Just picked up a 2002 RAV4 with 44K miles. (Sweeet!)
Unfortunately the check engine light came on shortly after buying it, and the error code was the P1135 bank 1 / sensor 1 error code.
I had my fingers crossed that it would be a 5-min repair to replace the air / fuel sensor in the exhaust manifold, but even with following the Hayes manual, the threads stripped out of the bung on the manifold. So it has now turned into a nightmare repair.
As I understand it I have 4 options:
- Clean up the threads using a thread chaser.
- Weld a new bung onto the manifold.
- Re-thread the bung using a HeliCoil kit.
- Buy a new manifold.
I tried a thread chaser but no luck.
So I’m going to try drilling out the bung and using this HeliCoil repair kit to fix it:
Here’s my question: Do you think I can use an electric hand drill to drill out the bung while the manifold is still attached to the engine? My concern is that the hole might not be perfectly straight (perpendicular) relative to the seating surface on the bung, which could lead to poor sealing between the sensor and the bung surface. But maybe I shouldn’t be concerned about this? After all, the original hole is basically a perfectly aligned pilot hole, and I should be able to get reasonably close to perpendicular (see attached photo or check it out here: http://www.guyfinley.org/testing/tim/img/rethreading-bung.jpg)
So do you think an in-place repair is possible? Or is this a situation where the manifold needs to be put in a jig at a machine shop?
I was going to remove the manifold, but there’s a mounting bold on the lower manifold bracket that is blocked by the engine mount. It would be quite an ordeal to take enough of the surrounding structure apart to get at that bolt.
What do you think?