O2 Sensor Wiring

[32valvZ]

Tried on the other forum... no replies... Anyone know if this is ok?
Thanks, John

I will need to lengthen my O2 sensors wiring harness due to adding headers. I have some old O2 sensors. Can I just cut the wires from the old ones and solder them together to get the length I need. Obviously, the wire gauge is the same, so the voltage through them should be consistent. Is this ok to do?

[Jagdpanzer]

I switched to NTK 21003 which have longer pigtails than stock O2 sensors and work great. $28.89 at Rockauto

[32valvZ]

Originally Posted by Jagdpanzer

I switched to NTK 21003 which have longer pigtails than stock O2 sensors and work great. $28.89 at Rockauto

So I would guess lengthening them on my own would be ok...

[Hib Halverson]

I wouldn't splice O2S harnesses. This from the Corvette Service Manual:

The heated oxygen sensor uses a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the heated oxygen sensor.

From a GM service information source other than the Corvette FSM:

Do not repair the wiring, the connector or the terminals. Replace the oxygen sensor if the pigtail wiring, the terminals or the connector is damaged. Proper oxygen sensor operation requires an external air reference. This external air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, the connectors or the terminals results in the obstruction of the air reference and degrades the oxygen sensor performance

Here's your solution:

Originally Posted by Jagdpanzer

I switched to NTK 21003 which have longer pigtails than stock O2 sensors and work great. $28.89 at Rockauto

[32valvZ]

Ok, got those ordered... Thanks guys..

[Paul Workman]

Originally Posted by Hib Halverson

I wouldn't splice O2S harnesses. This from the Corvette Service Manual:



From a GM service information source other than the Corvette FSM:



Here's your solution:

Well, w/ all due respect to you, Hib, I beg to differ with that particular GM source to the extent of warning against splicing the pigtails disrupting the function of the sensor.

In their defense, when considering the range of potential DIY'er talent, it is safer for the 'official GM documentation' to avoid the entire question of liability by simply recommending nothing be done to any part of the car except (maybe) changing/adding oil.

That said, when it comes to manipulating the sensor and inserting an extension, anyone with the equipment and ability to solder can do it w/o issues. I know first hand what will and what will not cause the O2 to fail: splicing in a section of wire to extend the length WILL NOT impede the sensor AS LONG AS THE SPLICE DOES NOT IMPEDE THE AIR FLOW WHERE THE WIRES ENTER THE SENSOR.

If you cut the wires leaving enough length so that soldering and shrink wrapping (i.e., weatherproofing) leaves the original wires entering the top of the sensor intact, there's NO PROBLEM. But, close off the wire entry with any kind of sealant or grime and then the sensor will fail. FACT!

NOTE: I extended my pigtails to ~ 18-20" long (passenger side) by splicing in a section between the sensor and the Weather Pack connector, allowing me to relocate the O2 to the side of the SW header collector (for ease of access).

The O2s have been there for 30k+ miles through torrential rains and and snow and survived bottoming out on a muddy hillside. They still work good as the day they were installed. That tiny space between the wires where they enter the O2 sensor is sacred to the O2's survival. If it gets blocked with anything, then the sensor cannot sample the atmosphere (air) which is essential to its operation.

[Jagdpanzer]

Here is a photo of the the NTK
IMG_1782.JPG


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[Karl]

I have to agree with Paul. I have extended o2 sensors without issues.

Also those NGK sensors are on eBay new for $14 each with free shipping.

[32valvZ]

ok, so there is no possible way that sensor wiring above will even remotely work.... Im looking at 18-20 inches too short on the passenger side.

[Jagdpanzer]

Bummer, the wiring harness on your car must have be different than on my 94.
Tell you what, the other day while digging through my parts stash I came across this 20” O2 extension I had picked up from Ron Woods many moons ago. You’re welcome to it if it’s what you need.Image1536375374.167077.jpg


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