masshead87 wrote:I'm intrigued by this abbreviated procedure, since in my case I've only got one KS throwing codes and I'm fairly sure it was due to my several-month span of filling up with 89 octane.
Lokim, could you identify which hoses you had to pull from the codes on the under plenum diagram?
While I don't recommend doing it this way, I know that the plenum had been off a year and a half or so ago for 2 injectors prior to my ownership. I inspected the hoses and all seemed well, so I proceeded with the "abbreviated procedure" as you so eloquently put it.
I started by draining the radiator and engine block. The radiator drains via a petcock on the passenger side. The block drain is a 22mm hex-head plug on the driver's side of the block, above the crossmember. There's really no neat way to drain it, so get your catch pan positioned, get the plug loose, and get out of the way! I drained the block because A: I didn't want a valley full of coolant, and B: I hadn't changed the coolant since I got the car.
I then disconnected the hard line to the EGR valve, the plenum-to-valve cover breather hoses, the throttle body coolant lines, and several electrical connectors.
I unbolted the plenum itself and pulled up a bit. You'll see what needs disconnection and what doesn't when you reach this step. Once I got enough upward play that I could prop up and work under the plenum, I plugged the intake runners with paper towels.
Now comes the fun part! I loosened the hose clamp for the coolant pipe-to-water pump outlet and got my special hose-freeing tool in there to get the hose free from the fitting. Then I unbolted the coolant crossover and finagled it out from it's spot (not easy.)
After that, the knock sensors are a breeze. MAKE ABSOLUTELY SURE YOU TORQUE THE KNOCK SENSORS TO SPEC! THIS IS CRITICAL!!! 12-15ft-lbs (I put mine at 14ft-lbs)
When you reinstall the coolant crossover, make sure both mating surfaces are SPOTLESS! Apply a bead of black or gray RTV to the crossover pipe-to-head mating surface not only on the pipe you removed, but the head surfaces as well. The reason for this is that when you maneuver the crossover assy. back in, you WILL scrape some of the RTV off, and having some on the head surface will make up for that.
Reverse all previous steps for reassembly, making sure to torque the plenum bolts to spec. Wait an hour or two before refilling cooling system so the silicone can set, bleed cooling system, and off you go!
