Does anyone have a suggestion on how to get a firewall/fender/floorboard penetration to fit the BIG A$$ plug or 02 sensor from the cabin to the outside?

Jeez, you need like a 1" hole to fit the damn thing. I was going to go through the same hole for the stock secondary 02, but I'd have to drill the hole too big for my taste. I don't see anywhere in the firewall to piggy back, you'd have to drill a new hole.

Any suggestions? I'm going to make a duplicate post in the engine section, but I don't know if the Bosch/VW sensor is typical to others, with the BIG A$$ plug on the end. A smaller connector would make it much easier.

 

You can go through the boot. Cut a slit in it and use a long pair of needle nose to fish it through : )...

 

Which boot? Need a bit more description

 

There is a plugged hole right after the drive shaft to the rear begins. If you place the O2 sensor right before the Cat, then it's almost straight up.

Look at Vishnu's O2 install for their self tuning XEDE & O2 install, they have a picture and description of the hole I'm talking about.

(edit) http://www.vishnutuning.com/Smart/wi...stallation.htm

I still had to wallow out that hole a little bit for the "VW" sensor to fit.

I think I actually go in from the cabin-side with the sensor (plastic protective cap ON!) and fish it into position that way (my bung is directly below that "factory" hole.

So in other words, the sensor fits through the enlarged hole easier than the connector plug(s)

Be Sure To Protect The Cable Where it Touches the Wallowed out hole.

 

nirvevo,

perfect! Thanks.