Downstream O2 sensor

99 4.0

So I was replacing my O2 sensors last night and got the upstream one (before the cats) done no problems. When I went to change the downstream one (between the cat and muffler), It actually broke the top part off of the O2 sensor and started stripping the nut portion of the sensor. I cut the wires to keep the plug connected and clean and left the sensor in the pipe. Obviously, my check engine light is now on.

Now, as I understand it, the downstream O2 sensor has no bearing on how the engine runs nor does it change anything in how the ecu operates, except to turn on the light and measure "how well the cat is working". My options as I see it now are; somehow get the O2 sensor out and put the new one in, redo my exhaust (does the Dynomax catback system have the bunghole for the O2 sensor?), or leave it like it is until it's time to get it inspected and plug in the new sensor and zip tie it up and out of the way (we have emissions testing but they don't use a sniffer, they just check for codes. Would this even work or would it still have a code?)

On a side note, My MPGs are back up to 17-18 on the freeway instead of 13.

Chrysler systems use the downstream O2 for fine tuning fuel trim, along with catalyst monitoring.

It monitors for rich or lean trends and adjusts long term fuel trim accordingly.

OP, here's some reading for you.

Oxygen Sensors

OPERATION (FSM Section 14)

An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0-1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7–to–1 air/fuel ratio necessary for proper engine operation and to control emissions.

An O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the wire harness (vent holes in the body of the O2S for NGK Sensors). This is why it is important to never solder an O2 sensor connector, or pack the connector with grease.

Four wires (circuits) are used on each O2 sensor: a 12–volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation.

Oxygen Sensor Heaters/Heater Relays:

The heaters on both sensors are fed battery voltage from the ASD relay which is controlled by the PCM.

The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70°F, the resistance of the heating element is approximately 6 ohms. As the sensor’s temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930°-1100°F (500°-600° C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle.

In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors.

Upstream Sensor:

The upstream O2S sensor is located in the exhaust downpipe before the catalytic convertor. It provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalyst efficiency.


Downstream Sensor:

The downstream heated oxygen sensor is located near the outlet end of the catalytic convertor. The downstream sensor is also used to determine the correct air fuel ratio. As the oxygen content changes at the downstream the PCM calculates how much air fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensor also provides an input to determine catalyst efficiency.

OXYGEN SENSOR (O2S) MONITOR (FSM Section 25)

Effective control of exhaust emissions is achieved by an oxygen feedback system. The most important element of the feedback system is the O2S. The O2S is located in the exhaust path. Once it reaches operating temperature 300° to 350°C (572° to 662°F), the sensor generates a voltage that is inversely proportional to the amount of oxygen in the exhaust. The information obtained by the sensor is used to calculate the fuel injector pulse width. This maintains a
14.7 to 1 Air Fuel (A/F) ratio. At this mixture ratio, the catalyst works best to remove hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxide (NOx) from the exhaust.

The O2S is also the main sensing element for the Catalyst and Fuel Monitors. The O2S can fail in any or all of the following manners:

• slow response rate
• reduced output voltage
• dynamic shift
• shorted or open circuits

Response rate is the time required for the sensor to switch from lean to rich once it is exposed to a richer than optimum A/F mixture or vice versa. As the sensor starts malfunctioning, it could take longer to detect the changes in the oxygen content of the exhaust gas.

The output voltage of the O2S ranges from 0 to 1 volt. A good sensor can easily generate any output voltage in this range as it is exposed to different concentrations of oxygen. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the threshold value.

OXYGEN SENSOR HEATER MONITOR

If there is an oxygen sensor (O2S) shorted to voltage DTC, as well as an O2S heater DTC, the O2S fault MUST be repaired first. Before checking the O2S fault, verify that the heater circuit is operating correctly.

Effective control of exhaust emissions is achieved by an oxygen feedback system. The most important element of the feedback system is the O2S. The O2S is located in the exhaust path. Once it reaches operating temperature 300°C to 350°C (572°F to 662°F), the sensor generates a voltage that is inversely proportional to the amount of oxygen in the exhaust. The information obtained by the sensor is used to calculate the fuel injector pulse width. This maintains a 14.7 to 1 Air Fuel (A/F) ratio. At this mixture ratio, the catalyst works best to remove hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxide (NOx) from the exhaust.

The voltage readings taken from the O2S sensor are very temperature sensitive. The readings are not accurate below 300°C. Heating of the O2S sensor is done to allow the engine controller to shift to closed loop control as soon as possible. The heating element used to heat the O2S sensor must be tested to ensure that it is heating the sensor properly.

The O2S sensor circuit is monitored for a drop in voltage. The sensor output is used to test the heater by isolating the effect of the heater element on the O2S sensor output voltage from the other effects.



CATALYST MONITOR

To comply with clean air regulations, vehicles are equipped with catalytic converters. These converters reduce the emission of hydrocarbons, oxides of nitrogen and carbon monoxide.
Normal vehicle miles or engine misfire can cause a catalyst to decay. A meltdown of the ceramic core can cause a reduction of the exhaust passage. This can increase vehicle emissions and deteriorate engine performance, driveability and fuel economy.

The catalyst monitor uses dual oxygen sensors (O2S’s) to monitor the efficiency of the converter. The dual O2S’s sensor strategy is based on the fact that as a catalyst deteriorates, its oxygen storage capacity and its efficiency are both reduced. By monitoring the oxygen storage capacity of a catalyst, its efficiency can be indirectly calculated. The upstream O2S is used to detect the amount of oxygen in the exhaust gas before the gas enters the catalytic converter.
The PCM calculates the A/F mixture from the output of the O2S. A low voltage indicates high oxygen content (lean mixture). A high voltage indicates a low content of oxygen (rich mixture).
When the upstream O2S detects a lean condition, there is an abundance of oxygen in the exhaust gas.

A functioning converter would store this oxygen so it can use it for the oxidation of HC and CO. As the converter absorbs the oxygen, there will be a lack of oxygen downstream of the converter. The output of the downstream O2S will indicate limited activity in this condition.
As the converter loses the ability to store oxygen, the condition can be detected from the behavior of the downstream O2S. When the efficiency drops, no chemical reaction takes place. This means the concentration of oxygen will be the same downstream as upstream. The output voltage of the downstream O2S copies the voltage of the upstream sensor. The only difference is a time lag (seen by the PCM) between the switching of the O2S’s.

To monitor the system, the number of lean-to-rich switches of upstream and downstream O2S’s is counted. The ratio of downstream switches to upstream switches is used to determine whether the catalyst is operating properly. An effective catalyst will have fewer downstream switches than it has upstream switches i.e., a ratio closer to zero. For a totally ineffective catalyst, this ratio will be one-to one, indicating that no oxidation occurs in the device.

The system must be monitored so that when catalyst efficiency deteriorates and exhaust emissions increase to over the legal limit, the MIL will be illuminated.

Get the old O2 sensor out, and install a new one, or have a shop weld in a O2 sensor bung.

Thanks for all that info Sidewinder.

I took it to a muffler shop to get the old sensor out. Turns out whoever put it in last time cross-threaded it. With an Oxy/Acetylene torch and a pipe wrench with a cheater bar he was able to break it loose. He popped a new hole and welded on a new bung. Then he replace some clamps that were mostly rusted and broken.

If you are in the Houston area I cannot recommend "Affordable Muffler" on Dairy Ashford enough. I had to convince him to take some money.