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Just checking out a spare LS1 block that came with a 2002 TA I picked up for my son and noticed it appears some winner was trying to drill the sensor out of the block, and went right through aluminum in more than one spot. What would you do? Somehow repair this, and run it, or relocate knock sensors to the side of the block, extend the harness, and use a block of valley cover?
I know the threads look boogered, but will the sensors thread in at all?
It looks like you have good threads below the damage, unless I'm not seeing it right.
I kinow the threads look boogered, but will the sensors thread in at all?
It looks like you have good threads below the damage, unless I'm not seeing it right.
Yes, there are still a few threads at the bottom. I ran a bolt down it, until it bottomed out, I’m just not sure it’ll hold much torque… I can’t find a knock sensor in any of my boxes, and we haven’t disassembled the blown motor in the car yet to rob one. Might go pick up a couple more Delco units and see if it’ll hold at all.
I don't know the torque spec for knock sensors, but it can't be much. If you can get it in good and snug with some Loctite, I would think it should hold.
LOL, I just saw we're almost neighbors! I live about 5 miles east of Hanford....
I don't know the torque spec for knock sensors, but it can't be much. If you can get it in good and snug with some Loctite, I would think it should hold.
LOL, I just saw we're almost neighbors! I live about 5 miles east of Hanford....
Oh no ****?! Close enough to be neighbors in my book! If I remember right, the torque for those sensors is 15ft lbs.
Oh no ****?! Close enough to be neighbors in my book! If I remember right, the torque for those sensors is 15ft lbs.
Yeah, I don't know how much that can be fudged, or if the boogered hole will take that much.
Plus I don't know how much thread the sensor has, to figure how deep into good threads it can go.
You just need to get one and see how it feels.
I think you have two issues there. The seals on the valley cover seal against the outside of the stands that have been drilled on your block. That will allow trash/water into the engine, as well as mess with the function of the PCV setup, because the engine is no longer sealed. The other issue obviously is the missing threads that the sensors screw into. The threads could be repaired with epoxy and a tap. The outer part of the stand that the valley cover seals mate against will have to be repaired perfectly, or you’ll have a permanent leak there. It’s doable for sure. A “plan B” might be relocating the knock sensors to an external part of the block and perhaps using a valley cover that’s designed to cover the original sensor locations on a Gen3 block. Just something to think about here.
OP might have luck using a piece of thick paper, like from manilla envelope. Encircle the bad side of the boss O.D. with it and a small hose clamp. Then used a small, but sufficient amount of steel epoxy/Deacon. Use only enough to bring the stuff to the top of the aluminum boss. Let it setup for 24 hours, then remove the paper and clamp. Without removing the engine, I can't think of any other realistic way of doing it. Of all the LS issues I've ever heard of, this is a new one for me. Best of luck, OP..
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Damaged Knock Sensor Boss 
