is always available to the Oil Cooler Bypass Valve. Oil flows from the oil pump (past the OPRV) to the oil filter through the Oil cooler and through the Oil Cooler Bypass Valve or directly through the Oil Temperature Control valve when the oil temperature is below 203 deg F. The oil cooler flow return and Oil Cooler Bypass Valve are open at the same time. The oil flow from the oil cooler is never totally blocked (half moon cutout of shuttle valve). The Oil pump flow at Idle is 1.6 gpm and the Oil pump flow at 7,000 rpm is 9.1 gpm.

4. Oil Filter Adapter Functional Details

Oil Temperature Control Valve Assembly.....................Oil Temperature Valve Thermostat opens at 203 deg F


Continued Next Page

Last UPDATE of post 13 Dec, 2018

[Dynomite]

Oil Temperature Shuttle Valve Open (HOT)............................Oil Termperature Shuttle Valve Closed (COLD)


Oil Cooler Bypass Valve Inside..................................................Oil Cooler Bypass Valve Outside
This valve raises the pressure a bit on the flow
trying to bypass the oil cooler making sure some
oil does go through the oil cooler.


Oil Temperature Control Valve Compensation..............Oil Filter Adapter (Oil Temperature Valve Housing)
The orifice allows the valve to move
without being hydraulically locked in place.


5. Oil Flow Paths.

COLD - Oil Temperature Less than 203 deg F.
a. The Oil is pushed up from the bottom Port on the Oil Filter Adapter Housing past the TOP Oil Cooler Port which is ALWAYS OPEN.
b. The Oil then is pushed through the Top Opening of the Oil Temperature Control Valve to the bottom of the Temperature Control Valve Port.
c. The Oil is also pushed against the Oil Cooler Bypass Valve which it will not open since the path through the Temperature Control Valve Port is Open.
d. Some Oil flows through the Oil Cooler back into the Bottom Oil Cooler Port since the Bottom of the Temperature Control Valve has a Half Moon Port that is Always Open.
e. The Oil then pushed up through the Oil Filter Outside Diameter and also against the Oil FIlter Bypass Valve just in case the Oil Filter is too Restrictive.
d. The Oil is then pushed out the center Oil Filter Adapter Fitting (M20x1.5) past the Oil Pressure Sensor for Dash Gauge, past the Oil Temperature Sensor, and past the Oil Pressure Switch Light on Dash Sensor out the Top of the Bottom Ports of the Oil Filter Housing Adapter to the Crankshaft and Top End Camshafts. The Oil pressurizes and lubricates the Timing Chain Tensioners and Timing Chains as the oil flows.
See Timing Chain Idler Sprocket Lubrication and Installation

WARM - Oil Temperature greater than 203 deg F but less than 266 deg F.
a. The direct Oil Path to the Oil Filter through the Oil Temperature Control Valve is not yet closed but is becoming Restrictive.
b. The Bottom Port of the Oil Temperature Control Valve is Opening beyond the Half Moon Port.
c. The Oil Path around the Oil Temperature Control Valve through the Oil Cooler Bypass Valve may come into play.
d. The Oil is then pushed out the center Oil Filter Adapter Fitting (M20x1.5) past the Oil Pressure Sensor for Dash Gauge, past the Oil Temperature Sensor, and past the Oil Pressure Switch Light on Dash Sensor out the Top of the Bottom Ports of the Oil Filter Housing Adapter to the Crankshaft and Top End Camshafts. The Oil pressurizes and lubricates the Timing Chain Tensioners and Timing Chains as the oil flows.
See Timing Chain Idler Sprocket Lubrication and Installation

HOT - Oil Temperature greater than 266 deg F.
a. The Top of the Oil Temperature Control Valve Port Through the Oil Temperature Control Valve is now completely Closed.
b. All Oil is directed through the Oil Cooler (Top Oil Cooler Port) or through the Oil Cooler Bypass Valve around (outside) the top of the Oil Temperature Control Valve.
c. The Bottom of the Oil Temperature Control Valve Port is now completely open allowing Oil to go from the Oil Cooler through the bottom of the Oil Temperature Control Valve directly to the Oil Filter and Oil Filter Bypass Valve.
d. Some Oil passing through the Oil Cooler Bypass Valve will flow directly to the Oil Filter and Oil Filter Bypass Valve depending on the Restrictions to Oil Flow through the Oil Cooler.
e. The Oil is then pushed out the center Oil Filter Adapter Fitting (M20x1.5) past the Oil Pressure Sensor for Dash Gauge, past the Oil Temperature Sensor, and past the Oil Pressure Switch Light on Dash Sensor out the Top of the Bottom Ports of the Oil Filter Housing Adapter to the Crankshaft and Top End Camshafts. The Oil pressurizes and lubricates the Timing Chain Tensioners and Timing Chains as the oil flows.
See Timing Chain Idler Sprocket Lubrication and Installation

6. There IS an Oil Level Sensor on the 91'-95' ZR-1 Oil Pan.

The Oil Pan for 1990, 91 & 92 are interchangable with the only difference being, the 1990 LT5 engine was not equipped with a Low Oil Level Sensor. The extra material was cast into the pan but not machined for the screw-in sensor. As such, the oil level indicator would not be functional if the 1990 oil pan is used for 1991 & 1992 applications Oil Level Sensor TIPS

Brass Oil Level Sensor 93'-95' Jerrys Brass Oil Level Sensor 93' to 95'


Plastic oil Level Sensor 91'-92' Summit Racing Oil Level Sensor
Jerrys Plastic Oil Level Sensor


Last UPDATE of post 14 Dec, 2018

[Dynomite]

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[Dynomite]

Creating Albums and Hosting Post Photos TIPS
Post 131 - Resizing Photos for Forum Posts and Creating Reference Links

1. This photos were resized on my computer using PAINT.
2. Then the photos were uploaded to my Registry Albums on this Forum.
3. I then clicked on one photo and copied the BB Code which is posted as [IM G]http://www.zr1.net/forum/picture.php?albumid=211&pictureid=3063[/IMG]
4. I left a space between the M and G so the photo would not show

Just showing what you can do with Album Photos using Paint on your computer before you upload to your Albums on this Forum.





Stumbled on something very interesting
The photo below is from my Album on the Other Forum.
On the Other Forum I can post the photos above that are in my Album on This Forum.



Last UPDATE of post 16 Feb, 2017

[Dynomite]

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[Dynomite]

Assembly Line Diagnostic Link (ALDL) Fault Codes

1. ZR1 ECM CODES 1990 TO 1992
Code #12: Normal No Codes.
Code #13: Left Oxygen Sensor Circuit.
Code #14: Coolant Temperature Sensor Circuit High.
Code #15: Coolant Temperature Sensor Circuit Low.
Code #16: Direct Ignition System (DIS) Fault Line Circuit
Code #21: Throttle Position Sensor Circuit High.
Code #22: Throttle Position Sensor Circuit Low.
Code #23: Manifold Air Temperature Sensor Circuit Low.
Code #24: Vehicle Speed Sensor Circuit.
Code #25: Manifold Air Temperature Sensor Circuit High.
Code #31: Camshaft Sensor Circuit.
Code #33: Manifold Absolute Pressure Sensor Circuit High - Low Vacuum.
Code #34: Manifold Absolute Pressure Sensor Circuit Low - High Vacuum.
Code #36: Direct Ignition System (DIS) Circuit (missing or extra EST signal)
Code #41: Cylinder Select Error (Faulty or Incorrect Mem-Cal)
Code #42: Electronic Spark Timing (EST) Circuit.
Code# 43: Electronic Spark Control (ESC) Circuit.
Code #44: Left Oxygen Sensor Circuit Lean.
Code #45: Left Oxygen Sensor Circuit Rich.
Code #46: Vehicle Anti-Theft System (VATS)(PASS-Key) Circuit.
Code #51: Mem-Cal Error.
Code #52: Engine Oil Temperature Sensor Circuit Low.
Code #53: System Voltage.
Code #54: Fuel Pump Circuit (Low Voltage)
Code #55: System Voltage
Code #56: Vacuum Sensor Circuit.
Code #61: Secondary Port Throttle Valve System.
Code #62: Engine Oil Temperature Sensor Circuit High.
Code #63: Right Oxygen Sensor Circuit Open.
Code #64: Right Oxygen Sensor Circuit Lean.
Code #65: Right Oxygen Sensor Circuit Rich

2. ECM Related Explanations.
31 LCD Data Circuit-Circuit shorted to battery voltage or CCM driver open
33 Data Clock Circuit-Circuit shorted to battery voltage or CCM driver open
35 Data Strobe Circuit-Circuit shorted to battery voltage or CCM driver open
37 M Clock Circuit-Circuit shorted to battery voltage or CCM driver open
72 LCD Dimming Open Circuit-Circuit open or shorted to ground (radio & Climate control)
H History code. May be intermittant.
Code 31, 33, 35 related to the circuit from the CCM to the Instrument panel LCD.
CCM 74 is also a lighting circuit problem.
CCM 41 is loss of communication with the ECM.

3. ZR1 ABS Code - Definition
1990 Service Manual:
(* = Requires Tech 1 Daignostic Tool)
12 - Diagnostic System Operational
21 - RF Wheel Speed Sensor Fault
22 - RF Toothed Wheel Frequency Error
25 - LF Wheel Speed Sensor Fault
26 - LF Toothed Wheel Frequency Error
31 - RR Wheel Speed Sensor Fault
32 - RR Toothed Wheel Frequency Error
35 - LR Wheel Speed Sensor Fault
36 - LR Toothed Wheel Frequency Error
41* - RF Solenoid Valve Fault
45* - LF Solenoid Valve Fault
55* - Rear Solenoid Valve Fault
61* - Pump Motor or Motor Relay Fault
63* - Solenoid Valve Relay Fault
71 - EBCM Fault
72 - Serial Data Link Fault
75 - Lateral Accelerometer Fault (Short to B+ or Ground, or Open Circuit)
76 - Lateral Accelerometer Fault (Signal Out of Range or Incorrect)
Clearing Codes
The fault codes in the EBCM's memory are erased in one of three ways:
1. Diagnostic Enable Line Procedure
2. Tech 1 "Clear Codes" Selection
3. Igniton Cycle Default
Whichever method is used, be sure to verify proper system operation and absence of codes when clearing procedure is completed.

4. ZR1 Ride Control (SRC) Codes.
12 = Start of sequence
13 = Left rear time out
14 = Right Front time out
21 = Left Front time out
22 = Right Rear time out
31 = Left Front out of position
32 = Right Front out of position
33 = Left Rear out of position
34 = Right Rear out of position
Out of position codes are triggered if the computer senses that the actuator has not found the end stop position on the shock. Remove actuator at the indicated shock. Turn the valve gear on the shock stops after about 3 / 4 of turn, then you have a bad actuator. If it spins around continuously then it is a bad shock
41 = Selective ride control switch short to voltage
42 = Selective ride control switch open contacts
You can have a code 42 if you leave the switch in between indented positions
43 = selective ride control switch circuit open.
23 = If you start the car more than 3 times and do not move the car this code will set. Drive 3-6 feet and the light will go out.
The ride control controller is located in the bin behind the drivers seat mounted with the ABS controller.

5. ZR-1 CCM Codes
Code Definition
1.1 DISPLAY CCM fault codes
12 On-board diagnostics no codes (this is a good thing: no problem found)
13 DIC switches open or shorted to battery
14 DIC switches shorted to ground
16 Ignition 3 fuse circuit open
21 Horn relay coil shorted to battery or CCM internal open circuit
22 Rear defogger relay coil shorted to battery or CCM internal open circuit
24 Courtesy lamp relay coil shorted to battery or CCM internal open circuit
25 Courtesy lamp relay coil circuit open or shorted to ground
26 LCD blanking control circuit shorted to battery or CCM internal open
27 LCD blanking control circuit open or shorted to ground
31 LCD data circuit shorted to battery or CCM internal open
32 LCD data circuit open or shorted to ground
33 Data clock circuit shorted to battery or CCM internal open circuit
34 Data clock circuit open or shorted to ground
35 Data strobe circuit shorted to battery or CCM internal open circuit
36 Data strobe circuit open or shorted to ground
37 M clock circuit shorted to battery or CCM internal open circuit
38 M clock circuit open or shorted to ground
41 Loss of ECM serial data communications
51 Pass-key invalid key detection
52 Pass-key key detection circuit shorted
53 Pass-key – key detection circuit open or shorted to battery
54 FEDS fuel enable failure
61 Pass-key – key #1 programming resistance out of range
62 Pass-key – key #2 programming resistance out of range
63 Pass-key – key #2 programming resistance low
71 LCD dimming output circuit shorted to battery or CCM internal open circuit
72 LCD dimming output circuit open or shorted to ground
73 LED display dimming output circuit shorted to battery or CCM internal open circuit
74 LED display dimming output circuit open or shorted to ground

6. 1990 SIR Codes
For 90-93 Cars jumper A to K on the ALDL and the INFL REST light will flash
1990 SIR Codes
14 Front Sensor #1 (LH); Short to Ground
15 Front Sensor #1 (LH); Open Circuit
16 Front Sensor #1 (LH); Sensor Fault
24 Front Sensor #1 (RH); Short to Ground
25 Front Sensor #1 (RH); Open Circuit
26 Front Sensor #1 (RH); Sensor Fault
31 Inflator Squib; Current leakage to Battery
32 Inflator Squib; Current shorted to battery voltage
33 Inflator Squib; Current leakage to ground
34 Inflator Squib; Current shorted to ground
35 Inflator Squib; Open circuit
36 Inflator Squib; Squib fault
41 Indicator lamp circuit; Shorted to battery or ground
42 Indicator lamp circuit; Open circuit
51 Diagnostic unit faulty
52 Firing sequence confirmation set
53 Firing current confirmation set
54 Squib current has flowed

7. 91 & 92 & 93 SIR Codes
21 Steering Column Resistance Too High
22 Steering Column Resistance Too Low
23 Steering Column Circuit Voltage Too High
24 Steering Column Circuit Voltage Too Low
25 Short to Battery in Steering Column
26 Open in Steering Column Circuit
31 Open 36 VLR to Deployment Loop
32 Grounded 36 VLR to Deployment Loop
33 Diode B Shorted in Wiring Harness
34 Open in Ignition 1 Feed to Deployment Loop
35 Discriminating Sensor Open
41 Deployment Loop Energy Reserve Voltage Fault
42 Deployment Loop Energy Reserve Voltage Fault
51 Accident Detected
52 EEPROM Accident Data Area Full
61 Force Low or “INFL REST” Warning Lamp Circuit
71 Internal DERM Fault

8. 94 & 95 SIR Codes
For 94-95 Cars, jumper Terminal 4 to 12 on the ALDL and enter the CCM diagnostics, or use a Tech1
14 Dual Pole Arming Sensor Disconnected
15 Passenger Initiator Circuit Resistance High
16 Passenger Initiator Circuit Resistance Low
17 Passenger Initiator Circuit Open
18 Discriminating Sensor Interconnect Open
19 Passenger Initiator Circuit Voltage High
21 Driver Initiator Circuit Resistance High
22 Driver Initiator Circuit Resistance Low
23 Driver Initiator Circuit Voltage High
24 Driver Initiator Circuit Voltage Low
25 Initiator Circuit Short to Ignition
26 Driver Initiator Circuit Open
28 Current Sink or Source Failure
31 Driver Loop Energy Reserve Feed Open
34 Dual Pole Arming Sensor Ignition Feed Open
35 Discriminating Sensor Open or Missing
36 Passenger Loop Energy Feed Open
42 Loop Energy Reserve Volatage Low
43 Driver Source Feed Low
44 Passenger Source Feed Low
51 Frontal Crash Detected
52 Data Area Full
53 Driver Side Low High Resistance
54 Passenger Side Low High Resistance
55 DERM Incompatibility
61 SIR Indicator Circuit Failure
62 Redundant Indicator Circuit Failure
71 and or 75 Internal DERM Fault
81 Driver Ignition Diode Open
82 Passenger Ignition Diode Open
83 Driver Reserve Diode Shorted
84 Passenger Reserve Diode Shorted

NOTE: SIR Code 13 will be displayed (In addition to Code 12) only if no history codes are in memory. To read history codes, a SCAN/TECH tool must be used.
Read more: The Seat Belt Question

[Dynomite]

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