Can someone give me a step by step process on how to remove the secondary 02 sensor on an Evo IX because I need to fix a damaged wire. Any help would be great!

 

Unplug the sensor wire under the passenger seat carpet(there is a whole for it in the carpet under the seat). Then, go under the car and unscrew the sensor from the exhaust with an O2 sensor socket.
Not difficult at all.

 

yep, he's right. some people take off their passenger seat. i was able to reach mine without it. i had to remove the passenger side door sill to get under the carpeting.

 

It makes it a little easier to remove the seat if you know what you are doing, but to some that is another project itself. You should be able to reach under the seat (moved all the way back) and feel for the plug, once located pull it out from under the carpet and unplug.

 

Very easy to do w/o removing any seats or paneling. Just find the bump (its a plug) under the carpeting under the passenger seat, work it out through the slit in the carpeting, unplug, and pull out from the bottom of the car. I prefer a big wrench on the o2 sensor instead of a special socket since they always seem to break or slip (even the Snap-On ones). Be sure to give the o2 sensor some good shots of PB Blaster to loosen things up a bit.

 

I've just pulled the o2 sensor wiring through the grommet hole on the bottom of the car. You can pull the connector through the hole, unplug the o2 then push the connector back into the hole (underneath the carpet). This way should take about 10 seconds at most.

Removing the o2 sensor is another adventure in itself. Last one I removed for a friend was cross threaded into the Cat. Took a nice big wrench and a vice to finally work it loose.

I cant imagine removing a seat to do this! It sure would be to see someone installing an exhaust and removing their seat though! I can imagine the conversation now --

"Sweet new seats?!!?"
"Nope, new exhuast!"
"hmmmm"

Look here and pay attention to Step #5 (Ignore the fact that it says under the carpet, just remove the rubber grommet piece and pull the wires through)
http://evomoto.com/tech_info.php?tPa...f4d678767d1b25

 

I'm said friend of that o2 sensor. We went through 2 different wrenches and then went out and bought an o2 Socket.. don't waste your money they suck... Like Chuck said, mine was cross-threaded and it was a ***** to get to get out. Just cross your fingers the guy who put yours in wasn't as lazy as the guy who did mine.

+1 on the grommet under the car... messing inside your car would be a waste of time. We pulled mine out through that grommet with no problems at all.

Oh and chuck i still owe you $11 for that PoS socket...