Bsmntcuts

I just installed the alphawerks header and ran into a problem which wasnt really a suprise but it sure was un-necessary and expensive. I just want to give everyone a heads up if they plan on installing a header. The O2 sensor (Air/Fuel Sensor) that is in the stock exhaust manifold was cross threaded when it was installed by the factory. I took all the proper precautions trying to get it out and was working in an auto shop with the proper tools and we spent a good hour trying to get it out without damaging it. Well we finally get it out and there are no more threads on the sensor but the threads still existed on the stock manifold therefore we came to the conclusion that it was cross threaded by the factory. Also the way it was coming out made it obvious. Now i have a car with no 02 sensor in the header and a hell of an exhaust leak. So the next step? Had to Buy a new one. A trip to the local toyota dealership and $230.00 later I had my car up and running. Be careful!! Heres some pics:

Air/Fuel Sensor after removal:


Stock Manifold after removal:


$230 Part from toyota:


Just an extra pic for all of those who havent seen one. ZPI Racing O2 Simulator. I havent installed it yet. I was waiting for my CEL to pop first. After about 20 miles it finally did so this install will be next... Hopefully it works


Otherwise the header is nice and i would recommend.

The_Instigator

Mine came out just fine. I put a lot of penetrating lube on the threads the night before and multiple times before starting and during the install the next day. I also didnt let the car get warm at all before I started the install. I also waited to take the O2 out of the exhaust manifold until the header install was almost completely finished to make sure the factory manifold was a cold as possible before I removed it. Of all the header worries, damaging the O2 sensor was #1 on the list and I feel that with enough precautions the situation can be avoided.

Then agian if it was truly cross-threaded form the factory you really are screwed...no pun intended

Bsmntcuts

I definatley used plenty of WD-40... A must.

TruTriNiPlaYa

i had the sameeeee exact problem.......$200 mistake...i just hand tightened the new one in now

WeDriveScions

Ouch.... wonder if taking to the dealer if it's tough to remove it a better option, but I bet they'd say you made the mistake somewhere.... sorry to hear about this happening...

JpJohn14

is it possible to install the dc race headers and not get a CEL...will it last?

tcholic

damn that sucks....damn o2 sensors are sooo freakin expensive

Bsmntcuts

Just wanted to update this thing real quick. The ZPI O2 Sim never worked. $100 down the drain. GARBAGE. Why do you think they discontinued it? They ripped so many people off with that damn thing. I payed $100 for a blinking red LED. Piece of ShXT. Never again.

Bsmntcuts

I have non-foulers on there now and i should have done that from the beginning. I tried e-mailing ZPI a while back to make a return and no response. I dont even want to bother with those people. Scam.

mksm2000

same here :D they rip us off man..........they reali did......

Sam_J84

ouch! that sucks. same thing happened to a friend of mine when he got his o2 sensor from his factory s-pipe removed to install the ZPI s-pipe.