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Finally, some good things are happening for me and my Z. So I put her up on jackstands a couple of weeks ago to get ready for the winter. Going to change out the antifreeze and oil, put on new belts and swap my marginal alternator out while I was underneath. Might as well find and fix my PS leak, too. Nice plans for a weekend that turned into a 3 weekend ordeal! First, replacing the alternator is a PITA!! Looking at it doesn't seem that it would be that hard, but getting to the backside nut was good for about 4 hours of cursing because I couldn't loosen it enough to enable me to hold it with my hand (more than about 1/2 turn before my hand would cramp up) and couldn't get a socket on it well enough to turn the bolt. Okay, I thought, "Fine, I'll pull the PS pump to give myself enough room." Of course, I can't get enough swing on the pump to remove the belt from its pulley and as I was working on it the pulley pulled right off of the driveshaft (without loosening the nut) as all of the PS fluid began to pour out of the front of the pump. Seems the shaft was no longer held in place internally. I didn't want to pull the pump and leave all the lines open during the week (expecting rain) so I left it in place and ordered a rebuilt pump and PS hose from Z1 which arrived in time for me to continue over the second weekend. Disconnected the high pressure hose and pulled the pump. Now I could access the alternator, which came out easy enough from here but as I'm trying to mount the new one (nice 160A unit from Ohio Gen) I find that the original mounting bolt is too big for the holes on the new one. Searched three different hardware stores in town and couldn't find a metric size bolt that was long enough to work. Finally, had to settle for a SAE bolt but at least it's mounted now. Now I'm trying to mount the pump in place and can't quite get it in because the rear bracket mounting tab seems a little too large for the cutout on the pump. Take out the ol' Dremel and grind the cutout a little larger and was finally able to swing it in place. Last step, pull the old PS hose and replace it. Maybe I should have just left the original since I wasn't sure if it was the source of the leak because whomever worked on the PS system last (before I bought the car) put the hardline clamp, mounted above the crossmember, in upside down. The screw was pointing down preventing me from getting a socket or screwdriver on it! Ended up using a set of tin snips to bend the clamp open enough to get the line out. To top all of this off, was unable to find the right size banjo washers locally, so on a NAPA recommendation I tried to use nylon washers. Big mistake, ATF everywhere! Had to order new washers from Coz. At last its all back together and as much as I was cursing and kicking tools the last couple of weeks, starting it in the morning with no belt squeal, driving with new/good parts that I installed myself brings a big grin to my face!
Just to make things better, received the heads back from my engine builder. 3 angle valve job with new valves and guides, had the casting flash removed, intake and exhaust porting and reconditioned/new lifters. When things finally come together, it's all worth it!!!
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