Installed Hotshot Header: Can't install new O2 Sensor

[g35pm]

Just installed a Hotshot Header on my 1990 240sx KA24E. Dumb O2 sensor wire broke off cause it was rubbing on the firewall. Picked up a new Bosch OEM replacement O2 Sensor and I can't get it on the bung! There's not enough clearance between the header and the firewall.

Any ideas on how to get the O2 sensor on? I'm trying to avoid taking the header off, putting the new O2 on, then reinstalling the header. Getting the EGR and AIV to thread is a PITA. I searched. Any thoughts are appreciated.

Why do they put the damn O2 sensor bung so close to the firewall?

[brokeAs240sx]

You have 3 immediate options:

1) remove header, add o2, reinstall - this still may not clear the firewall :( - some hammering may be involved.

2) clip off a piece of the bosch o2 sensor (this is what I had to do when I installed mine). The very top of the sensor, there is a metal heatshield, you can actually pull/uncrimp that off, then heatwrap or whatnot the sensor. Of course, I am not liable for any problems this may cause ;)

3) There is a shorty version of the o2 sensor from ngk; however I don't know the part #, but it exists (remember it from a few posts years ago when ppl first encountered this problem).

Good luck!

[NemeGuero]

Or you can have the bung welded shut and put a new one somewhere else on the header...

I'd probably do that. Won't be too bad.

[g35pm]

Appreciate the ideas. I might look around for the NGK O2 or trim the Bosch. I considered welding but I can't weld. Would need to bribe a friend for that.

Do you guys get any rattles with this header? I occasionally get some. I'm thinking it's the header hitting the front of the tranny. The proximity of the header to the tranny is really close, maybe 1/2". It clears everything else pretty well.

[40daws]

Buy a universal O2 sensor for a Buick Grand National 3.8 liter. Fits in without banging back the firewall and without modifying the o2 sensor itself.

[NemeGuero]

^ then you have to wire up the sensor to match.

Some prefer wiring.. some prefer banging.

[EchoOfSilence]

I'll ALWAYS prefer banging ;)

[Neejay]

I'll ALWAYS prefer banging ;)
^post-whore, but LOL. :)

You could take it off, and take it to a muffler/welding shop and have them weld the oem spot shut and re-weld a bung somewhere else. (assuming you have another means of transportation/someone can take you)

[S14DB]

New engine and Tranny mounts.

[grudge]

Or you can have the bung welded shut and put a new one somewhere else on the header...

I'd probably do that. Won't be too bad.

this is exactly what was done to mine. but on an S&S header.

oh btw, it's for sale if anyone's interested. just pm me for pics.

[g35pm]

New engine and Tranny mounts.

For what? I actually have new Nismo engine and tranny mounts.

[brokeAs240sx]

For what? I actually have new Nismo engine and tranny mounts.

I think he's talking about the rattling you are experiencing. older engine/tranny mounts could have moved too much & caused the header to hit stuff. Of course, now you noted that you have the nismo stuff -> that actually makes the o2 sensor location a lil worse since it pushes it up even more on the firewall, hahaha - same thing happened to me, but I digress.

Did you connect the connector from header->tranny? Sometimes those get loosey goosey too, and start banging under the car.

Other than that, the only thing you can try to figure out exactly where the header is hitting the firewall/frame/chassis, and "persuade" that section of chassis in a little bit w/ a hammer.

[g35pm]

I think he's talking about the rattling you are experiencing. older engine/tranny mounts could have moved too much & caused the header to hit stuff. Of course, now you noted that you have the nismo stuff -> that actually makes the o2 sensor location a lil worse since it pushes it up even more on the firewall, hahaha - same thing happened to me, but I digress.

Did you connect the connector from header->tranny? Sometimes those get loosey goosey too, and start banging under the car.

Other than that, the only thing you can try to figure out exactly where the header is hitting the firewall/frame/chassis, and "persuade" that section of chassis in a little bit w/ a hammer.

Connector from header -> tranny? Is there a brace or something attached to the tranny that holds the header in place? The instuctions don't mention this. Maybe it was on the OEM Header? I actually replaced a POS Pacesetter header and didn't notice a connector.

[brokeAs240sx]

Connector from header -> tranny? Is there a brace or something attached to the tranny that holds the header in place? The instuctions don't mention this. Maybe it was on the OEM Header? I actually replaced a POS Pacesetter header and didn't notice a connector.

Think we found your rattling problem :). Yea, there's suppose to be a brace there.

20621, 20651, 20652 in the image below (and friends). To get the part #'s, follow the carfiche link.

http://carfiche.com/fiche009/s13/?2:a:9

http://carfiche.com/fiche009/s13/2/b09.gif

[g35pm]

Thanks BrokeAs240sx. Appreciate it.