I don't know why manufacturers dont use a resin encapsulation process on them similar to how a coil packs is done. Must interfere somehow.

 

Didn't drive the past couple of days but did today. Not sure if this tells us anything but I was able to make my commute without any lurching by avoiding 4th gear. I spent a little time at fourth gear but went 3rd to 5th anytime I was going to maintain a constant speed. Seems like the common denominator of the occurrences is driving at a consistent speed in 4th gear.

Went ahead and ordered new spark plugs and an OBDII scanner that should arrive tomorrow.

Cleric - still sound like cam/crankshaft sensor(s)?

 

OBDII scanner arrived today...1 pending code = P0327 Knock Sensor 1 Circuit Low. Did some research and sounds like the harness itself is what needs to be replaced. Looks like a really lovely spot to place a little harness and sensor! Anyone have recent experience with this job? Trying to think of parts I should get and replace while I'm in there.

 

Haven't removed my plenum since installing my MD spacer. Will I need to purchase replacement plenum gaskets? Any other gaskets to get for this knock sensor job?

 

No, they're reusable unless they get damaged during disassembly.

 

Thanks for the help. Lucky me, I have a 11/02 production date so I had to purchase the new style knock sensor in addition to the harness. Guess it can't hurt to do while I have the collection off. I'll post after install to let all know the outcome.

 

There's two easy mistakes to make, first is not torquing the plenum in the proper order using the proper interval of torque from low to high.

Next is accidentally pinching the oil fill neck between the plenums.

Don't make those mistakes and you should be fine.

 

And make sure you don't bend the plenum gasket at all. If you do you'll have to buy another, not many members have bent it and got it to fit correctly after that.

 

Thanks guys. I'm at the lower plenum...removed all of the bolts, nuts, and harness brackets. Trying to remove the lower and it's completely stuck in place. It's never come off before that I know of so I'm guessing it's the gasket between the lower and intake manifold? Any suggestions on how to get this sucker off without screwing anything up?

 

Dead blow mallet on a non-gasket surface. If you don't have one then a regular hammer with a block of wood to deaden the blow. It won't take much so just tap lightly.

 

Neighbor lifted one end while hit the other with a rubber mallet and that did the trick. Unfortunately the intake manifold gasket is no longer in one piece (knew i should have ordered replacements from Z1). Is it a sin to reuse the one I have? Doubt this would be something the stealership has.

And really starting to feel intimidated as I look at this intake manifold, fuel rail, injectors...I thought I read I didn't have to remove fuel assembly to get to this bitch?

 

Moved on to the spark plugs since I'm puzzled with this knock sensor job. Just snapped a coil pack bolt with my torque wrench and I'm slipping away into a really dark place...

 

62 INCH/lbs right? Fortunately it's a small thread and very easy to get out with a bolt extractor.

 

I read 95 in/lb for the coil pack bolts, got that from numerous threads online and a FSM screenshot from ByThaBayPlayer 3 part video. Based on that I torqued the bolt to 8 ft/lb. Maybe torque wrench failure??? Anyways, I used a nut driver to tighten the rest by hand.

Ended up getting the confidence to remove the fuel rails and get to the intake manifold (which came off easier than that lower plenum collector). Swapped out knock sensor with the new version, piece of cake. Stuck here until my replacement gaskets from Z1 arrive. Hopefully reassembly goes smoothly...I will follow up with how it goes.

 

Here's a screenshot of the FSM.