I tightened the intercooler piping clamps today.
Was able to use a 1/4" drive ratchet and an 11mm deep socket.
There is not a lot of room between the radiator and the intercooler (good for scraping the forearms).
I won't say the clamps were loose but I did tighten them about one to one and a half turns (didn't want to over do it).

Initial test drive produced boost ALL the time, not intermittent.

I will reserve final judgment after a few more days of driving.

 

There is no way to not replace the O-rings, because without them the sensor just flops around in the hole and the vehicle wouldn't start. The new O-rings are much larger than the ones that come on the sensor. They are actually injector O-rings.

 

The sensors can be installed without the new o-ring. I witnessed a tech doing it last Wednesday. Once bolted in place you would not know. But the system would leak and loose boost.

 

Can you suggest any dealers in the Detroit area that have done the installs and already know the right way to do it? I've talked to a couple in the area and neither really wanted to touch it....

 

Rinke Chevrolet in Warren.

 

WAS ok until this morning, intermittent is back. I experimented a bit, while rolling along with no boost, I put it in neutral and revved the engine a bit. After waiting for it to return to idle, placed it back in "D" and the boost returned. Still seems like it could be a leak, or what?

 

Take it to a dealer that knows what their doing under the hood. Not all service departments are equal.

 

I got my upgrade kit installed today they charged me 2.5 hours. The tech had trouble with the lower sensor and had to loosen my radiator to get to it. I also got Maintenance II done as well, overall bill $579.00. Tech said the vehicle was very responsive on the test drive and got 26psi out of boost.

On the way home I could not really get on it do to traffic but the places I played with the vehicle was very responsive and no lag time. I down shifted my auto tranny from 3rd to second about 45mph and goosed the go pedal and got some chirping of the tires. Overall so far I am impressed and happy. I now have a nice little pocket rocket.