Since my visit, I've....

[Figure8it]

Since my visit at Haibeck Automotive and setting up an appointment, I had to try and take care of a few items that he pointed out during my inspection. While there are many things they will need to address, I really do want to get to know my car and the best way is to complete projects yourself.

As you read my posts, please keep in mind that I'm nowhere near being a mechanic. I'm learning most things (on my ZR-1 ) from past projects, friends, videos and just the willingness to try something on my own. I know I will make mistakes (and I'll even tell you about them) but my plans are to do what I can and leave the hard stuff to the pros.

My first large project was planned when my wife was gone for a long weekend. I replaced all wheel bearing/hubs, the front top and bottom ball joints and tie rod boots, all new pads and rotors, plus a large cleaning effort and paint a few small items such as caliper brackets and lug nuts. I worked on things from Thursday evening until Sunday afternoon to complete everything. Attached are some before and after?s....

With all this work complete, I figured that if I kept my car in the garage at my office that I could do a few things each day at lunch (you know, until my visit at Haibeck). My next project was to clean and polish the Borla stainless steel exhaust. This was originally installed in 1998 so I?m sure it was just installed and has never been polished. I dropped the exhaust down, cleaned it with soap and water and started this labor of love. By hand I started with 400 grit, then 600, then 1000 to get everything cleaned. I then stepped up to a polisher starting with 1000 grit, then 1500, then 2000, then 2500 and finally 3000 grit. Before the final polish I used Meguiar?s Mirror Glaze Fine-Cut Cleaner and finished everything with Sledbrite Metal Polish. I was very happy how things turned out. Attached are some before and after?s....

Now the exhaust is hung back up and I?m really happy how the car is starting to look. I start searching for more projects (you know, until my visit at Haibeck). I know it needs new fuel injectors so I get Marc?s video and see if this is something I can do myself. I watched his video, I make myself instructions all the way down to bolt size and torque spec, emailed Marc questions, bought parts and started the project. All and all it went well. Although I broke some things (clips and vacuum lines -GRRRRR) that were easily repairable, I was able to remove the plenum. I went as far down as removing the starter to clean the out the drain in the back of the motor and all the gunk from over the years. Once clean, everything went back together fine. I followed the testing procedures and when hooking up the fuel pump, there was a tiny bit of fuel that came out of the fuel pressure regulator that I was able to clean with a paper towel (I did not know this was not normal and it became a big problem). I tested the vacuum lines, all good and reinstalled the plenum. I got everything hooked back up and started the car. She started and ran for about 2 minutes and then died. It sounded like it had no fuel when it happened. I went and tried to start it again and it just cranked. My son watching says ?there is something leaking in front? and when I get out of the car, I notice it?s gas! I immediately disconnect the battery and clean up the gas, like over a gallon from the air intake. I removed the intake, cleaned the air filter and everything else.

A good friend who owns a repair shop came by in the evening to help and we found the fuel to be coming from the throttle body when I tried to crank the motor to start. Another message to Marc and he suspected and told me how to test the fuel pressure regulator. The FPR was bad, it was filling the plenum/throttle body with fuel and needed to be replaced. I was fearful that lots of fuel leaked into the cylinders, so I pulled the spark plugs and the INJ1 fuse while having towels over the plug holes and cranked it over. Luckily there was nothing on the towels. A new FPR replacement ordered from Jerry's, another new set of plenum gaskets and I was back removing the fuel rail.

On December 24th, I left my house early and put everything back together. It was around 8:30am I was able to start the car. She ran well for about 5 minutes before I decided to take a quick drive. I short run up the road to test things. I got to 40mph, put it in 4th, and hit the gas?.. much smoother acceleration now. The roads were wet, I had no traction but could feel the car was running better. I decided to take it home. On Christmas Day I was able to take a drive with my wife. The car is running much better than before. I still can?t believe I have a ZR-1 at home in the garage!

Next month my car gets to visit the experts, Marc and Bob, because 30-year-old cars need checkups from good car doctors to keep them in top shape. Looking forward to the drive in 2022!

[secondchance]

Great job! You are more than a mechanic.

[gtcollins@maxnet.co.nz]

Good on you for having a go even professional mechanic make mistakes (I know 39 years at it still make the odd mistake but do try to keep that quiet ) if you get factory manuals for these cars and follow them they there isn't to much you won't be able to do just takes a little longer
Glen

Sent from my SM-T865 using ZR-1 Net Registry mobile app

[Young1]

Good job. If you are capable of suspension components, wheel bearings and brakes you are qualified to pull off a plenum for sure. You are on your way of enjoying the legend. PS remove the cover of the starter solenoid and shine the copper contacts ?while yer in there?.

[Figure8it]

Thanks for the encouraging messages! Low temps and snow will keep her in the garage. Hopefully a sunny day or two in the next month and I can get some drivetime.

[Figure8it]

Recently I was able to get my service work completed at Haibeck Automotive Technology. It is a pleasure to work with such honest and knowledgeable people like Marc and Bob. To cap things off, I was able to be there with Marc as he dyno tuned the Z. FANTASTIC!!!! Here is a summary of the work that I had completed:

• Compression tested: #1: 220 psi, #2: 222 psi, #3: 225 psi, #4: 220 psi, #5: 220 psi, #6: 225 psi, #7: 225 psi, #8: 230 psi.
  Left bank +/- 2.5 psi. Right bank +/- 5 psi or 2%. Average LT5 is +/- 5%
  
• 50% of clutch life remains. Battery is good. Gear Ration is OE 3.45
  
• NHRA driveshaft containment box installed
  
• Clamp added for the left header collector exhaust ball flange. Muffler mounts were relocated rearward for clearance as the exhaust system heats and expands.
  
• Spare tire was mounted correctly.
  
• Right wheel bearing inner Teflon washer was installed
  
• Autometer tach removed, Raptor shift light installed in vent, set for 6800 RPM.
  
• Door light switches were adjusted and shimmed. Left dog leg trim reattached. Left fender adjusted. Missing fasteners were installed in right wheel housing.
  
• Console pad/lid was repaired to open properly.
  
• Six new coolant hoses installed. TB bypass installed. New serpentine belt and tensioner pully installed. New coolant pressure cap and 170-degree thermostat installed.
  
• All four speaker amplifiers replaced. CD player reconditioned. GM CD player skip reduction upgraded installed.
  
• AC refrigerant leak located at pressure cycle switch, new switch installed. System converted to modern R134a refrigerant.
  
• Parking brake lever adjusted. New hatch weatherstripping installed. Right hood latch adjusted.
  
• New cam cover emblems installed. (Old emblems that were removed were kept)
  
• Left headlight motor gear case repaired.
  
• Fuel system tested. Pressure is normal at 48 psi at 6500 RPM.
  
• Replaced accessory vacuum tube and secondary port vacuum tube (under plenum)
  
• Throttle position sensor was installed. MAP sensor hose installed. AIR pump removed.
  
• Haibeck chip and dyno tune for 475 hp engine. Rev limit is 7200 RPM (Doug Rippie Motorsports chip removed and kept)

With the car in top shape, if the weather would cooperate I'd be on the roads!!!
JimS

[AirbusDriver]

Your great looking ZR1 is fortunate to have you as its owner. I look forward to getting my 90 to Marc in the not too distant future.
Regards,
Mark

[Figure8it]

Here is the final dyno run: https://www.youtube.com/watch?v=UxGPzj1KUuk

[WARP TEN]

Glad to hear you got it all done Jim. You have a great car and I share your disappointment with our Chicago area weather. Haven't even had mine down off the lift yet but hoping for later next week. Fingers crossed. --Bob

[Figure8it]

Bob, this rain we are supposed to get all week can wash the salt from the roads for what looks to be a nice weekend coming up. Time to get cleaned up, she?s gonna be on the streets for sure.


1992 Polo Green ZR-1, DRM500