Checked out some post's on changing this. A video shows a guy changing it without cutting the cover above it. I'm looking at an '01 and you can barely see the end of the harness. I cannot begin to get a hand in there to get the harness off. So how did he do it? Do other years of the C5 allow a little more room?

 

No they don't have more room -

It can be done and the stuff can be moved somewhat out of the way to get to it - You can even simply pull the coil packs off the valve cover that will greatly help it accessing the unit.
Plus you can take off the valve cover to get even closer - The valve cover has a O-Ring style gasket and does not need to be changed! It can go right back on afeter done!

You can also move the brake booster vacuum supply out of the way and any other piece that is in the way - all the stuff that lays across the manifold and towards the back can unplug and plug back in later!

Thanks,Matt

 

Just remove the intake, It isn't that hard at all, I bet if you have the tools ready you can have it off in under 20 minuets.

 

Mr. Bill has it correct. Just remove the intake plenum. I was frightened of it the first time I removed it to get to the sender. The only special tool you need is a fuel line quick disconnect tool (it slips into the fuel line before the rail/splitter and separates the two, be ready with a rag though). Be sure to pull the fuse for the fuel pump and start the car and let it burn off the fuel and pressure in the fuel lines to keep it from gushing gasoline everywhere. The hardest part was getting the 2 most rear bolts on the intake undone because its too tight to fit a socket back there. I just had to be very patient and use a wrench.

 

Welp, did this about a week ago and overall I'm pretty happy I took the time to read up, do it and learned something.

I was a bit intimidated with removing the manifold, having never done something like this I was a little worried about what could happen if I messed something up. After reading numerous how-to's and taking the better part of a week to order all the pieces for a relocation kit from various online retailers I decided what the heck.




Got this little guy from A&A Corvettes so I could connect a 45* -4AN aluminum line fitting which would connect to a nylon braided line to the sensor.



And here's the relocation line I made, all -4AN fittings till I got to the sensor and needed a step up. So the break down: 45* -4AN fitting > Nylon braided line (nylons is covering the stainless braid, I didn't want the "bling" of an SS braided line.) > 180* -4AN fitting > -4AN to -6AN step up (usually referred to as a reducer) > and finally a -6AN to M16x1.5 fitting. The sensor is M16x1.5 so it fit perfectly in the fitting and butted right up against the crush seal that came with the sensor.



I would mention the specific write-up I used for removing the intake manifold but the member's name escapes me at the moment. Now the total time for me was about 4.5hours. But and this a is a big "but," I was at a auto hobby shop at an Army post and was constantly having to check out tools and turn them in if it were the wrong item. Also it took about 45 min to finish up the relocation line as the shop didn't have a single decent pair or dykes or wire cutters of any kind, so I was left with an insanely dull pair of sheers cutting the stainless braids literally 1 by 1.

A bit of warning for anyone else going to attempt this. I should've known better (as I'm an f16 mechanic) but be sure to double check all the fittings in the relocation setup before putting everything back together. This weekend I had to dive back behind the manifold because I neglected to tighten the 45* fitting tight enough on the A&A fitting which caused some oil to leak out producing a rather unpleasant smell. 2 days later and a good bit of miles on her with no signs of leaking and the best part is I can now pop of the red Corvette cover, unplug the sensor and replace the damn thing if it ever fails.

Any question?

 

You don't need to remove the fuel lines. And if you take off the intake you only need to slide it down about 6 inches. This comes from Evil Twin who was one of the C5 engineers.

I'm going to replace mine the next opportunity because mine is leaking badly. But to answer your question the guy in the video used a coat hanger to get the connector off.

 

After you remove the intake for the first time I gets pretty easy to do again. 10-15min is pretty easy. Thats why I love these cars, supercar performance yet you can do almost any job on them in your home garage.

 

Harbor Freight sells needle nose pliers that are 11" long. I purchased the straight and the 45 degree angle 11" pliers. Both cost a total of
$10.00 plus shipping. The above is to get the connector off.