Extending o2 sensor length

[haywire]

Hi all,Silly me has bought wrong length Bosch Premium o2 sensors. I bought 2 E39 pre-cat o2 sensor from a US seller knowing full well its a US LHD version. A fellow forummer has bought post-cats from them and it fits perfectly and I assumed that the pre-cats should fit too.Upon arrival I noticed that it is considerably shorter. Later check on the RealOEM reveals that LHD o2 sensors have 320mm long harness, while the RHD ones have 570mm harness (I'm 250mm short). Don't ask why I didn't check earlier. Totally my fault.Contacted the seller and he is willing to refund me the price of the o2 sensors. However, I paid $34 for postage, and I will need to pay some more for the return postage and I still need to buy a set of o2 sensors. Thats quite a loss and I'm trying to avoid that.Guys at Optimum suggested cutting the new harness and connect to the old o2 sensor harness. However, these things should not be soldered and needs a clean connection, protected from heat.I have a product that could work, which is Posi-Lock

Does anyone know if this product (or similar ones) are available in KL? If so, where?It have temperature-resisting properties and is used by Bosch themselves for their O2 sensor harness connection (couldnt find any of this for sale without the o2 sensors):http://www.boschautoparts.com/Technical%20Resources/Oxygen%20Sensors/OxygenSensorInstall.pdfOtherwise I would have to buy from ebay (GBP16 for 9 connectors) for such a small piece of plastic.Any other wire connecting product that can be recommended for such high-temperature application, and where to get it from?

 

[haywire]

Right, I think I've found a much better product, Delphi Weatherpack 4 pins connectors. Much better price too for what I get. Used on high performance Nascar cars.

$20 including postage for 2 connectors.

 

[pussy]

yup, better use good connectors hence it's below, with the heat and water everyday...

update us on the works...

 

[leforte]

just cut the wire in between and replaced the required length with a similar gauge wire. solder the connections with a good amount of flux to ensure a good wire connection. insulate the connection with heat shrink wrap. works perfectly fine.

 

[initialM]

Why u bought the sensors from US? is it too cheap?

 

[haywire]

just cut the wire in between and replaced the required length with a similar gauge wire. solder the connections with a good amount of flux to ensure a good wire connection. insulate the connection with heat shrink wrap. works perfectly fine.

These wire uses stainless steel wires, not the usual copper ones so not that easy to solder on. No need for new wires in between as I can connect to the old o2 sensors wires (1 connection rather than 2)

Anyway the connectors have already been bought and awaiting arrival.

 

[haywire]

Why u bought the sensors from US? is it too cheap?

Its about RM500 for 2 sensors, here its nearly RM400 for one sensor. I wouldn't bought it if I know it was the wrong one.

Apparently I'm not the first one to make that mistake in this forum, you know who you are he he he :4:

 

[bmw7833]

Its about RM500 for 2 sensors, here its nearly RM400 for one sensor. I wouldn't bought it if I know it was the wrong one.

Apparently I'm not the first one to make that mistake in this forum, you know who you are he he he :4:

Bro, can give me the link where u bought the sensor from? Anyway i know who bought wrong before..:4:

 

[haywire]

Search for SoCal Motorsport on Ebay.

But, rather than buying a wrong one like me and needing to cut and buy connector, why not buy Universal O2 sensor like my link in the first post, already come with connectors.

 

[leforte]

These wire uses stainless steel wires, not the usual copper ones so not that easy to solder on. No need for new wires in between as I can connect to the old o2 sensors wires (1 connection rather than 2)

Anyway the connectors have already been bought and awaiting arrival.

any type of wires can be soldered. a good solder paste or flux or fluxed wire, and heating the wire connection properly with a good solder iron is all you need to do.

 

[jarance]

Right, I think I've found a much better product, Delphi Weatherpack 4 pins connectors. Much better price too for what I get. Used on high performance Nascar cars.

$20 including postage for 2 connectors.

This connector will worked. Just cut the cable from the old O2 sensor to lengthen the cable.

 

[jarance]

any type of wires can be soldered. a good solder paste or flux or fluxed wire, and heating the wire connection properly with a good solder iron is all you need to do.

stainless steel cannot be solder with lead/silver base solder. The melting point of lead and steel is different.
You will end up with what we call a dry joint.

I doubt haywire O2 sensor wire is stainless steel because SS is a bad conductor of electricity. It could be
copper with tinted zinc that make it look like SS.