Shorter O2 Sensor? (Miata content)

A while back I put an aftermarket exhaust on my NB. The downstream O2 sensor was really close to the bottom of the car and required the wires to be sharply bent to clear. A couple days ago the check engine light came on, and the code was a non-responsive O2 sensor. I haven't dug into this yet, but since the sensor was new when I did the exhaust, I have a hunch the problem is a break in a wire. SO! Does anyone make a shorter O2 sensor, or do any of you have another solution for this problem? Thanks guys.

Antifoul with a 90 degree angle

Here's one: http://boost-controller.com/index.php?main_page=product_info&cPath=11&products_id=53&gclid=CLGZr-rpmtICFVM8gQodpYEHkQ

Weld a bung into a proper location. That's the right way to fix it.

Welcome back, I was getting worried about you!

Keith Tanner wrote: Weld a bung into a proper location. That's the right way to fix it.

What's the proper location? As far as I know, this is where it has always been.

In reply to NordicSaab:

Link doesn't work.

bravenrace wrote:

Keith Tanner wrote: Weld a bung into a proper location. That's the right way to fix it.

What's the proper location? As far as I know, this is where it has always been.

The proper location is one where the sensor doesn't hit anything, for one! It sure didn't come that way from the factory. It'll take less time to figure out once you get under the car than it will to talk about it on a forum. Mark a location that won't interfere with anything using a sharpie, pull the exhaust and take it to a local exhaust shop. They'll put a bung in it for you. They should also have a bolt to plug the other one.

In reply to Keith Tanner:

I have a bad O2 sensor. Getting a shorter one, if available, is a much more appealing fix than what you are suggesting. That's why I asked the question. I have looked under the car and didn't find the answer to that question there.

It has to be possible.

Mind sharing what kind of exhaust? I know some of the super-cheap crap (hello, OBX) is fairly random in the O2 sensor bung placement.

Sound like a problem that can probably be solved with a ball peen hammer.

In reply to Keith Tanner:

It's not part of the aftermarket exhaust, it's on the pipe coming off the converter. And because you mentioned it, the sensor doesn't hit anything. It's the stupid way they route the wire problem. A shorter sensor will allow a more graceful bend that won't end up fatiguing the wire. I really don't want to discuss this aspect with you, as I thought of relocating the sensor before I posted this. I just don't want to go thru all of that if a shorter sensor is available. So if you know of one, please post it here.

I don't know of a shorter sensor. I've never gone looking, because I've never needed one. There doesn't appear to be a fundamental design problem with the factory location or wire routing.

in the event that you can't find a shorter sensor, could you replace the bad one with the same part and then splice in a section of the original wire to make for a more graceful bend?

In reply to Woody:

Possibly. Its hard to explain, but it has to make a sharp bend off the sensor to route to the hole in the floor where the wires pass through. I also have to miss the drive shaft and the shifter. Looking at diagrams, it looks like its in the factory location, and the cat looks to be factory as well, but it would only need to be slightly off to cause this problem.

Without knowing what the failure is exactly it is tough to know what needs to be done. You could re-rout the wires through a new hole in the floor. You could also put some additional protection over the wires coming off the sensor if they are rubbing on something and that is causing the problem.

I think a photo would answer a lot of questions. As for a shorter O2 I found these but I have no clue if they would work.

Delphi Mini Switching O2 sensors

I thought I covered the failure, it was in a wire coming off the O2 sensor because it needed to be bent so sharply to clear the floor of the car. I have two options for correcting this. One is a shorter O2 sensor. The other is take the exhaust off the car, plug the O2 Bung, weld another O2 bung in a different place. I don't want to do the second option, so I'm asking about the availability of the first.

bravenrace wrote: I thought I covered the failure, it was in a wire coming off the O2 sensor because it needed to be bent so sharply to clear the floor of the car. I have two options for correcting this. One is a shorter O2 sensor. The other is take the exhaust off the car, plug the O2 Bung, weld another O2 bung in a different place. I don't want to do the second option, so I'm asking about the availability of the first.

You say it's a factory cat -- is it a factory header? Which aftermarket exhaust?

This is not a common problem with Miatas, which suggests to me that there's something else going on here. Is something bent? Are all the exhaust hangers present and in good condition? Is the brace that holds the exhaust to the transmission present?

FWIW, if you want to extend Miata O2 sensor wiring, the easy way is the extension harness that Racing Beat sells. It's $43 and comes with factory connectors on both ends, so you just plug it in, easy peasy.

Why can't somebody just answer the question I asked. That's ALL I need. :)

bravenrace wrote: Why can't somebody just answer the question I asked. That's ALL I need. :)

Which one? You asked TWO!

The people who are MORE knowledgeable about the car in question are asking why because it isn't right to have the problem you're describing, indicating an issue with YOUR car that is unique and therefore not normal and ideally it should be repaired properly.

If the Oxygen sensor or any of the other parts aren't OE, then it could explain some of the issues, and since you're assuming the parts on your car are OE, how could one find a solution?

In reply to Stefan:

What you fail to recognize, and should by now if you've read the thread is that I already know all of this. I have determined that the best fix would be a shorter o2 sensor, if one is available. But you are correct, I did ask two questions and forgot that along the way. My apologies to all.
You may also be correct about something not being OEM. Thing is, I don't care if they are or not, because I'm only willing to go so far with this. This car has been nothing but trouble for me, and will be sold as soon as I can get rid of the check engine lights. The easiest way by far to do that is with a shorter o2 sensor. I could just put another one on like it has and it would last long enough to sell it, but I won't do that. If that option doesn't work out, then I'll go to another option, but not until I determine if a shorter o2 sensor is available or not. I own and maintain 10 vehicles. I don't have time to do more work than is necessary, so I'm trying the easiest correct fix first.

You saw dean1484's post yesterday, right?

@ Keith

Quoting my self because I can.

dean1484 wrote: As for a shorter O2 I found these but I have no clue if they would work. Delphi Mini Switching O2 sensors

bravenrace wrote: Why can't somebody just answer the question I asked. That's ALL I need. :)

I did but YOU need to do some homework. :)

Nine posts and 26 hours ago. LOL. .. . ok I will stop now.