Plug anti-fouler O2 sensor mod seems to be working so far.
01-24-2006, 07:11 AM
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Plug anti-fouler O2 sensor mod seems to be working so far.
Last friday my bank 2 ignition amp decided to turn off for a bit, while under full boost in 6th.
The excess fuel from non firing cylinders 4,5,6 melted my bank 2 cat, and blew quite a bit of it out the back. Caused quite the spray of orange chunks in the rearview, and a flashing CE light. I immediately thought I had blown my engine with the power loss and orange spray out the back..
Soo, after "fixing" the amp by cleaning the contacts, car ran fine, but I had a DTC for bank 2 warmup cat efficiency. Since the exhaust didn't smell, I figured some of the cat must be left..
I pulled the cat for inspection, and found this:
Frothy!
<img src="http://tychl.txf.com/catmelt/melt1.jpg">
<img src="http://tychl.txf.com/catmelt/melt2.jpg">
I knocked off most of the chunks, and opened the channels as best I could. I did a little more work after these pics. Looks good when held up to a light.
<img src="http://tychl.txf.com/catmelt/littlebetter1.jpg">
<img src="http://tychl.txf.com/catmelt/littlebetter2.jpg">
I'll deal with the cat in the spring.
For the "mod", I used the 42009 non fouler, and drilled it out using a lathe and a 19/32" drill. I tried a 5/8" as the archives said, and it was too big, fouler threads broke off.
Came out to this size:
<img src="http://tychl.txf.com/o2mod/drilled-out-diameter.jpg">
Diameter of sensor:
<img src="http://tychl.txf.com/o2mod/sensor-diameter.jpg">
Sensor in non fouler:
<img src="http://tychl.txf.com/o2mod/tight-fit.jpg">
Since the walls of the non fouler are so thin after drilling, I brazed the non-foulers together, figured it might help keep it from cracking off.
<img src="http://tychl.txf.com/o2mod/brazed.jpg">
This morning I went through the DB047 cat check that was failing after the "incident" and setting the B2 cat efficiency DTC.
Passed!:
<img src="http://tychl.txf.com/o2mod/catok.gif">
It even passes faster than my "good" cat on B1.
We shall see how this works out long term, so far so good.
The excess fuel from non firing cylinders 4,5,6 melted my bank 2 cat, and blew quite a bit of it out the back. Caused quite the spray of orange chunks in the rearview, and a flashing CE light. I immediately thought I had blown my engine with the power loss and orange spray out the back..
Soo, after "fixing" the amp by cleaning the contacts, car ran fine, but I had a DTC for bank 2 warmup cat efficiency. Since the exhaust didn't smell, I figured some of the cat must be left..
I pulled the cat for inspection, and found this:
Frothy!
<img src="http://tychl.txf.com/catmelt/melt1.jpg">
<img src="http://tychl.txf.com/catmelt/melt2.jpg">
I knocked off most of the chunks, and opened the channels as best I could. I did a little more work after these pics. Looks good when held up to a light.
<img src="http://tychl.txf.com/catmelt/littlebetter1.jpg">
<img src="http://tychl.txf.com/catmelt/littlebetter2.jpg">
I'll deal with the cat in the spring.
For the "mod", I used the 42009 non fouler, and drilled it out using a lathe and a 19/32" drill. I tried a 5/8" as the archives said, and it was too big, fouler threads broke off.
Came out to this size:
<img src="http://tychl.txf.com/o2mod/drilled-out-diameter.jpg">
Diameter of sensor:
<img src="http://tychl.txf.com/o2mod/sensor-diameter.jpg">
Sensor in non fouler:
<img src="http://tychl.txf.com/o2mod/tight-fit.jpg">
Since the walls of the non fouler are so thin after drilling, I brazed the non-foulers together, figured it might help keep it from cracking off.
<img src="http://tychl.txf.com/o2mod/brazed.jpg">
This morning I went through the DB047 cat check that was failing after the "incident" and setting the B2 cat efficiency DTC.
Passed!:
<img src="http://tychl.txf.com/o2mod/catok.gif">
It even passes faster than my "good" cat on B1.
We shall see how this works out long term, so far so good.
01-24-2006, 07:24 AM
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Yep, drill one out, leave the other alone, stack them, sensor goes in drilled one, non drilled in.
exhaust.
I was going to gut it, but it cleaned up so easily and seemed to be working at least a little, I figured I'd give it another chance
I was going to gut it, but it cleaned up so easily and seemed to be working at least a little, I figured I'd give it another chance
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01-24-2006, 07:38 AM
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Me either! I think metal matrix cats might do a better job of spreading localized heat.
Though the ceramic makes it really easy to scrape off melted parts. Still surprising to see ceramic melt like that.