not your typical exhaust questions...
 

Hey folks.

I have a d16y7 which as you know integrates the cat into the exhaust manifold.

After my turbo has been slapped on there I'll be hooking up an aftermarket cat after the downpipe, followed by custom 2.5" piping and out a muffler of course. The reason for an aftermarket cat is, obviously, that the D16Y7 manifold with built in catalyst will be gone.

I have three questions.

1)How do I go about getting my o2 sensor wires extended? (this will be necessary since I'm relocating the cat and the stock wire lengths aren't long enough)

2)If I plug the primary o2 sensor into the turbo manifold and the secondary one after the cat, that should work right? Or should the primary sensor go right before the cat? Does it matter either way?

3)Where's the best place to probe for an EGT gauge?

I'm trying to work out all the odds and ends here since I pretty much have got everything else worked out in my head. Thanks in advance!

Re:not your typical exhaust questions...
 

For the o2 sensors I would mimic whatever the setup is for a normally placed cat. Like the EX? it's cat is under the car, put the o2 sensors in the same place as that car. Also, just extend the wires, but you shielded wire.

as far as the EGT goes, place as close to the exhaust ports as possible. this information is supposed to be combustion temps so the further it is away the less accurate it will be.

Re:not your typical exhaust questions...
 

Well I'm not sure how to extend wires..if I need to get a special wire or just cut the wires and splice them into any wire??? hehe..I'm really clueless about that sort of thing.

I believe on the EX the primary 02 is plgged into the bottom of the header and the seconary right at the exit of the cat.

For the EGT probe, so where the 4 runners merge to one before exiting into the turbo would be good?

Re:not your typical exhaust questions...
 

for o2's use the same wire that is there stock, shielded wire will have the rubber wire sleeve, then like a shiney silver jacet around the wire.

and for the EGT. yes.

Re:not your typical exhaust questions...
 

To do this right, you'll need a few things:

• Soldering iron
• Flux
• Heatshrink
• Wire - same gauge as wire on O2 sensor
• Wire cutting tool of some sort - wire cutters / Knife / etc
• Something that puts out directed heat - Heat gun / Hair Dryer / Exhaust pipe

You can get it all at Radio Shack. I'd cut the existing wire in the middle and strip off about ½" of shielding on it and the new wire you're going to splice in. Now, Cut your heatshrink and put it over one of the wires. Twist the wires together and dip the twisted wires into the flux. Use the Soldering iron to heat up the wires and apply the solder. The Flux should pull the solder into the wires and bond them together very tight. Now fold it over so it's flat against the wire. Slide the Heatshrink over it and heat it up until it's tight. Repeat for all the other wires. This is how I splice wires together and it makes for a good, reliable connection. There are many other ways to go about it, but once you have the few supplies you need, this is the only way to go.

Re:not your typical exhaust questions...
 

wow! Thanks for the solid info there man. I've never heard of flux before - what exactly is it?

I'm guessing heatshrink is just a protective 'sleeve' you run the wires through to protect them from sources of heat?

All I need to do now is find out what kinda wires to get...hopefully my helms manual back home will tell me...

Re:not your typical exhaust questions...
 

I have a ex 2000 with the d16y8 the primary 02 is in the end of the header or exhaust manifold. the second one is in the cat if you want to just worry about the first one they make 02 simulators that mimic a signal to the secondary 02 I have one on mine with a high flow cat it works great. also Landspeed racing makes a high flow cat with a o2 bung in it for like 130 it works great for my friend. the o2 simulator is like 40 so the landspeed is your best choice since I got the Catco high flow cat it was 100 and then the simulator was 40 so there both good choices hoped this helped

Re:not your typical exhaust questions...
 

I've thought about the o2 simulator - doesn't seem like a bad idea but I've heard they crap out a lot of times.

The high flow cat you bought ddidn't come wiht the secondary o2 sensor bung I take it?

I also planned on getting a high flow cat - really any muffler shop can weld a bung on any cat. I guess I'll just do whatever is cheapest. This is HMT after all. 8)

I think magnaflow also sells nice high flow cats with o2 bungs included.