Help with header install - I'm stuck - Toyota Yaris Forums

fmicle · 09-19-2009, 10:02 PM

Everything was going great, I got the stock header out, had disconnected the O2 sensor, moved the donut from the stock header to the new one and started to remove the O2 sensor from the old header. It was very difficult, so I went and bought a longer wrench, so I can apply more force. After a few revolutions, just enough to see the washers inbetween moving, it got stuck. I've been trying really hard to get it moving again, but no luck. I sprayed a little W40 at the base of the bolt, but so far it hasn't helped...

Any advice? Should I try a bigger wrench? I'm slowly starting to ruin the nut with all the force. What should I do?

YarisSedan · 09-19-2009, 10:10 PM

tighten it
then loosen it
tighten it again
then loosen again

its a trick ive used with boogered hard to come out spark plugs it may work with o2 sensor

Brian · 09-19-2009, 10:39 PM

It also helps to use an O2 sensor socket

fmicle · 09-19-2009, 10:40 PM

Yeah, I was wondering if I can get the O2 sensor from a Toyota dealer if I ruin it. Does anyone have an idea how much the part costs?

And also, can I drive the car without the O2 sensor in place? Until I get a replacement?

Brian · 09-19-2009, 10:46 PM

You can order a new one but they're over $100 I think. I wouldn't recommend drivng without one.

supmet · 09-20-2009, 12:32 AM

Quote:

Originally Posted by fmicle

Yeah, I was wondering if I can get the O2 sensor from a Toyota dealer if I ruin it. Does anyone have an idea how much the part costs?

Quote:

Originally Posted by hatchbackkid82

Just bought a brand new primary O2 sensor that cost me $171

, the original one broke when I was installing my header.

http://www.yarisworld.com/forums/sho...d.php?p=388327

i lol'd

fmicle · 09-20-2009, 01:47 AM

Alright, I'm done, it was a bitch, to say the least

I took my bike rack apart so I could use the main bar/pipe as an extension to my wrench. Then I slowly loosened the O2 sensor until it came off. I noticed that the thread on the bolt is 75% ruined, but I was able to mount it on the new header just fine.

Another disappointment came when I realized I wasn't going to be able to attach the header to the engine bracket. No matter what I tried, the holes just wouldn't align. So I used a smaller diameter bolt and nut to fasten it, instead of the original thicker bolt that threads into the header collar. I hope it's strong enough.

Then I took it for a ride and everything feels alright

Did anyone experience similar issues with the fitment?

Brian · 09-20-2009, 02:09 AM

Mine fit perfectly.

YotaYaris · 09-24-2009, 01:56 AM

What header did you buy? Was it a DC Sports?

Tamago · 09-24-2009, 02:05 AM

why not a box end wrench? you're taking the manifold out of the car anyway, just unclip it from the harness and do this on the ground?

bronsin · 09-24-2009, 08:53 PM

Next time heat the header with a torch near the sensor...

hatchbackkid82 · 09-29-2009, 02:46 PM

mine broke too i had to pay 180 for a new one, my header lined up perfectly, car feels great now

09-19-2009, 10:02 PM	#1
fmicle Drives: 2007 Yaris LB Join Date: Mar 2007 Location: San Jose, CA, USA Posts: 685	Help with header install - I'm stuck Everything was going great, I got the stock header out, had disconnected the O2 sensor, moved the donut from the stock header to the new one and started to remove the O2 sensor from the old header. It was very difficult, so I went and bought a longer wrench, so I can apply more force. After a few revolutions, just enough to see the washers inbetween moving, it got stuck. I've been trying really hard to get it moving again, but no luck. I sprayed a little W40 at the base of the bolt, but so far it hasn't helped... Any advice? Should I try a bigger wrench? I'm slowly starting to ruin the nut with all the force. What should I do?

09-19-2009, 10:10 PM	#2
YarisSedan Drives: 08 Yaris Sedan Join Date: Oct 2008 Location: California - Bay Area Posts: 2,773	tighten it then loosen it tighten it again then loosen again its a trick ive used with boogered hard to come out spark plugs it may work with o2 sensor __________________ http://www.cardomain.com/ride/3210549

09-19-2009, 10:39 PM	#3
Brian Drives: '07 Yaris turbo, '11 Juke Join Date: Mar 2007 Location: Riverside, CA Posts: 849	It also helps to use an O2 sensor socket __________________ http://www.cardomain.com/ride/3875996

09-19-2009, 10:46 PM	#5
Brian Drives: '07 Yaris turbo, '11 Juke Join Date: Mar 2007 Location: Riverside, CA Posts: 849	You can order a new one but they're over $100 I think. I wouldn't recommend drivng without one. __________________ http://www.cardomain.com/ride/3875996

09-20-2009, 02:09 AM	#8
Brian Drives: '07 Yaris turbo, '11 Juke Join Date: Mar 2007 Location: Riverside, CA Posts: 849	Mine fit perfectly. __________________ http://www.cardomain.com/ride/3875996

09-19-2009, 10:40 PM	#4
fmicle Drives: 2007 Yaris LB Join Date: Mar 2007 Location: San Jose, CA, USA Posts: 685	Yeah, I was wondering if I can get the O2 sensor from a Toyota dealer if I ruin it. Does anyone have an idea how much the part costs? And also, can I drive the car without the O2 sensor in place? Until I get a replacement?

09-20-2009, 01:47 AM	#7
fmicle Drives: 2007 Yaris LB Join Date: Mar 2007 Location: San Jose, CA, USA Posts: 685	Alright, I'm done, it was a bitch, to say the least I took my bike rack apart so I could use the main bar/pipe as an extension to my wrench. Then I slowly loosened the O2 sensor until it came off. I noticed that the thread on the bolt is 75% ruined, but I was able to mount it on the new header just fine. Another disappointment came when I realized I wasn't going to be able to attach the header to the engine bracket. No matter what I tried, the holes just wouldn't align. So I used a smaller diameter bolt and nut to fasten it, instead of the original thicker bolt that threads into the header collar. I hope it's strong enough. Then I took it for a ride and everything feels alright Did anyone experience similar issues with the fitment?

09-24-2009, 01:56 AM	#9
YotaYaris Drives: 09 3dr (sold), 12 SE 5spd : ) Join Date: May 2009 Location: SA TX Posts: 140	What header did you buy? Was it a DC Sports? __________________ Its all about the MPG's !!

09-24-2009, 08:53 PM	#11
bronsin Drives: 2009 Base Hatch 2 Dr Auto Join Date: Dec 2008 Location: nj Posts: 4,790	Next time heat the header with a torch near the sensor...

09-29-2009, 02:46 PM	#12
hatchbackkid82 Drives: . Join Date: Apr 2007 Location: . Posts: 1,828	mine broke too i had to pay 180 for a new one, my header lined up perfectly, car feels great now

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