Lambda sensor fiasco

[wizard124]

Well, I couldn't leave well enough alone

The car has been running well. Replacing the O2 sensor was on my to do list to get the engine more dialed in. It has over 57k miles, so by the book, it was pretty close to scheduled replacement anyway. it may be original..

I ended up breaking off the threads inside the manifold I should have quit but i kept spraying PB Blaster and working for more leverage. Then "snap". Tried an easyout but no luck. I ended up pulling the exhaust manifold, breaking some downpipe studs in the process. Interestingly, there is what appeared to be a surface crack and it is more pronounced looking inside the passages.

Good luck is that i have a spare exhaust manifold in my parts bin Its sensor removed easily.....go figure.

Hopefully, it will be driving by tomorrow. My hope is to attend the Italian Show in Alameda this weekend!

Warren

[narfire]

Good luck is that i have a spare exhaust manifold in my parts bin Its sensor removed easily.....go figure.

Atta-boy. Another funny thing, our better half's just don't really understand the value of all those old lumps of metal we keep stashed away for times you have described.
I'm fortunate though I can keep the parts cars at the shop...
Chris

[wizard124]

When my wife ventures too far from the washer and dryer, I simply ask what she is doing in MY garage She really is a great sport, all kidding aside.

I put it back together and she is running well. My butt thinks it has better kick with a working lambda sensor. Pics to follow.

[wizard124]

Broke off the sensor, leaving the seized threads:


The surface crack (bad casting?). Way worse when viewed from the inside. I don't think it leaked.


Welded/repaired heat shield. I took this to a local muffler shop:


I had to make the manifold/exhaust pipe gasket. Sheet from Napa Auto Parts. There was no gasket when I took things apart and Napa didn't have a listing. The goal was to get it running for this weekend so I didn't try to source this gasket elsewhere. I hope it holds up:


Back together and on the road. The heat shield painted with Rustoleum Hi Heat Silver:

[narfire]

The 6 stud pipes and manifold does not use a gasket. Might consider taking it out....metal to metal..

[wizard124]

The 6 stud pipes and manifold does not use a gasket. Might consider taking it out....metal to metal..

Really seems odd to me??
It looked like there was an outline of a gasket there at some point. After my effort, i will leave it in there. If it burns or develops a leak, then ill pull it.

[narfire]

Yea...weird. When I purchase a complete gasket kit for the engine, there is a 4 stud exhaust gasket but not a 6 stud. Every 2L I've pulled apart has never had a gasket at the manifold-down pipe.

[81SPIDERMATT]

SAME HERE ... NO GASKET WHEN I PULLED MINE APART TO FIX EXACT SAME PROBLEM WHEN CHANGING O2 SENSOR

[wizard124]

The 6 stud pipes and manifold does not use a gasket. Might consider taking it out....metal to metal..

Really seems odd to me??
It looked like there was an outline of a gasket there at some point. After my effort, i will leave it in there. If it burns or develops a leak, then ill pull it.

It turns out the gasket didn't last; more like it roasted and disintegrated. It was made of the wrong material.

[81SPIDERMATT]

The 6 stud pipes and manifold does not use a gasket. Might consider taking it out....metal to metal..

Really seems odd to me??
It looked like there was an outline of a gasket there at some point. After my effort, i will leave it in there. If it burns or develops a leak, then ill pull it.

It turns out the gasket didn't last; more like it roasted and disintegrated. It was made of the wrong material.

I thought It was supposed to have a gasket also... I replaced manifold gaskets but one of the old ones was in not bad shape so I cut it up for that location.... so far it is holding just fine with no problems .... I am doing the wait and see... if/when I need to take it apart I will not put it back in