Update from Bosch
A Bosch representative actually called me today!! 
Not email, an actual phone call!!.. Kewl..
They recommend using the Universal O2 Sensor #15727 as the exact equivalent 4 wire replacement for our sensor. He also recommended that we wire the Gray signal grounding wire to the same location as the PCM (ECU) grounding location (which is on the rear of our intake mani)..
In our conversation, we discussed options for grounding the 3wire O2 sensor. He said that would be impossible to accomplish once installed because the outside shell is internally insulated and all modification would have NO effect (like the test showed)... And he also said that any modifications to the O2 seal washers above the threads (additional washer, wires inserted, etc) would impact: the depth of the sensor and possibly cause exhaust leaks; NOT recommended..
Only 2 options recommended: Install a 4-wire equivalent (15727) or improving the grounding properties of the header/exhaust system. He said the main reason for the development of the 4-wire O2 was the use of OEM Stainless Steel and other non-conductive components in the exhaust systems by manufacturers.
So everyone, we are definitely on the right track here... I need someone to lookup which cars use the Bosch #15727 O2 sensor. I will grab one at the junkyard tomorrow or Saturday (when Im not drinking and watching March madness!! :rofl
..
Not email, an actual phone call!!.. Kewl..They recommend using the Universal O2 Sensor #15727 as the exact equivalent 4 wire replacement for our sensor. He also recommended that we wire the Gray signal grounding wire to the same location as the PCM (ECU) grounding location (which is on the rear of our intake mani)..
In our conversation, we discussed options for grounding the 3wire O2 sensor. He said that would be impossible to accomplish once installed because the outside shell is internally insulated and all modification would have NO effect (like the test showed)... And he also said that any modifications to the O2 seal washers above the threads (additional washer, wires inserted, etc) would impact: the depth of the sensor and possibly cause exhaust leaks; NOT recommended..
Only 2 options recommended: Install a 4-wire equivalent (15727) or improving the grounding properties of the header/exhaust system. He said the main reason for the development of the 4-wire O2 was the use of OEM Stainless Steel and other non-conductive components in the exhaust systems by manufacturers.
So everyone, we are definitely on the right track here...
I need someone to lookup which cars use the Bosch #15727 O2 sensor. I will grab one at the junkyard tomorrow or Saturday (when Im not drinking and watching March madness!! :rofl..
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Originally Posted by jquesadar 
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