The threads on my O2 sensor were total seized up, and therefore I ended up breaking the sensor trying to get it out. It never did budge until the nut porition broke -- leaving the threads in the hole. I guess I am spending tonight taking the upper portition of the exhaust manifold off and trying to drill out what is left of the the O2 sensor. Anyone have any suggestions and/or pointers?

 

Aw crap! Sorry to hear that, man. Maybe try ebay for a cheap header, or ask around for a stock manifold. I'm sure one of the turbo guys on this board would let their old one go for cheap or free. I have a CX manifold that you can have, but I'm sure you don't want it. It's tiny. If I could afford a header right now, I'd give you mine.

It might be a lot less difficult to replace it than to drill and tap it. Helicoils like to melt on o2 sensor applications if you can even find one that big. I've snapped off tons of bolts, and I know easy-outs won't help you with a siezed o2 sensor. Take your time, and don't damage those threads.

Put it in a vise, drill a medium-small hole through the sensor a mm or so away from the threads, and work that sucker over with a BFH, punch, and lots of penetrating oil.

 

Dude, it keeps getting worse!! I was looking the exhaust manifold over tonight and I see a crack in it! It wasn't near the O2 sensor that's why I didn't notice it yesterday. So now I for sure need a new upper manifold. I guess I will post here to see if anyone has one for sale cheap. If not, I might consider getting headers -- but I don't want to spend a lot and I don't want the headers to rob any low end power (cause we all know this 1.6L is weak enough down low). I also don't want anything loud. Boy do I sound picky! If anyone has any suggestions please let me know. I see a lot of cheap headers on eBay -- wonder if any are decent?

Thanks for chatting with me about this Jafro. It's nice to have someone to talk to because my wife sure doesn't understand me!