Well I was reading through, kdub790's DIY on this and I understood it but not that many people did, so I decided to write my own up using his information but with more pictures of course.....
Picture of the car with the rear o2 sensor problem:
- Dremel with a sanding/grinding bit.
- Socket wrench with a 10mm bit, you might need an extension.
- Adjustable open ended wrench.
- Drill with a 1/2" drill bit, nothing bigger.
- 42002 and 42009 by Motormite, they are spark plug non-foulers (Costed $3.99 a package at my local AutoZone YMMV)
Now you can start
1. I would suggest you raise your car with something other than the scissor jack, although I am cheap and thats what I used. MAKE SURE IN ANY INSTANCE YOU USE JACK STANDS!!!!
2. Once the car is secure, get under your car and locate the AFTER cat, oxygen sensor.
3. Use the 10mm socket and remove the two plastic nuts that hold the black box to the car.
4. Once removed the box should look something like this, clip all of the zip ties so you can unplug the rear o2 sensor and take it off of the car.
5. Now that all the wires are loose it will be MUCH easier to remove the o2 sensor from the downpipe. Get the adjustable open ended wrench and work your magic on removing the o2 sensor. Be careful not to strip the o2 sensor.
6. Once you get the o2 sensor out of the downpipe, unplug it from the black box, and have it handy when you drill part 42002 out.
7. Grab only one of the 42002 pieces, it should be the longer of the two. Take your drill with the 1/2" bit and drill straight through the part. The 1/2" drill bit will not take care of everything but it will noticably make it easier on you. Take the Dremel and make the hole bigger, that you just have drilled. Keep testing the o2 sensor in the piece until it fits nicely. Once you are all done it should look like this:
8. After you get the piece to fit correctly over the o2 sensor, screw it on and make sure it is snug. Then take one of the 42009 pieces and screw it onto the end so it looks like so, make sure the 42009 has a crush washer on it:
9. With that all said and done you can put that back into the hole for the o2 sensor, and tighten everything back up, here is what it looks like when the o2 sensor is back in the hole:
10. When completely tight, you can start reassembling everything back together, and zip tieing the wires how they were. With all that done the finished product should look just like this:
Thanks to kdub790, for the inital write-up, for this non-permanent fix!