O2 Sensor Connector Crumbled, $1300 Replacement Part???

[DRACO A5OG]

Here is another Contribution in re-payment for all the help on this Great Forum! Thanks Pelicans!

All right guys, you've changed your 02 Sensor only to find the male connector crumbled as soon as you pulled off the old sensor rubber cover. Revealing a green wire and stab. What the Duck


What the Heck do you do? Take out the electrical tape, silicon glue, or even cut the brand new O2 Sensor rubber sleeve so that you can insert the stab?

Unfortunately that yellowish plastic part is not replaceable and one must invest $800-1300, yes $800-1300 to replace the entire harness which is connected to the DME, UNACCEPTABLE! (Thanks SloDave for the info) Part area #1


Here is my humble fix:

Total Cost = $1.29 USD
1" Nylon Spacer $0.33 (1"x1/2"x 1/8 dia. whole)
1/2" Nylon Spacer $0.30 (1/2"x1/2"x1/8 dia. whole)
Male DIN 8 Pin Connector $0.63 (only need the sleeve to fit the 1/2" outer diameter of the spacers)
Sales Tax: $0.03

1. Take off the rest of the yellowish plastic, it is dust anyways.


2. Crazy Glue/ Epoxy the the spacers together

Note: There must be a good reason for the engineers to put so much rubber around that connection. Errand sparks i.e. electrical fire? I do believe it is the heating wire for the O2 Sensor (Vets please correct me if I am wrong)

3. Using a carving/engraving Dremel tool, cut an 1/8' slot down the side center and a divet to match the locking divet in the New O2 Sensor. Use a clamp for better support


4. Bevel the the two ends so it will slide into the new O2 Sensor's protective rubber sleeve and the DIN 8 Pin Sleeve, It will make your Mod Part slip on more easily while working in the engine compartment. You may choose not to use the DIN 8 Pin Sleeve but I figure I would add extra insulation for this area.

I used a bit of lube on the DIN 8 Pin side to make sure it won't be difficult to slip on inside the engine compartment. The new O2 Sensor side is perfect, just don't over dremel the divet, test to fit.

5. Test with old O2 Sensor


Note the stab is a hair wider then the 1/8" whole but with the slot, it will fit. I decided to use liquid electrical tape to ensure the stab and wire will stay in place.

Caution, It is tight in there becareful not to damage the 3 plugs on the brass harness, the one with the CHTS and Ref/Speed Sensors. I detached and moved them out of the way. It allows more room to manuveur.

I tested this with only a 1/2" sloted spacer it worked but was too short to be supported by the bracket. this new 1.5" length is almost the same length of the OEM.

Break a Leg.

[3.2 CAB]

Nice fix!! Those damn connectors seem to fail on every German made car, that I have seen them on. BMW, Mercedes, and Porsche use that same connector. Piss poor quality of compound used for the connector.

[Nickatnyt]

I hope mine doesnt crumble. All be darned if I would never remember this post down the road if it did. But just in case, thanks for sharing your handiwork!

[WI wide body]

Good posts. Question:

On the 3.2 Carrera engine what are the symptoms when the O2 Sensor has failed?

[DRACO A5OG]

According to the Bentley guide:

Engine does not start or starts hard
Erratic Idle
Poor Acceleration

Also CO Levels and Idle Speed adjustment incorrect

[GH85Carrera]

One simple question is where did you get the nylon spacers? Is this a home improvment store, auto parts store or Ace Hardware part? Where can I find these parts. One thing for sure it is not the Porsche dealer.

[DRACO A5OG]

Originally Posted by GH85Carrera

One simple question is where did you get the nylon spacers? Is this a home improvment store, auto parts store or Ace Hardware part? Where can I find these parts. One thing for sure it is not the Porsche dealer.

Home Depot, hardware section in the Specialty Hardware Drawers, I think Ace has them too, can't be sure. There are plenty of them
As far as the Protective Sleeve, an Electronics Supply Store, in a loose poop bin. Becarefull the rubber RCA sleeve are too tight the DIN sleeve fits the best.

Break a Leg!

[Buckterrier]

Ace has them in the fastener section. Great job Draco!

[DRACO A5OG]

Just Contributing to the P-Community, I feel Communist Now :?

[88911coupe]

Are these pictures still available?

[dshepp806]

Originally Posted by 88911coupe

Are these pictures still available?

ditto...

Doyle

[DRACO A5OG]

Oh Crap what happened to my Pics?

Let me see if I still have them

[Halm]

Draco, did you ever find the pictures for this thread. I am in need now too.

Thanks.

[80-911SC]

mine just did the same thing last week , did an earlier posted "bullit fix yours sounds better

sure wish there was a picture , if you find the can you rpost or take one of final result , thanks

[Starless]

Just a minor "bump" until the pics show up.

[80-911SC]

bump,bump ... draco photo please , ... .

[WilsonTC]

Looks like you moved them to their own directory (DRACOA5OG > 911 > 911 Project > O2 Sensor). Is this them?

[DRACO A5OG]

Yeap, that'll be it.

Caution, make certain the crimp is not falling apart.

I ended up using insulated male and female "Bullet" connectors. I had some shorting issues so was forced to solder mine crimps to allow for a good signal.

I understand from some that you do not want to solder, but in my case I had to,

[lr172]

For future reference, Bosch makes a universal O2 sensor that mathces the characteristics of the OEM sensor. THe part numbers are:

15725 ( 0258005725)...universal type
15726 ( 0258005726)...universal type

I forget which one I got (one has a longer harness than the otehr). This kit includes a very nice, sealed connector that will perform as well or better than the stock. I got this for a bit less than $50 at the local auto parts store. These part numbers were recommended by Bosch as a replacement for our engines.

They use the rubber connectors because the O2 sensor is designed to pull reference air through the wire. The best practice for designers is to keep the wire connection air tight through the harness and let it pull air from the intrior of vehicle. This is way it is suggest not to solder, as the rubber can melt and possibly hamper the air flow through the wire. The sensor does not require much air and it is able to pull what it needs through the wire.

[DRACO A5OG]

Thanks for the clear explanation of how the connector works. It looks like I am going back in for some work on the connector.

Originally Posted by lr172

For future reference, Bosch makes a universal O2 sensor that mathces the characteristics of the OEM sensor. THe part numbers are:

15725 ( 0258005725)...universal type
15726 ( 0258005726)...universal type

I forget which one I got (one has a longer harness than the otehr). This kit includes a very nice, sealed connector that will perform as well or better than the stock. I got this for a bit less than $50 at the local auto parts store. These part numbers were recommended by Bosch as a replacement for our engines.

They use the rubber connectors because the O2 sensor is designed to pull reference air through the wire. The best practice for designers is to keep the wire connection air tight through the harness and let it pull air from the intrior of vehicle. This is way it is suggest not to solder, as the rubber can melt and possibly hamper the air flow through the wire. The sensor does not require much air and it is able to pull what it needs through the wire.