> RE:  3. O2 sensor thread problems
>
> I went to Auto Zone today to buy an O2 sensor for my 91 XE and when i got
> home, the thread pattern was larger on the OE one, so the new one wouldn't
> fit.   Anyone ever had this problem?

I replaced my  my sensor last summer, I bought it at autozone too. It was
a Bosch sensor and was identical to the oem one. I noticed that there is a
coupler in the exhaust manifold that acts like a reducer, perhaps your new
O2 sensor will fit if you remove the reducer? Sometimes the reducer comes
off with the O2 sensor (mine did). When I unscrewed the old sensor the
coupler was  fused to it and both pieces unscrewed from the cast iron
exhaust manifold. It too some effort to separate the threaded coupling
from the old sensor, I had to destroy the old sensor in the process.
I don't know the sizes off hand, but maybe you could try threading it
in without he coupler removed.
p.s.  use anti seize when re-installing the O2 sensor (if it didn't come
with anti seize on the threads from the factory)
-dave



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