I checked out http://www.motorvate.ca/mvp.php/507 for his method of changing the knock sensor without removing the intake manifold. I did get my hand into that small space with a wrench (and he wasn't kidding about bleeding) but when I finally did, I could not for the life of me get that nut off. BTW, the nut is 12mm, I found out the hard way.

So now I'm resigned to using the Haynes Manual for this repair and having to take the whole intake manifold off. While I'm in there I'm going to replace the upper intake manifold gasket and the head gasket.

Anyone else try this? Any advice?

 

I was resigned to the 'hard way' until this morning. I used a 12mm socket (1/4" drive), a universal joint, a 14" extension and an adapter that let me use a a 1/2" ratchet (lots of torque!).

I sprayed it with PB Blaster about an hour before starting. I also ground the 12mm socket down to half it's original size so that I got a better angle with the universal joint. With the big ratchet it broke loose immediately. Took 5 mins to get set up and remove the bolt/sensor.

The tricky bit was geting the bolt lined up again. I started by hooking the new sensor to the wire, slotting the bolt through the sensor and pushing it back down under the manifold. Then I used a long pickup tool (attached to the wire next to the sensor) and the 14" extension bar to align the sensor/bolt pretty close to the hole. Finally I reattached the socket/universal joint, reached it back in dropped the socket back on to the nut. With the grab tool still attached I was able to push/pull the sensor so that the bolt lined up with the hole - then tightened it down using the extension/socket. Took 10 mins to complete the install. No bloody stump and no reaching in.

Even though I had to wreck the socket (and you may need to buy the 14" extension etc) but it's still cheaper than buying all the gaskets and stuff)

 

There are no gaskets needed when removing the IM. They are all reusable. I'm filing down the sharp areas in the valley of my engine in case I have to do this in the future. Why couldn't they just do that stock of make the head casting not have these deadly areas? Oh yeah they want to charge you the $800 to remove the IM.