I am trying to install the zzp plug and play 3 bar map sensor kit for my 09 SS. I went to install the upper one on the manifold and the screw hole doesnt line up. It is off and the screw will not thread in. Ha anyone else had this problem? I tried everything and if I screw this in it will cross tread for sure. I have no idea what I can do. Unless its the wrong sensor, I dont know. Any info/suggestions will help.
thanks

 

The hole are on different centers. The new sensor is a hair less than 9/16" on center. The old one is closer to 5/8" on center. This is more than 1/16" difference. This is causing the bolt to not thread. Could they be the wrong sensors? Thanks again

 

Take a picture of the actual sensor and post it.

 

Should be blue and silver on the back and say bosch.
It should be part number 0281002845

 

The sensor's fine and is correct. These sensors were never designed specific for the cobalt. They're just an off the shelf bosch 3bar map sensor that happens to fit "close enough" to work with out cars.

The easiest way to make the sensor fit is simple.

*Lube the o-ring,
*Slide the bolt through the mounting hole in the sensor BEFORE installing the sensor in the manifold,
*Line the sensor up as to be installed in the manifold so the threads of the bolt start to thread into the mount on the manifold but don't push the snout with the o-ring all the way in it's hole yet,
*Once the bolt starts to thread and the snout is lined up to seal in the manifold, carefully start threading the bolt down the rest of the way. All while being careful the sensor goes in as straight as possible.
*Great, now your done. Pat yourself on the back and come to the realization that this was a solid .05 on a 1-100 scale of difficulty. Also while realizing that this is by far the the easiest of the 2 sensors you'll need to install.

 

Don't forget to shave the tab off the lower one and ensure you have the right orings as the ones that come on the sensors are not correct.

 

Ok, thanks I will try and mount it. Im not mechanically stupid. However when a sensor doesn't line up its not something I want to force in. Knowing now that this is the way it needs to fit Ill try. I can also clip the edge of it so it has a slot instead of a hole and nothing has to be forced. I have the ZZP lower pipe and already have the old sensor out. The only bitch now is going to be plugging the old holes as they recommend with the set screws. Thanks again for the help.

 

At least with the zzp lower you don't need to shave the tabs as its a flat block and doesn't have a little ledge in the way.

 

Ok, it just didnt seem to fit right with starting the screw and running it down, It wasnt sitting flush. It was cocked to the right. So a quick clip with the hacksaw and a rat tail file. Fits like a glove. The bottom was a bit of a bitch. I should have ordered these when I put the ZZP pipe in. I had to play with those little set screws to fill the old map holes but it only took about 30min to get everything in. I did it all from underneath. These sensors came with the thick black o-rings on them already from ZZP, I am assuming they are right. (I hope). I will say you need hands like a woman to work on these cars. Next install is the Powell PCV upgrade. Thanks to all for the help.

 

Yeah I think the black ones are correct. The normal ones that come on then are like an aqua blue I think.

 

Glad you got it figured out.

If you think these cars are tough to work on then you must have been very lucky in your prior vehicle selections.

IMO these engine compartments are pretty well laid out and in general everything is easily accessible.

 

I agree with that, cobalts are pretty simple to work on

 

I hear ya. I have big mitts. Reaching through wires and around hoses get to be painful sometimes. Especially when trying to do it with minimal disassembly. Im an older guy (40) so I never really got into hot rodding any of the smaller FWD engines. I used to laugh when someone would pull up in a typical riceburner with that that annoying exhaust tone. Ive owned 69 camaros, Montes, Buicks, the kind of cars where you can have a sleepover in the engine bay. Thats not to say I cant fix something if needed, I just dont know the ins and outs of this engine. Who the hell would know you need to force a map sensor to fit. I've always learned if you need to force it something isnt right. (Especially with engines) I know im asking questions that have been answered for 6 years now. Sucks being late to the game. I guess thats why forums were created. For my sake, Im glad this one is still around.

 

Even when looking at the engine bay of a cobalt I say it looks simpler to work on that many other cars, but yeah cars now have almost no room to work on.

 

U need to take out those metal inserts where the screw goes. Then ull have enough play room

 

Thanks, I got it. I cut a slot into it and it fits perfect. I thought about knocking the sleeve out but mine looked off a bit and it didn't look like removing the sleeve would work.

 

It doesn't look like it but it does... Just