Canadiangeek.net How do you know you can't do something if you haven't tried

So a few days have passed since the last post.

My family and I have been sick for the last few days so progress has been slow.

I picked up some "Metal Rescue" from CanadianTire and filled an ice cream bucket. I then completely submerged the wheel bearing assemblies. After 4 hours these things are spotless, no rust, no oil, look brand new. Now its possible that this isn't good for the wheel bearing itself, time will tell. My theory was that this part has to be water tight because of its location. So far the wheel bearings are spinning a little easier then before, I think this is due to the reduction in surface rust. I plan to paint these black with some high temp paint.

I also picked up a better grease remover from CanadianTire (see photos). Using this new degreaser I was able to clean some of the harder to clean pieces. I also used the new degreaser to clean of the brake calipers. I then followed that up with a wire brush and some brake cleaner. These are now ready for paint, I plan on painting them red/black (caliper red, mounting bracket black)

I used a winch strung off through the attic hatch and over 2 rafters to lift the engine off the pallet that it was on. My buddy and I then mounted the engine down to a stand with wheels. This allows better access to the front and sides and makes the overall size smaller so it will easily fit into the corner of the garage. I then removed the power steering pump, water pump, AC bracket, etc so I can start to clean the rest of the engine. (I do have a friend with an engine hoist, so far I have been to lazy to pick it up)

I ordered new tie rods so I started to remove the old tie rod ends. These nuts were locked on and required some heat to expand the nut and loosen them up. Old Tie Rods are now off waiting for the new parts to come in the mail. I will hit these with a little black paint to make them look better.

Once the new ball joints come in I can start putting the suspension back together. In the meanwhile I have been researching fuel system options including which aluminum tanks to go with (there are two kinds) and which fuel rail/pump/regulator/filter combination to run with.

Does anyone know if the Aeromotive rails fit under the factory engine covers?

Daily Update

I have been out in the garage for most of the evening, my fingers are numb, i'm sick with a cold and have a pounding headache. Regardless it didn't keep me out of the garage. Fun enough i have so many cuts on my hands from cleaning parts that my iphone wont unlock with my finger print anymore. Aluminum is SHARP!

I am down to the last knuckle and A arm, i am letting them sit in degreaser overnight, they are rough, like someone pored oil on them and drove down a dirt road. 2 hours cleaning them and they now to the point the others started. Once that was done i decided to move over to some engine cleaning, figured a top down approach should work best. I have swapped engines in the past but never cared enough to make them spotless so this is new territory for me. I started by removing the coil packs, and then the metal mounts that the coils mount to, followed by the wiring harness as a whole. I was then able to remove the fuel rail and the air intake. Throttle body came off after that followed by the valve covers. I used gunk degreaser to carefully remove the gunk being careful to keep it out of the engine. I used non scratching SOS pads and a soft bristle brush to get into those hard to reach areas.

Tomorrow i may pull off the accessories and start cleaning the mounts, bolts and accessories themselves.

The Donor comes home

All the donor parts are now safely in my garage. My engine hoist isnt here yet so i had to think of a way to get the engine out of the crate and into my garage. I cheated a little using the car ramps and the quad winch but it all worked out great.

Here is what my garage space looks like. I have some mess to clean up. Believe it or not this is after 2 loads to the dump and about 12 hours of tool sorting. TV on the wall is so i can watch TopGear while i work. I have been trying to talk myself into a 2 post portable lift. They are pretty cheap shipped to my door. Being able to move the car up and down may make the job a little easier.

Donor Teardown

OK may be a little early as I just ordered the GTM kit today but the donor parts are here so i have some cleanup and prep that i can start documenting.

A few weeks ago the donor looked like this

Everything has now been taken apart and it now looks like this.

The Donor

Found the donor in Norwich, ON.  I was able to have the car disassembled in Ontario and shipped via pallet to Calgary Alberta.  Its a 2003 CORVETTE Convertible. Car is in mint shape and runs like a dream.  45000 Km on the Odometer branded Irreparable (Flood Damage).

Off the donor i was able to pick up the following parts

FRONT SUSPENSION

1. 1 each LH Front lower control arm (rubber bushings installed and ball-joints pressed in) 10326693-LH
2. 1 each RH Front lower control arm (rubber bushings installed and ball-joints pressed in) 10326694-RH
3. 1 each LH Front upper control arm (rubber bushings installed) 10333408-LH
4. 1 each RH Front upper control arm (rubber bushings installed) 10333409-RH
5. 1 each LH Knuckle (upper ball-joints pressed in) 10332530-LH
6. 1 each RH Knuckle (upper ball-joints pressed in) 10332529-RH
7. 2 each Front bearing/hub assembly 7470569
8. 1 each LH Hub backing plate for wheel speed sensor wiring attachment 10263081-LH
9. 1 each RH Hub backing plate for wheel speed sensor wiring attachment 10263082-RH
10. 2 each Locknuts for lower ball joints (M14 x 2mm) 10282253
11. 2 each Locknuts for upper ball-joints (M12 x 1.75mm) 3537772
12. 6 each Torx bolts (T55) for bearing/hub assembly to knuckles (M12 x1.75mm x 55mm) 10414261
13. 8 each Bolts for upper control arm to chassis (M10 x 1.5mm x 40mm) 11515768
14. 8 each Washers for upper control arm to chassis (10mm) 10289125
15. 4 each Cam bolts for lower control arms to chassis (M14 x 2mm x110mm) 10254819
16. 4 each Locknut for lower control arm bolts (M14 x 2mm) 11516382
17. 4 each Cam washers for lower control arm bolts 10254818
18. 4 each Bolts for lower shock mount (M8 x 1.25mm x 55mm) 14066450
19. 4 each Locknuts for lower shock mount (M8 x 1.25mm) 11517031
20. 1 each LH Front rotor 10445857-LF
21. 1 each RH Front rotor 10445856-RF
22. 1 each LH Front caliper 12530683-LH
23. 1 each RH Front caliper 12530682-RH
24. 2 each Front caliper mounting brackets 12455799
25. 4 each Front caliper guide pins 12530697
26. 4 each Front caliper guide pin bolts (w/o threads) 14067559
27. 4 each Bolts for front calipers to knuckles (M14 x 2mm x 47mm) 14084051
28. 4 each Washers for calipers to knuckles (5/8” ID, 1 1/8” OD) 10268875
29. 2 each Flexible brake lines with mounting brackets 10361617
30. 2 each Banjo bolts for brake line attachment to calipers (M10 x1.0mm)('97-'00) 22163795
31. 2 each Banjo bolts for brake line attachment to calipers (M10 x1.0mm)('01-'04)
32. 4 each 4 crush washers 21012386
33. 1 pair Front brake pads 12530681
34. 10 each Lug-nuts for front suspension (M12 x 1.5mm)(Stainless steelcapped) 9595165

1. 1 each LH Rear lower control arms (rubber bushings installed and ball-joints pressed in) 10233635-LH
2. 1 each RH Rear lower control arm (rubber bushings installed and balljoints pressed in) 10233636-RH
3. 1 each LH Rear upper control arm (rubber bushings installed) 10233620-LH
4. 1 each RH Rear upper control arm (rubber bushings installed) 10233621-RH
5. 1 each LH Knuckle (upper ball-joints pressed in) 10332530-RH
6. 1 each RH Knuckle (upper ball-joints pressed in) 10332529-LH
7. 2 each Rear bearing/hub assembly 7470571
8. 2 each Locknuts for lower ball joints (M14 x 2mm) 10282253
9. 2 each Locknuts for upper ball-joints (M12 x 1.75mm) 3537772
10. 6 each Torx bolts (T55) for bearing/hub assembly to knuckles (M12 x 1.75mm x 55mm) 10414261
11. 2 each Cam bolts for lower control arms to chassis, forward most mount (M14 x 2mm x 110mm) 10254819
12. 2 each Locknut for lower control arm bolts, forward most mount (M14 x 2mm) 11516382
13. 2 each Cam washers for lower control arm bolts, forward most mount 10254818
14. 2 each Cam bolts for lower control arm, rearward most mount(M12x1.75) 10200097
15. 2 each Locknut for lower control arm bolts, rearward most mount (M12x1.75) 11515744
16. 1 each LH Rear rotor 10445859-LR
17. 1 each RH Rear rotor 10445858-RR
18. 1 each LH Rear caliper 12530685-LH
19. 1 each RH Rear caliper 12530684-RH
20. 2 each Rear caliper mounting brackets 12455800
21. 4 each Rear caliper guide pins 12530698
22. 4 each Rear caliper guide pin bolts (w/o threads) 14067559
23. 4 each Bolts for rear calipers to knuckles (M14 x 2mm x 47mm) 14084051
24. 4 each Washers for rear calipers to knuckles (5/8” ID, 1 1/8” OD) 10268875
25. 2 each Flexible brake lines with mounting brackets (rear, slightly longer than the fronts) 10333773
26. 2 each Banjo bolts for brake line attachment to calipers (M10 x 1.0mm)('97-'00) 22163795
27. 2 each Banjo bolts for brake line attachment to calipers(M10x1.0)('01- '04)
28. 4 each 4 crush washers 21012386
29. 1 pair Rear brake pads 12530688
30. 10 each Lug-nuts for rear suspension (M12 x 1.5mm)Stainless steel capped) 9595165
31. 2 each Outer CV-joints 12532153
32. 2 each Locknuts for outer CV-joints (M27 x 2mm) 10257766
33. 2 each Rear toe link, 7844424-boot/7844100-sm clamp/26036823-lg clamp 88955489
34. 2 each Locknuts for rear toe link to chassis (M16 x 2mm) 11516383
35. 2 each Rear outer tie rods (M14 x 1.5mm)(includes jam nut) 88955488
36. 2 each Jam nuts (M14 x 1.5mm) 26017267
37. 2 each Locknuts for tie rod ball-joints (M12 x 1.75) 3537772

EMERGENCY BRAKE

1. 1 each LH E-brake backing plate 12455802-LH
2. 1 each RH E-brake backing plate 12455803-RH
3. 1 each LH Parking brake lever boot protector at spindle 12530694-LH
4. 1 each RH Parking brake lever boot protector at spindle 12530695-RH
5. 2 each Parking brake kit (includes shoes, and misc. parts) 12530691
6. 1 each LH e-brake cable to knuckle brackets 10262949-LH
7. 1 each RH e-brake cable to knuckle brackets 10262950-RH
8. 4 each Bolts for e-brake cable to knuckle brackets (M10 x 1.5mm x 70mm) 11516356
9. 1 each RH E-brake cable 10299165-RH
10. 1 each LH E-brake cable 10409250-LH
11. 1 each E-brake handle (includes attached front cable with equalizer bar, black hand grip and boot) 10323579
12. 1 each E-brake cable connection bracket (connects front cable to both rear cables) 10255639

1. 1 each LH Fuel tank ('03 second design)('04) 10362744-LH
2. 1 each RH Fuel tank ('03 second design)('04) 10337582-RH
3. 1 each Fuel tank crossover hose 2" dia.('03 second design) ('04) 15223882
4. 1 each Fuel filter ('99-'04) 10299146
5. 1 each Fuel feed hose rear ('03 second design) ('04) 10362524
6. 1 each Fuel feed & return hose rear-RH ('03 second design) ('04) 10337581-RH
7. 1 each Fuel feed & return hose rear-LH ('03 second design) ('04) 10337583-LH
8. 1 each Fuel sender connector w/leads -LH ('03 second design) ('04) 15306361-LH
9. 1 each Fuel sender connector w/leads-RH ('03 second design) ('04) 15326833-RH

COOLING SYSTEM

1. 1 each Fan shroud ('98-'04) 12365307
2. 2 each Fans 22098787
3. 2 each Fan blade mounting nuts (M8 x 1.25 LH THD) 22082538
4. 2 each Fan motor 22104439
5. 2 each Fan motor to shroud mounting screw kit (contains 3 screws) 22062547
6. 2 each Fan motor connector w/leads 12101917
7. 1 each Radiator 52470606
8. 1 each LH Radiator lower rubber isolator 10278679-LH
9. 1 each RH Radiator lower rubber isolator 10188023-RH
10. 1 each Coolant overflow tank ('00-'04) 10430189
11. 1 each Cap for coolant overflow tank 25713160

1. 1 each OBD2 PCM computer ('01-'03) 12200411
2. 1 each Computer mounting bracket, inner piece ('99-'04) 10288066
3. 1 each Computer mounting bracket, outer piece ('99-'04) 10288067
4. 2 each Screws to connect computer brackets together 20430420
5. 1 each TAC module , and (for fly by wire throttle) 12578953
6. 3 each U-nuts for TAC module to computer bracket 11513599
7. 3 each Screws for TAC module to computer bracket 20430420
8. 1 each Throttle pedal (fly by wire) 12565643
9. 1 each Fly by wire harness (connects throttle pedal to TAC module) 12116247
10. 2 each Short 4 wire oxygen sensors 25312184
11. 2 each Long 4 wire oxygen sensors 25312202
12. 1 each Vehicle speed sensor (VSS) with mounting bracket 12369458
13. 1 each VSS connector w/leads (black) ('97-'04) 88987993
14. 1 each VSS connector w/leads (gray) ('01-'04) 15306302
15. 1 each Engine Harness 12189523
16. 1 each Brown plug that connects to the under-hood fuse box 15303514
17. 1 each Gray plug that connects to the under-hood fuse box 15303512
18. 1 each OBD2 Engine scan plug with about 12 inches of all wires extending out of it 12167308
19. 1 each Under-hood fuse box 10443148
20. 1 each Power terminal nut on fuse box 11514596
21. 1 each Brake light switch with plastic holder 10447139
22. 1 each Brake light switch connector w/leads and capacitor 12166226
23. 1 each Ignition switch 10308321
24. 1 each Ignition switch connector w/leads (6-way natural) 12167156
25. 1 each Ignition switch connector w/leads (6-way black) 12162229
26. 1 each Ignition switch connector w/leads (3-way black) 12101864

1. 1 each Ignition cylinder, lock cylinder(s) and 2 key set 12458190
2. 1 each LH Exterior door handle 10439373-LH
3. 1 each RH Exterior door handle 10439374-RH
4. 1 each LH Exterior door handle gasket 12531227-LH
5. 1 each RH Exterior door handle gasket 12531201-RH
6. 1 each LH Exterior rear view mirror 10416055-LH
7. 1 each RH Exterior rear view mirror 10416056-RH
8. 6 each Exterior rear view mirror mounting nuts 11609411
9. 2 each License plate lamps 16519986
10. 2 each License plate bulb socket 88986416
11. 4 each License plate lights mounting screws 10400761
12. 1 each Horn, high note 89046917-high
13. 1 each Horn, low note 89046916-low
14. 1 each Horn connector w/leads (gray) 15306302
15. 1 each LH hood latch 15804048-LH
16. 1 each RH hood latch 15288474-RH
17. 1 each Hood release handle and 2 attached cables 10411704
18. 2 each Hood strikers 10273708
19. 1 each LH hood hinge 10326221-LH
20. 1 each RH hood hinge 10326222-RH
21. 1 each Wiper motor with rotating assembly 12494759
22. 3 each Wiper motor mounting screws 11588831
23. 1 each Wiper motor connector w/o leads 12129126
24. 1 each Wiper rubber hose 22154854
25. 1 each LH Power window mechanism w/motor 10344131-LH
26. 1 each RH Power window mechanism w/motor 10344132-RH
27. 2 each Window motor connector w/leads 15305982
28. 1 each Steering column (w/stalks, 2 piece cover, steering wheel nut M14 x 1.5mm)(telescoping) 26070622
29. 1 each Drive belt Tensioner ('01-'04) 12568181
30. 1 each Drive belt idler pulley 12564401
31. 1 each Alternator 10353440
32. 2 each Rubber motor mounts 11515744-nuts 4each 10284134
33. 1 each LH Aluminum motor mount bracket 10260642-LH
34. 1 each RH Aluminum motor mount bracket 10260643-RH
35. 6 each Motor mount to engine bolts 11515767

1. 1 each A/C bracket 12556444
2. 1 each A/C Compressor w/clutch 1137031
3. 1 each A/C Condenser 52470569
4. 1 each A/C Accumulator 1132765
5. 1 each A/C Mounting hardware (110mm bolt) 11516714
6. 1 each A/C Mounting hardware (165mm bolt) 12552922
7. 1 each A/C Mounting hardware (90mm bolt) 11509202
8. 1 each A/C Mounting hardware (nut) 10255857
9. 1 each A/C Mounting hardware (40mm bolt) 11515768
10. 1 each A/C Mounting hardware (stud) 12556447
11. 1 each A/C Belt Tensioner 12560345
12. 1 each A/C Idler pulley 12557334
13. 1 each A/C Belt 12569528