That 7mm bolt is supposed to have loctite on it(per gm turbo upgrade instructions)to prevent it from lossening. Common sense would tell you not to locktight a metal screw into plastic but im sure its included in the instructions for a reason. As VictoryRedSS said, make sure that tab is trimmed off or the sensor will not seat correctly causing a leak. I remember seeing a picture in one of these threads, showing how the sensor sits when the tab or "boss" was not removed and the wires coming off the plugs tilted downward which is not correct.

 

Also if the sensor was loose and wiggling around you could have damaged the o-ring. I would advise removing the sensor and replacing the o-ring just to be safe.

 

I'm going to drive it tomorrow to see how it's acting. I'll let ya know. Thanks for all of the idea's and input....I'm going to check out everything that you guys are suggesting

 

Round #2...on my way out...and lost all power again..no boost.

Ended up having a Ford Dealer look at it since I was already there fixing dents on their lot (I have my own paintless dent repair business)....


They undid all of the connectors and got the harness down. Looked at the connectors and said the connectors looked fine. They pulled really hard on them...and they didn't move at all. They said that it was probably in a bind...and hitting the AC compressor. So....the put some kind of plastic coating around the wires and plugged everything back in. So far...so good, no problems.

 

Hope that fixes it for you. Still, I would replace that 0-ring from that previously loose sensor.Also, looking at my upgrade kit, which is still in the box, the 0-rings seem to be a specific size(and part #) for the Bosch upgrade sensors. Make sure to get the right ones.

 

If it is hitting the AC you may need to shim the IC out. That is what GMPD had them do on my SS when it hit the AC. It takes only a 1/4 to fix the hit issue. In time I would expect any coating will be damaged.

 

I shim seems about the only way to go

I've been through that problem too. When I went to get the GMTU installed....one of the o-rings had a crack in it. So....my car sat at the dealership for about 3 days...because they had to order the correct o-ring. It's an "off the wall" o-ring and they didn't have them instock.

 

I know I mentioned the bracket before so I won't get all redundant about it.....but since they put it in , zoom, zoom. Didn't you order a new intercooler? CS there is no room to push it forward, in fact you will be moving the radiator deal for the air conditioning back to make a 1/2" more room for it. Maybe you can shorten the end of the cold air before you hook it up and gain a smidgin thats all you need.

 

It is not as hard as it appears to be to move the IC. You do need to pull the bumper cover off to get to it and that is the hardest part.

once off just use fender shims and move it out just a little. you can test drive it with the bumper off but make sure to clear the inter fenders as the can it the tires and rub.

Mine was moved about 1/4 inch and it has not cut out since then.

I think as engine mounts get worn and if engines start to rock back more others may see this issue in the future. There is just too little room there on some SS but not all.

My issue was when they replaced the IC and it was fine with the stock map but the Upgrade kit map it was too dang close.

It just took a lot of laying under the car and looking for the reason and I finally spotted it. GMPD said that is what was doing it and shim it. He even sent me a diagram of what to shim.

 

I bought a new Intercooler (crazy steve's)

When I get everything apart....I'll look and see what I can do with the intercooler....hopefully...I can shim it as well, to squeeze a little more room for the sensor to move a little without hitting the AC compressor