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Tech Info - LT5 Modifications/Rebuild Tricks (500+hp)

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Old 06-26-2016, 05:09 PM   #261
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Default 90 (#8550) Corvette (L98) Modifications

90 (#8550) Corvette (L98) Modifications

New SW Headers
New Magnaflow Exhaust
New TPiS Air pump delete kit with New Billet Aluminum Pullley
New Belt Tensioner Billet Aluminum Pulley
New 180 deg thermostat
New Chrome Water Pump
New Chrome Alternator
New Plug wires
New C4 Beam Plates
New Differential oil drain plug (drilled and tapped)
New Differential oil drain plug
New Billet Aluminum oil cap
Existing Existing Aluminum Radiator
New Oil Pan and Gasket including New Milodon 18309 Oil Pump Pickup
Fluids Mobile 1 75W-90 Differential oil (limited slip)
Fluids Mobile 1 10W-30 synthetic Engine oil
Fluids Castrol TWS 10W-60 Transmission oil
Eliminated Water Pump Frisbee and added Aluminum Water Pump Pulley
Eliminated Air Induction system
Eliminated CATS
Eliminated EGR
Doc Don's Bose
Modified Oil Cooler Use NAPA 8020 and 9808 hoses cut to length
L98 Oil Cooler Housing Modifications for Headers
Modified Marc Haibeck Chips

87 octane calibration (ARFPCL)
29 deg at WOT.
Enabled manual transmission.
Both fans to go on at 195 and both off at 190 degs.
Added +5% at WOT fuel to support +20 hp from headers.
Disabled deceleration fuel cut off.
Disabled EGR.
Idle speed is OE at 600 rpm.

91 octane calibration (ARFPCL1)
29 deg + 4 deg = 33 deg at WOT.
Enabled manual transmission.
Both fans to go on at 195 and both off at 190 degs.
Added +5% at WOT fuel to support +20 hp from headers.
Disabled deceleration fuel cut off.
Knock retard reduced by 50%.
Disabled EGR.
Idle speed is OE at 600 rpm.






SW Headers and with Magnaflow Exhaust



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Old 02-28-2017, 06:10 AM   #262
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Default Oil Cooler Modifications

Oil Cooler Modifications

I had to modify my oil cooler with two additional slots so I could rotate the Oil Cooler and associated Hoses a bit more towards the block away from SW Headers

I rotated the oil cooler such that the two long bolts (of the spin on oil filter adapter) fit in the
new slots of the oil cooler. I then tightened the big hex nut on the oil cooler

I used new NAPA 8020 and 9808 hoses cut to length replacing the old oil cooler hoses shown
which work perfectly.




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Old 02-28-2017, 06:10 AM   #263
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Default Timing Chain Cover/Water pump Interference

Timing Chain Cover/Water Pump Interference

I know this has come up before but am not sure if there is another water pump out there that would work for my 90'. The back of stock water pump has a plate and bolts which interfere with the JEGS cast aluminum timing cover (I would say 1/8 inch interference when water pump backing plate bolts are removed).

Is there any water pump with just a bit more clearance on the back side with the same distance to the center of the water pump pully from face of engine

The JEGS Spectre 4935 cast alumimum timing chain cover is extremely nice and sturdy....not tinny



L98 Water Pump Modifications

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Old 02-28-2017, 06:10 AM   #264
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Default Air Pump Eliminated

Air Pump Eliminated

1. The Air Induction System removed from a 90' L98

Quote:
Originally Posted by Steel Blue 91 View Post
This is some of the "stuff" that can come out.


I installed SW headers with Magnaflow Exhaust without the Air Induction on my 90' L98

Eliminate The L98 Air Pump

Air Pump Eliminator from Mid America Motorworks or TPiS Air Pump Delete




In this case I replaced the plastic Idler Pulley with a New Billet Aluminum Pulley.



2. Billet Aluminum Ultra Light Belt Tensioner Pulley
This Belt Tensioner Pulley will fit the ZR-1 (LT5) as well as a standard C4 with L98 engine.
Ebay Billet Aluminum Belt Tensioner Pulley



Belt Tensioner with High Speed Idler Pulley...............Diameter of Billet Aluminum Pulley is
Use Red Loctite on Pulley Bolt......................................3/16 inch larger than stock pulley




Hand File Small Bevel around diameter of outer ...........Pulley is placed on Belt Tensioner with pulley
Collar to clear bearing Snap Ring.................................bearing Snap Ring facing Collar (Forward)




Close up of minor modification of Belt Tensioner Flange



The amount of pressure on the belt depends on belt length and compression of the Belt Tensioner itself. You want enough slack to get the Belt over the Alternator Pulley when Belt Tensioner is fully compressed using a long 1/2 inch Socket wrench. You can start the compression process of the Belt Tensioner by using a heavy Broom Handle compressing the Belt Tensioner so you can engage the socket in the Belt Tensioner socket 1/2 inch socket hole provided. This Billet Aluminum Belt Tensioner Pulley will give you just a bit more belt tension given the pulley is a bit (1/8 inch more or less) larger in diameter than a stock pulley.

As an aside......After removing the Serpentine Belt, remove the Belt Tensioner Bolt and Washer. Get hand under passenger side coolant manifold in front of alternator pulley and grab hold of Belt Tensioner Pulley. Lift Belt Tensioner up and sideways through slot under coolant manifold/Radiator Inlet Pipe (Passenger Side) while lifting coolant Radiator Inlet Pipe (Do NOT disconnect any coolant hoses). Use Red Loctite on Belt Tensioner Pulley Bolt.


Last UPDATE of post 264 Dec, 2017

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Old 02-28-2017, 06:11 AM   #265
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Default Aluminum Finned Oil Pan including New Milodon 18307 Oil Pump Pickup

Aluminum Finned Oil Pan and Gasket including New Milodon 18307 Oil Pump Pickup



1. The Oil Pan Modification began by draining the Coolant such that the Oil Cooler line could be separated under the Oil Pan. The two Front Angled Struts under the front of the Oil Pan were removed (two 18mm and two 14mm bolts each).

2. The Bell Housing Shield had to be removed to remove the Oil Pan. This required that the Starter be removed. The Starter was reconditioned by separating components, cleaning and repacking the gears and bearings with grease, and reconditioning the Starter Solenoid (wire brushing the contacts and cleaning the cylinder.



The Thickness of the new one piece blue gasket and the thickness of the New Aluminum Oil Pan Bosses is 1/8 inch
thicker than Original Oil Pan flange, flange stiffener (separate bar on each side) and gasket. This required that New
longer Oil Pan bolts be used as shown on left in photo.




3. The Existing Oil Pick Up shown at top in photo will be replaced by the Milodon Oil Pump Pickup to fit inside the
Aluminum Finned Oil Pan shown at bottom in photo.




Milodon 18307 Oil Pump Pickup.
The Milodon 18307 shown below is the correct Oil Pump Pickup to be used in this application which intake will end up in front of the Oil Pump.




Last UPDATE of post 265 Dec, 2017

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Old 02-28-2017, 06:11 AM   #266
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Default Rebuilding Chrome Alternator

Rebuilding Chrome Alternator

A GM CS144 Alternator Rebuild was found on YouTube (By the Alternatorman) as follows which is the best Video I have seen.

All the Internal Alternator Parts between the Front Cover and Rear Cover (including Bearings, Voltage Regulator, Capacitor, Brushes, and Rectifier), are available on Ebay. In this case the Rectifier was toasted by maybe a screw driver stuck in the wrong place from the rear frying a Diode. The Chrome Alternator now charges perfectly.

1. Standard Motor Products RX131 Alternator Brush Assembly
2. NEW HEAVY DUTY VOLTAGE REGULATOR FOR DELCO 13120469, D677, D685, D698, VR472
3. Standard D-72 Alternator Rectifier - Diode(N) or Rectifier Assembly

A very nice Billet Aluminum Pulley is also available on Ebay.
This Alternator Pulley is the correct size replacing the Stock Alternator Pulley.
The Serpentine Belts does not have to be changed in most installations
. MCH-208 Pulley installed See All Aluminum Alternator Pulley



Alternator Major Parts



Bench Testing Alternator Components
A. You can check the resistance of the Stator with Ohm Meter (checking each of three Stator wires to Stator Housing). Should NOT be an open circuit.
B. You can check each Diode with the Diode checker on Ohm Meter. Should be Infinity one direction and low reading other direction.
C. You can check the continuity and shorting of the Circuit from the Capacitor to Top Brush. Should be Infinity Reading on Ohm Meter.
D. You can check Bottom Brush to ground.....should be zero Ohms on Ohm Meter.
E. With Alternator assembled you can check Battery Post to Case with Diode checker on Ohm Meter. Should be infinity one direction and low reading other direction.

Rotor and Front Cover Separated from Rear Cover holding the Stator, Rectifier, Regulator, Capacitor, Brushes



Rear Cover with Stator Removed..................................Rear Cover with Rectifier
Be careful when removing Rear Cover
as Brushes can get caught on Rotor Bearings





Front Cover showing Input Shaft and Bearings



Last UPDATE of post 266 Dec, 2017

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Old 02-28-2017, 06:11 AM   #267
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Default SS Air Intake

SS Air Intake

A Stainless Steel Air Intake with K & N Air Filter was added.




The Stainless Steel Air Box has been offered for those that want to add Bling and Higher Intake Air Flow for the LT5 or L98

1. SS Air Box Installation and Air Filter Selection

George Braml fabricates the SS Air Box.

Just an installation tip....If you use that Orange FRAM Air Filter you will find it about 1/4 inch too high. The bottom end of the SS Air Box Square Filter Retainer lip will not engage the Built In (L) of the Air Box at the bottom end as shown in the first photo (the Orange Fram Air Filter has a gap at the bottom end). You will also notice the two Retaining screws for the Square SS Air Box Filter Retainer have tilted towards the engine indicating the top Square Retainer has moved upward out of the SS Air Box (L) at the bottom end.

If you look closely at the SS Air Box Square Filter Retainer you will see a cut out about 1/4 inch deep and the width of the Square Filter Retainer on the bottom end. The height of the Air Filter cannot be higher than that cut out (The Orange Fram Filter is about 1/4 inch higher than that cut out).

The K&N 33-2035 High Flow Air Filter is the correct Air Filter matching the SS Air Box Cut Out.

George Braml did a perfect fabrication job on the L98 SS Air Box as he did on the LT5 SS Air Box (Both SS Air Boxes are IDENTICAL)

2. Facts and Photos

The L98 and LT5 SS Air Box and Air Filters are Identical.

A. The Air Filter opening is 9.5 in x 16.25 in or 154 square inches (both OEM and SS).
B. The Air path inside the Air Filter housing to the oval outlet is 1 in x 17.25 in or 17.25 square inches (both OEM and SS).
C. The OEM metal cover Louvers are 3/8 in x 4 in or 1.5 square inches and there are 24 Louvers or 36 square inches for Air Flow into the Air Filter area (OEM only).
D. Space between top of OEM metal Louvered cover and closed hood exceeds 1 inch all around (more space with SS Air box since metal louvered cover is not used.
C. Using SS Air Box with FRAM decreases the space between top of Air Filter and closed hood by 1/4 inch or 12.5 square inches around the perimeter of the Air Filter.
D. Using the SS Air Box with K&N High Flow Air Filter eliminates the need for the OEM metal Air Box cover (36 inches of air flow area) making available the total air flow area of 154 square inches to the K&N 33-2035 High Flow Air Filter.
E. The K&N 33-2035 High Flow Air Filter is Washable and Reusable. K&N 33-2035 High Flow Air Filter

SS Air Box installed with FRAM Air Filter with bottom of Filter Square Retainer not engaged



3. Technical Discussion
The air is drawn from top side of Air Filter in the OEM set up through the louvers in the metal cover. There is a gap of at least an inch between that Air Filter metal cover and closed hood (OEM or SS Air Box).

With the SS Air Filter housing, there is NO metal cover and air is drawn from air gap between the filter and closed hood not restricted by the 36 square inch Louver area of the OEM Metal cover. With a K&N High Flow Air Filter that gap is 1/4 inch larger (than when using a FRAM Air Filter).

The OEM filter housing metal cover will accomodate both FRAM and K&N 33-2035 Air Filters. The difference between the SS Air Box and OEM Air Box is that the SS Air box rides a bit higher requiring the 1/4 inch Cut Out for the small front crossover (see photos of the bottom of both the OEM and SS Air Box.

Because of the Cut Out the SS Air Filter housing with correct K&N 33-2035 High Flow Air Filter will sit at the same height as an OEM Air Box. However if you use a higher FRAM Air Filter that exceedes the Cut Out height in the SS Square Retainer, the overall height of the top of the filter has changed and will interfere with the front small corss over. This will in turn cause interference bwtween the FRAM Air Filter and small cross over preventing the Top Square Retainer of the SS Air Box from engaging at the bottom end.

The L98 and LT5 are IDENTICAL in regard to these issues as the OEM Air Filter housings are IDENTICAL and the radiator shrouds appear to be IDENTICAL in regard to top side of that shroud.

K&N 33-2035 High Flow Air Filter K&N 33-2035 High Flow Air Filter



5. Powder Coating or Painting SS Air Box
I did not Powder Coat or Paint the SS Air Box as it looks very very nice as a SS Machined look and the welding is absolutly perfect......so why cover up with Powder Coating or Paint

Last UPDATE of post 267 Dec, 2017

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Old 02-28-2017, 06:11 AM   #268
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Default C4 beam plates and Installation (ZF S6 40 Transmission)

C4 beam plates and Installation (ZF S6 40 Transmission)

1. Advantages of C4 Beam Plates.
a. The C4 Beam Plates also tie together each pair of bolts (Transmisison pair and Differential pair) with a SS Plate vice aluminum.
b. Each C4 Beam Plate also offers a larger contact area of the tensile bolt loads onto the C-Frame. This eliminates the wear on the "C" Frame from a smaller original washer and resulting release of bolt tension.
c. The C4 Beam Plate also acts like one big washer wherein the tensile load from each individual bolt is now shared a bit between bolts (minimum effect).
d. The C4 Beam Plates correct the condition caused by the bolt holes in the Aluminum C-Frame getting bigger or elongated with wear or the thickness of the Aluminum C-Frame from top to bottom between the original bolt two washers becoming worn so that thickness is less releasing bolt tension.
The C4 Beam Plates are definitely worth it if only for the Bolt Load Distribution (Two BIG SS washers on each end) on the C Frame and Ease of Installation. Take Note of the additional Stiffeners on each C4 Beam Plate (The BIG H). There is a BIG Difference between a Clamping Load distibution by two washers and the Clamping Load on ONE BIG PLATE on the Transmission Yoke as well as the Differential Housing.

2. Captured Free Floating Nut Design.
The C4 Beam Plates by Bill Boudreau have Free Floating Captured Nuts on the Top Plate as previously mentioned (which is a bit more complex in manufacture than a welded nut on a plate) This Captured Nut allows the Nut to Float a bit making it even easier to catch with the bolts as you insert them from the bottom.

This Captured Free Floating Nut Concept also allows self equalization of the distance between bolts (as if you are inserting them singularly THE TOP BOLT HOLES ONLY) especially after having one bolt started. The Nuts float and are prevented from turning by the design of the Capture. This Free Floating Capture of the Nuts in the Bill Boudreau Design is more important from an engineering concept (even if only floating on the TOP END) and overlooked by many in this discussion

3. Installation of C4 Beam Plates.
a. ALIGN DRIVELINE COMPONENTS: Take the following measurements directly above and to the right of the Propeller shaft front yolk universal joint between the C-Frame and the inside of the underbody.
b. To ensure proper alignment of the driveline, a clearance of 45 mm +/- 6mm (1.77 in +/- 0.236 in) must be maintained between the top of the support to the underbody. I set the clearance to 1.5 in to account for unloading deflection when I remove the hydraulic jack supporting the transmission.
c. A clearance of 28 mm+/-6 mm (1.1 in +/- 0.236 in) from the (passenger side of vehicle) right side of the support to the side wall.
d. Do not use any of the 4 original C-Frame bolt washers on the front (Transmission) or rear (Differential) bolts.
e. Tighten support bolts at Carrier (Differential) to 80 Nm (59 lb-ft).
f. Tighten support bolts at Transmission to 50 Nm (37 lb-ft).
g. Do not go over the Bolt Torque on the Carrier and Transmission or you risk changing the Dimensions of the Carrier and Transmission Connections.

C4 Beam Plate Installed On Differential ......................C4 Beam Plate Installed On Transmission
........................................ ........................................ ..Note C4 Beam Plate Bevel Location



4. Why Take Measurements?
It is kind of a corny measurement since you are measuring between the C-Frame and the side wall/Underbody which is heavily coated and made of light steel and the accuracy of the measurement needs only to be within 1/4 inch + or -. I think you are just making sure you did not put an angle in that front driveline U-joint by moving the transmission appreciably during the installation of the new C4 Beam Plates.

A Quick Measurement in regard to Transmission Yoke height can be checked from inside the car by measuring the height of the Shifter. A height of 6.25 inches from the counsel to the top of the shifter (at the center of the shifter in neutral) will be very close to the correct transmission height.



a. The 1.77 in spacer should fit between the top of the driveline support to the underbody. The 1.1 in spacer should fit between the right side (passenger side) of the driveline support to the side wall.
b. You might check that alignment spacing before you start the project to see where your alignment is now. Then just keep that alignment with the installation of the new C4 Beam Plates.



Secondary to Transmission/Driveline Alignment is ground clearance of Transmission Drain Plug. The Transmission Drain Plug clearance to ground is approximately 4 to 4.5 inches on my ZR-1s which is NOT the lowest point on the ZR-1 Drive Train/Chassis. The Ground Clearance depends on many things including Tire Pressure, Tires, Wheels, and Suspension.

5. Caution on Jacking the Engine.
Always remove the C4 Beam plate bolts on the transmission yoke when jacking/lifting the engine to minimize potential of twisting transmission yoke or C-Frame.

USE A TORQUE WRENCH

C4 Beam Plates and Installation

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Old 02-28-2017, 06:12 AM   #269
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Default Differential case drain installation

Differential case drain installation

Installed an aftermarket Differential Case Drain Plug for easy fluid change.
The kit is available from Corvette Central



The kit provides a template that puts the hole just left of the center bolt in the valley of the differential.
Original Photos provided by Scrrem with Red notes added.



The tap size is 1/8-27 pipe and it installs easily with drill (11/32) and tap supplied in the kit.

I drilled the bottom flange just under the ring gear and let the old fluid drain (which drained in about 10 minutes). I then tapped the drilled hole for the 1/8 inch allen pipe plug. When you tap the hole, try the pipe plug several times as you tap so you end up with the pipe plug out maybe 1/16 inch when tight .

I pumped in a pint of Mobile 1 75W-90 and let that drain cleaning out a lot of old oil and any tap debris. 1/8 inch Aluminum Allen Head NPT pipe plugs

I inserted the 1/8 inch allen pipe plug and pumped in a bit over 3 pints of Mobile 1 75W-90 into the fill port on the North side of the differential (Z facing West)

The Differential case can be COMPLETELY drained and flushed with new oil using this method as compared to trying to suck out the old oil.

Last UPDATE of post 269 Jan, 2018

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Old 02-28-2017, 06:12 AM   #270
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Default Modified L98

Modified L98




Last UPDATE of post 270 Dec, 2017
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Old 02-28-2017, 06:12 AM   #271
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Default Modifications Summary 5 ZR-1s

Modifications Summary 5 ZR-1s

1. 1990 #2067 UL LOSE
1990 Z 1G1YZ23J7L5802067

TB Coolant Blocked at IH
C4 Beam Plates
Starter Relay
INFL REST Sensor Re-installed L&R
Aluminum Radiator
SW Headers/Exhaust
New Nitto Tires
Haibeck Chip AYBKG4CS1a 91 Octane
Wilwood C5 Z06 Brakes
Differential Drain Plug
Oil Catch Can
Braided SS Oil Cooler Lines
Billet Alum Belt Tensioner Pulley
Billet Alum Power Steering Pulley
Billet Alum Water Pump Pulley
Billet Alternator Pulley
Carter Bling Oil Filter, Power Steering, Radiator
Carter Bling Brake Fluid, Throttle Cables, Washer


2. 1990 #3032 ULNOTWN
1990 Z 1G1YZ23J4L5803032

TB Coolant Blocked at IH
C4 Beam Plates??
Starter Relay
INFL REST Sensor Re-installed L&R
Fluidyne Radiator
New Nitto Tires NT555 F, Dunlop 8000 R
RC Injectors
Haibeck Chip AYBKG4 91 Octane
Differential Drain Plug
Braided SS Oil Cooler Lines
New Fuel Filter
Air Pump Delete
New Windshield
Billet Alum Belt Tensioner Pulley
Billet Alum Power Steering Pulley
Billet Alum Water Pump Pulley
Billet Alternator Pulley
Carter Bling Oil Filter, Power Steering, Radiator
Carter Bling Brake Fluid, Throttle Cables, Washer

3. 1990 #0072 UWLNTWN
1990 Z 1G1YZ23J1L5800072

TB Coolant Blocked at IH
C4 Beam Plates
Starter Relay
INFL REST Sensor Re-installed L
New 124 Amp Alternator
Ron Davis Radiator
New Heater Core
RC Injectors
Haibeck Chip AYBKG5 91 Octane
Differential Drain Plug
Oil Catch Can
New Gauge Oil Pressure Sensor
Braided SS Oil Cooler Lines
Billet Alum Belt Tensioner Pulley
Billet Alum Power Steering Pulley
Billet Alum Water Pump Pulley
Billet Alternator Pulley
Carter Bling Oil Filter, Power Steering, Radiator
Carter Bling Brake Fluid, Throttle Cables, Washer

4. 1991 #1427 BAD Z
1991 Z 1G1YZ23J4M5801427

TB Coolant Blocked at IH
C4 Beam Plates
Starter Relay
INFL REST Sensor Re-installed L&R
New 200 Amp Alternator
Ron Davis Radiator
New Nitto Tires NT555
RC Injectors
SW Headers, Air Injection Eliminated
Haibeck Chip BFXBG2CS2 91 Octane
Modified Camshafts
Ported Plenum/Inj Housing
Secondaries Eliminated
Wilwood C5 Z06 Brakes
Differential Drain Plug
Oil Catch Can
Braided SS Oil Cooler Lines
New Blue Label Transmission
Billet Alum Belt Tensioner Pulley
Billet Alum Power Steering Pulley
Billet Alum Water Pump Pulley
Billet Alternator Pulley
Carter Bling Oil Filter, Power Steering, Radiator
Carter Bling Brake Fluid, Throttle Cables, Washer


5. 1995 #0186
1995 Z 1G1YZ22J5S5800186

Dunn Heads Left and Right
TB Coolant Blocked at IH
C4 Beam Plates
INFL REST Sensor Re-installed L&R
Fluidyne Radiator
Haibeck Chip BMCBG4 91 Octane
New Fuel Filter
Wilwood C5 Z06 Brakes
Differential Drain Plug
Oil Catch Can
Braided SS Oil Cooler Lines
Rebuilt ZFdoc Black Label Trans with short shifter
New U-Joints Main Drive Shaft
Billet Alum Belt Tensioner Pulley
Billet Alum Power Steering Pulley
Billet Alum Water Pump Pulley
Billet Alternator Pulley
Carter Bling Oil Filter, Power Steering, Radiator
Carter Bling Brake Fluid, Throttle Cables, Washer

Last UPDATE of post 271 Jan, 2018

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Old 02-28-2017, 06:13 AM   #272
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Old 02-28-2017, 06:14 AM   #276
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Old 02-28-2017, 06:14 AM   #277
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Old 02-28-2017, 06:14 AM   #278
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Old 02-28-2017, 06:15 AM   #280
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