Hi Everyone,
Well, I finally managed to purchase my first Porsche - a 2004 Turbo Cayenne with 86k miles and most of the normal out of warranty work already done (coolant tubes, cardan shaft, etc) and am thrilled to be a member of the Porsche community! Prior to purchasing it, I read through many articles on Porsche ownership to get an idea of normal problems and remedies. Renntech has been a treasure of information and I would now like to give back a little bit to the community.
The dreaded CEL arose after 2 months of ownership and I took the CTT into O'Reillys (thanks O'Reillys) to get a fault code read out. It showed that my passenger side pre-cat O2 sensor was bad so I order a new one and proceeded to read through as many DIY articles as I could find on the topic. This one and the one on Pelican Parts were most helpful and are what I used as my basis.
My initial plan was to remove the inner wheel well per sswong98"s good details above. I started down this path, took off the wheel and decided to take a peek underneath before removing the wheel well simply to assess how much room I had to work with. To make a long story short, I ended up being able to remove and replace the O2 sensor within the very confined space given and without removing the wheel well. In all, it took 90 minutes after jostling about quite a bit and trying different tools. I thought this might be another alternative of value to offer to this community so I'll describe it briefly here.
1) Follow SSwong98's steps of:
a) jack up vehicle
B) turn wheels right to wheel lock
c) remove front passenger tire
d) remove 02 sensor electrical connection at firewall.
At this point you can see how much room I had to work with between the body, suspension, etc. The photo with the end of the 3/8 ratchet extension shows where to view and then subsequent photos show the amount of clearance and the 02 sensor.
Basically, I was able to use a 22mm open ended wrench and get it into the space shown in the photos. Lying on my back, I was able to get the wrench between the suspension and inner wheel well and break the 0@ sensor loose. Once I had it broken loose, I could use my fingers to unscrew the O2 sensor, again lying on my back and from underneath the vehicle. Unscrewing the )2 sensor was not difficult but took about 5 minutes as I could only turn it slightly, then re-grip the sensor so that the wire did not cause it to screw back in, and then continue this process until it was removed. I could have also cut the sensor wire which would have eliminated some of the torque produced by the wire and made it slightly easier to unscrew the sensor.
Once the sensor was out, I removed the original heat shield from the original O2 sensor wire by cutting it lengthwise. My goal was to reuse it on the new sensor. I then drilled 4 small pilot holes on both side of this heat shield (sorry, forgot to take photos) and placed a pop rivet into each in order to have it hold in place around the O2 sensor wire.
The most challenging part was getting the new 02 sensor started into the mounting hole. I dropped the sensor in from the top of the engine and was able to locate the sensor quite easily. I was also able to reach up from underneath the vehicle, grasp the sensor with a thumb and finger and get the O2 sensor into the mounting hole. However, once again, the sensor wire created a torque that prevented me from being able to start the sensor correctly into the threading. After trying various options for 5 minutes, I called in the calvary... I asked my son to hold the sensor wire from the engine bay side and to turn the wire slightly in a clockwise manner so that the sensor wire torque worked in my favor. I also repositioned myself so that I could get a much better grasp of the sensor. Instead on lying on my back looking up at the sensor, I sat down in front of the caliper and was able to reach the sensor through the same opening as before. While I could not see the sensor, I had it placed into the mounting hole from before so all I needed to do was to get it to start threading properly. In this seated in front of the caliper position, I was able to much more easily grasp and turn the sensor and got it threaded within a few seconds. At the same time, I told my son to slowly keep tuning the sensor wire. Once the sensor was hand tight, I used the 22mm open ended wrench to tighten it. All told, it took about 90 minutes from wheels up to wheels down.
Some other notes: I ordered the special O2 sensor socket from Pelican (same one shown in SSWONG98's write up) but, very oddly, could not get enough room from the top or bottom to be able to get it onto the sensor. Removing the inner fender well would have helped here. I also would suggest getting a stubby 22mm open ended wrench as this would allowed more freedom for movement. The one I had was about 14 inches long. I also had a line wrench (shown in one photo) that was a bit shorter in length and worked very well.
Well, I hope that this is some value to this great community