'89 Audi 200TQ Stripped O2 sensor boss

[Mark J. Besso]

Jim,

I had a similar occurrence with my old 4KQ many years ago.  Brett's 
suggestion of finding a local exhaust specialty shop was the route I took 
and it worked fine for many years after that.  They welded the original O2 
port closed and installed a new one right next to it.  If you choose this 
route be SURE to warn the exhaust shop of the size of the O2 sensor. 
They'll need to plan accordingly.  You'll also want easy access to it for 
future replacement of the sensor.

~Mark


----- Original Message ----- 
From: "Brett Dikeman"
Subject: Re: '89 Audi 200TQ Stripped O2 sensor boss


>
> On Jun 30, 2005, at 11:05 AM, wrote:
>
>> well the O2 sensor came out along with the threads in the exhaust
>> manifold.  What can be done in this case, do I need a new exhaust 
>> manifold?  can
>> it be retapped?
>
> Can't retap what isn't there, though I suppose you might be able to 
> helicoil it (no idea if expansion+contraction from the significant  heat 
> cycles would affect it).  Finding an exhaust shop and having  them weld up 
> a new bung would probably be cheaper, easier, and more  reliable in the 
> long run.
>
> Check the Bentley for recommendations on preparations for welding- I 
> believe they recommend both the ABS and airbag unit be disconnected,  but 
> I'm not positive.  If you don't have a Bentley, I can check mine  later.
>
> Brett
> -- 
> "They that give up essential liberty to obtain temporary
> safety deserve neither liberty nor safety." - Ben Franklin
> http://www.users.cloud9.net/~brett/