O2 Sensor Thread Repair For Exhaust Tube, Exhaust Manifold And Catalytic Converter (ITB98-048)

Publication date: 1998-11-15
Reference number: ITB98-048

O2 SENSOR THREAD REPAIR FOR EXHAUST TUBE, EXHAUST MANIFOLD AND CATALYTIC CONVERTER

TECHNICAL SERVICE BULLETIN

Reference Number(s): ITB98-048, Date of Issue: November 15, 1998

INFINITI:	All models with O2 sensors
CLASSIFICATION:	TE98-006
SECTION:	Tool and Equipment
APPLIED VEHICLE(S):	All models with O2 sensors

SERVICE INFORMATION

When removing a front or rear O2 sensor, material may remain on the internal threads of the exhaust tube, catalytic converter, or exhaust manifold. Special service tools (see Fig 1 ) are available to clean the internal threads in such cases. This will minimize the need to replace these components. These required special tools will be mailed separately.

Use this bulletin when replacing O2 sensors as part of the 1996 I30 OBDII Campaign ITB98-036 or whenever there is a need to clean O2 sensor threads.

NOTE: This tool is not to be used for tapping threads.

Fig 1: Thread Repair Tool

SERVICE PROCEDURE

CAUTION: Always follow these general guidelines when servicing O2 sensors.

Do not apply severe shock to the sensor when installing it. Do not use an impact wrench for installing it.
Discard any sensor that has been dropped.
Never attempt to clean an O2 sensor by applying solvent to it.
Anti-seize must only be applied to the threads, not the sensing element.

Remove the O2 sensor from the exhaust tube, exhaust manifold, or catalytic converter.
Select the correct thread repair tool based on the thread diameter of the removed O2 sensor (see Fig 1 ).
- Zirconia O2 sensors use the 18 mm diameter tool: J-43897-18.
- Titania O2 sensors use the smaller 12 mm diameter tool: J-43897-12.
Make sure that the tool is clean of all debris from prior usage.
Liberally apply the anti-seize compound, specified in the Parts Information section of this bulletin, into the flutes (see Fig 1 ) of the thread repair tool.
CAUTION: Only use the anti-seize material specified. Other materials may chemically damage the O2 sensor.
Carefully screw the thread repair tool into the exhaust tube, exhaust manifold, or catalytic converter by hand. It needs to be installed until the tool's taper is fully inserted within the internal thread of the exhaust tube, exhaust manifold, or catalytic converter.
CAUTION: Ensure the tool goes in straight.
After the thread has been adequately started by hand, a tool such as a socket or wrench can be used to continue the removal of the material.
- When only light removal of material is needed, screw the thread repair tool in until the cutting surface of the mating surface shave cylinder touches the sealing surface for the O2 sensor. Then turn it one full turn further.
- When there is a lot of material to be removed, occasionally back off the tool to remove accumulated material from around the tool before continuing.
CAUTION: Do not expect the tool to screw in to an absolute stop. The tool's spring and mating surface shave cylinder will rotate until the spring is completely compressed.
Wipe the threads of the exhaust tube, exhaust manifold, or catalytic converter to remove any debris or anti-seize before replacing the O2 sensor.
NOTE: If the O2 sensor could not be removed or there is permanent damage to the internal threads, it will be necessary to replace the exhaust tube, exhaust manifold, or catalytic converter.
Install the O2 sensor and confirm that there is no exhaust leak from the mating surface of the O2 sensor to the exhaust tube, exhaust manifold, or catalytic converter. If there is leakage, then there may have been permanent damage to internal threads. This would require replacement of the exhaust tube, exhaust manifold, or catalytic converter.
Completely clean the anti-seize compound and metal debris from the tool to ready it for its next use.

PARTS INFORMATION

Description	P/N	Source	Qty
Anti-seize lubricant	Permatex. 133AR or similar meeting MIL specification MIL-A-907	Local	As required