3.2 oxygen sensor issue
 

Yes, I searched and found good info but I still need to ask. Performed most of the 60K service on my '84 yesterday and when replacing the O2 sensor I found that the lower plug was broken. Pulled the old sensor, tried to epoxy it back together (sorry, had to try), that failed, so now the new sensor is connected normally on the upper, 3-prong part, but not on the lower, single prong part. Car ran like a champ after the tune-up with the O2 not fully connected. Any thoughts on how to proceed?

On a side note, the car ran great after the tune, noticeably better, but then today on the PNW Pelican XXX drive, after maybe 80 miles of driving, the car started to run slightly rough at idle and has continued to have a slight roughness at idle. Car still drives fine, just a new, different sound to the idle. Not a miss but almost a miss-like sound. Maybe a little rich too as it smelled rich after shut-off.

Thanks in advance.

Broken female end:

http://i12.photobucket.com/albums/a2...ps7157f807.jpg

Broken male end with a dab of JB epoxy (fail):

http://i12.photobucket.com/albums/a2...ps5fd65d90.jpg

it is toast, just get a male and female bullet style connectors and solder it on and use heat shrink, take carefull attention to the sheilding.

find a piece of hose same od of the clamp, slip it on to hold it in place.

Thanks Draco, I'll do that. It was already broken before I bought the car (PPI missed that) so it didn't seem to effect the way it runs.

Jim,
I saw this car today..its a time capsule..real beauty

Have you seen this fixed and have ideas were to source parts that will look OEM?
Any pics or threads been posted ?

Here you go:
http://img.photobucket.com/albums/v5...125_160615.jpg

a better pic,

http://img.photobucket.com/albums/v5...703_191556.jpg

Awesome Jim!

Yep, looks like a no-brainer!

To make sure about the shielding, take apart that crumbled connect to see exactly how it is assembled so you can duplicate the solder/connection, this connector supposedly takes air samples from the engine bay :eek:

Okay, thanks, will do.

Upon further review...
 

More searching revealed this thread that I had missed before:

http://forums.pelicanparts.com/porsche-911-technical-forum/497025-o2-sensor-connector.html

PM sent to Louie85 with fingers crossed.

I love this place. :D

just make sure you address the shielding no matter what you do, it is critcial for the DME to operate the o2s properly.

Roger that.

So can I drive it in the meantime?

Heck yeah, our euro brother don't even have a o2s :-)

But not too long, you will over work your DME because it was programed with it.

HA! I just noticed that the upper retaining clip on your sensor plug is broken. Guess what I did today? I broke mine the same way trying to disconnect it and yes, I was being careful.

Do not solder the connector on an O2 sensor. The O2 sensor uses air pulled through the conductor as part of its operation.

Sounds weird and I know someone will cry "Bull!" so let's hear it from Bosch...
http://www.boschautoparts.com/BAP_Technical_Resources%2FOxygen%20Sensors%2FO2Ins tallGDWEB09.pdf

Dupped post...

Thanks Wayne, I did read that Bosch article in another thread while searching today.

Hooray! Louie answered my PM and his broken O2 sensor repair kit is on the way!

I love this place!

BE911SC. The green wire coming out from the wiring harness is very short not much you can do there unless you remove the whole harness. You can try to crumble the rest of existing connector to get an extra 1/2 inch. I would just cut it at the end of the connector, carefully trim the shielding about 3/8 of an inch. Then strip the inner wire about 1/4 inch and crimp the electrical connector then secure with heat shrink.

Outstanding, let us know how it went :D

Success! Took a while because I over-think simple stuff but I got Louie's trick replacement part installed today. Runs like a champ! Nice positive connection too--Louie's part has a longer metal shaft that gets all the way into the O2 sensor boot connection.

http://i12.photobucket.com/albums/a2...psceb05ac0.jpg

Update
 

Update: After connecting Louie85's neat replacement O2 sensor connector two weeks ago I read more posts in this thread. Well, I realized that I had grounded the coaxial shielding to the core wire and thus still had a non-functioning O2 sensor signal. The car ran poorly so my hunch was correct. My buddy Thor (Brown747) came over early this morning and dove in. He, being more competent than me, was able to access more of the sensor wire and get it out to where he could properly strip the shielding back, heat-shrink it out of the way and crimp+solder an eyelet onto the center wire. Viola! Car started, idled and ran like a champ! Never better. Went out for a 2-ship drive and the cab is running amazingly well now. No more fussy idle and rich smell out the back. Sure is nice to have competent friends!

http://i12.photobucket.com/albums/a2...psf13edc12.jpg

http://i12.photobucket.com/albums/a2...ps6c4b3ef7.jpg

http://i12.photobucket.com/albums/a2...ps417e50b0.jpg

Where did you buy the white sensor plug? mine is broken and can not find the part.
Thanks
Tommy

Pelican Louie85 made them and may still have some for sale. Look him up here.