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Thread: How to: Install fat O2 sensor into GTI-R J-pipe

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2010-08-03 03:47:32
How to: Install fat O2 sensor into GTI-R J-pipe
I thought I would write this short how to since I ran into this problem recently. I picked up a GTI-R mani/jpipe, and found out that the fat o2 sensor that I had would not fit in the GTI-R jpipe. Since my current one was perfectly good, I opted to drill and tap the jpipe, instead of getting a new sensor. The size of the drill I used was 41/64th, and the tap was M18x1.5.

Have this problem?

Use the 41/64th bit and drill the hole out.

Use the M18x1.5 tap to thread the hole.

Now clean up the threads, and screw in the fat o2 sensor.

Here are the boxes doe the tools needed.
2010-08-05 17:42:26
Wait I thought the big nut was removable? At least it is on the RR manifolds, the big nut looks the same as the one you have now.
2010-08-05 17:45:16
Pretty sure it is on the non RR ones too. I'm betting it's a bitch to remove though. Also I hope in the above method it sits the sensor properly in the exhaust stream. Because I would hate to get bad readings from a front o2.

edit: wait I had a fat sensor in my gtir jpipe. I don't recall anyone ever having to drill out and tap it? I did not do the install though so I can't say for 100% certainty.
2010-08-05 23:31:21
The nut appears to be removable, if you can get it off. We tried with numerous large tools, and did nothing but beat it up. So if you can get yours out, and swap them, then that is ideal. If you cant, you can use the method above.

I had a fat sensor in my 91, and a skinny sensor in my 93. The fat sensor was too large (pictured). The skinny sensor fit, but hole size for the threads was different. So since my O2 sensor was perfectly good, this made sense.

I measured the sensor between the avenir j-pipe, and the gti-r j-pipe, and they appear to be the same distance in the exhaust stream. They look identical when installed.
2010-08-06 00:24:52
It is def. removable. One hit with the impact, and mine came right off, took 30 sec. to install the larger nut.
2010-08-06 01:01:24
Hit it with the impact. Hit it with a pipe wrench. Hit it with my lightsaber. Didn't come off. I guess the point of the writeup was for those that cant remove it, I thought it was worth posting the method and tools I used to get it to work.
2010-08-06 01:23:36
It is removable, use PB Blaster to cut threw the rust.
2010-08-06 01:45:51
Might as well take down my writeup then...Seriously. I take the time to snap some pictures and do a little writeup for those that potentially run in to this problem. All I get is people saying you can remove it. I guess I am a complete idiot...I guess everything we tried, which included all of the suggestions and then some are moot. Let me get back to my job at Burger King.

Can a mod go ahead and remove this useless writeup. Thanks.
2010-08-06 04:00:23
Don't take it wrong, it's definitely nice to know we have another option. If it's stuck it's stuck, my exhaust bolts where stuck too, I took an angle grinder to it because i got tired of dealing with it.

All write-ups are good, it's just good to tell a novice user that it is removable before they start tapping it.
2010-08-06 12:45:01
Definitely keep the writeup. As these cars get older those nuts will be harder to remove. Someone else is going to have to do the exact same thing your doing.
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