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Old Oxygen Sensor Won't Come Out... Now What?


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#1 AM-DB5

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Posted 08 September 2008 - 08:52 PM

I have a '93 SPi with 57K km and it DEFINITELY has a bad oxygen sensor, (runs the same with or without it after all
vac leaks, temp sensor, stepper motor, TPS have been checked), so it's time to change it.

Just to qualify the statements below... in a former life I was a Serviceability Engineer... It was my responsibility to make sure a product design was readily serviceable AFTER it had been assembled.

Problem 1: Oxygen Sensor location is the product of demented Engineers who have never maintained a car in their lives.
So is the Coolant Temperature Sensor. Post '96 models were different... no wonder... the warranty costs must have been
totally over the moon!
Problem 2: A normal Oxygen sensor removal socket can't be used as the location is too tight for it.
Had to use a clever tool known as an Oxygen sensor offset socket that WILL fit down over the Oxygen sensor in its
reduculous location.
Problem 3: Rust-busting chemicals, lots of heat from a propane torch, shocking the sensor with a 3lb hammer and a drift, using a
massively torquey air impact wrench, and a 4ft long levering pipe WON'T BUDGE it.
Problem 4: The marvelous offset socket is so rugged it has now skipped off the peaks of the "nut bosses" on the Oxygen sensor
and thus, I can now NEVER produce enough tourque to remove it without use of a gigantic pipe wrench... although it's
doubtful there's enough torque on EARTH to do so.

An observation: American cars NEVER have oxygen sensors located in cast exhaust manifolds... they are ALWAYS located
downstream in the post-manifold, pre-catylizer plumbing. So why the F*&% did Rover engineers place it where it IS?

Q: If I don't care to remove the intake and exhaust manifolds just to work up a hernia trying to wrench off the old POS
(last word being *******) sensor with a massive pipe wrench, Why can't I draw the line right where it is and simply drill a hole
in the post-engine, pre-catylizer downstream "plumbing" and mig on a threded sensor mounting boss?

Edited by AM-DB5, 08 September 2008 - 09:15 PM.


#2 WiredbyWilson

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Posted 08 September 2008 - 09:00 PM

as long as the sensor is mouted pre-cat i cannot see it being a massive problem, you would also need to lengthen the wires accordingly (obvious).

i tend to find if they are that tight, that when you do getthem out they strip all the threads too which means fitting the new one is a total nightmare.

#3 Sprocket

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Posted 08 September 2008 - 09:06 PM

:D

Best topic yet :(, Love it!

Yes you can re locate it, but you obviously relise you have to extend the wiring :errr: Make sure the new Oxygen sensor is a genuine bosch item for Rovers. For what ever reason, the universal and Non Rover sensors dont work, I have tried several times and the result was the same every time. :P

#4 minicooper1.3i

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Posted 09 September 2008 - 02:41 PM

Sounds to me like it would be a lot less hassle to just fit a new LCB manifold with the sensor point in the Y piece at the bottom. My one is stainless and only cost about £80 :proud:

#5 AM-DB5

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Posted 13 September 2008 - 12:55 AM

Sounds to me like it would be a lot less hassle to just fit a new LCB manifold with the sensor point in the Y piece at the bottom. My one is stainless and only cost about £80 :o


Hi, thanks.

I pulled the old downtubes and welded in an Ox sensor bung at the "y" total cost about 5Quid.

Engine is STILL "hunting" but DOES attempt to idle down which it WOULDN'T do before. Smells lean.

I also had a friend tell me a catylizer bypass tube was 50quid... I MADE one for about 8.

I rekon there's something else like a coolant sensor or MAP plumbing that's keeping it "hunting". It IS less
frantic tho.

#6 AM-DB5

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Posted 13 September 2008 - 01:02 AM

:o

Best topic yet :dontgetit:, Love it!

Yes you can re locate it, but you obviously relise you have to extend the wiring ^_^ Make sure the new Oxygen sensor is a genuine bosch item for Rovers. For what ever reason, the universal and Non Rover sensors dont work, I have tried several times and the result was the same every time. <_<


Oh DRAT! Freaking Rover !!! Wiring is no problem when one combines old and new pigtails.
I completed relocation by welding on my own Ox sensor bung at the "y". Total cost about 5 quid.

I used a universal sensor and it does try to idle down better but still obviously hunting with occasional
"lapses" to low rpms and the stepper "gooses" it a bit. I'm sure it'll still stall when driving.

This is going to be a stupidly long problem to solve and it's some WANKIKNG Rover engineer's fault.




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