02 Sensor Wiring?

[Carlwalski]

Hi guys,


In my haste to remove my headers last week and get them to HPC Coating before they closed for the year, I accidentally let one of my headers drop which in turn made the header pull away from the 02 sensor and it's wires, releasing itself from the clips. I remember briefly seeing the wiring combo before my bumbling fingers dropped the header and I'm 90% sure the blue wire doesn't go to blue and white doesn't go to white. I remember thinking: "WTF, how dumbs that!". Not sure if it's factory or if it were done by the exhaust shop but now I have no idea HTF they should be wired! This is the sensor IN the header on the RH side (the 1st 02). I have my sparky coming around on the 24th to relocate the battery and other odds and ends so was hoping to have a diagram or something to help him wire it back correctly. Pissed me off lol, I labeled EVERYTHING and then this happened. I've done searches (I love doing them) and nothing. I also couldn't find anything obvious in the owners manual, which is weird as it's helped me many times. Thanks for any help.



Cheers,
Carl

 

[FastRam]

Carl, I call this incident an oh $hit, oh dear deal. A project wouldn't be fun without these. But, from 06 service manual:

Factory Wiring Connections, Right Front 02, 4 pin connector

Pin #1: Brown/Yellow, connects to pin #1 of left front O2
Pin #2: Brown/Violet, heater control circuit to PCM
Pin #3: Dark Brown/Dark Green, connects to pin #3 of left front O2
Pin #4: Dark Brown/Light Green RF O2 signal to PCM

From your photos it looks like you have an aftermarket O2 sensor. You may have to contact that manufacturer to find out from them what wire from the sensor performs what function in order to splice those wires back into the factory harness. Also, it looks like compression style splices were used. If so, for the repair I'd go with soldered connections and use a heat shrink sleeve with the sealant, Chrysler part number 04778570 (there may be other part numbers for different diameter sleeves). Good luck mate I hope this helps.

 

[Carlwalski]

Carl, I call this incident an oh $hit, oh dear deal. A project wouldn't be fun without these. But, from 06 service manual:

Factory Wiring Connections, Right Front 02, 4 pin connector

Pin #1: Brown/Yellow, connects to pin #1 of left front O2
Pin #2: Brown/Violet, heater control circuit to PCM
Pin #3: Dark Brown/Dark Green, connects to pin #3 of left front O2
Pin #4: Dark Brown/Light Green RF O2 signal to PCM

From your photos it looks like you have an aftermarket O2 sensor. You may have to contact that manufacturer to find out from them what wire from the sensor performs what function in order to splice those wires back into the factory harness. Also, it looks like compression style splices were used. If so, for the repair I'd go with soldered connections and use a heat shrink sleeve with the sealant, Chrysler part number 04778570 (there may be other part numbers for different diameter sleeves). Good luck mate I hope this helps.

You're the man mate, thanks a heap. I was getting worried. I have all my new powdercoated goodies back, about to mask the engine to paint and in the back of my mind I have this small yet very annoying 02 issue lol. "Hopefully" between your info and my geeky tech guy, we'll get it sorted without any issues. I agree, I'm glad this happened as everything else is soldered and taped that I've had installed so this is good that it's happened, I can get to it and do it properly. Thanks again mate, if you were local it'd be my shout on the pints for sure!!


:cheers:

 

[FastRam]

You're the man mate, thanks a heap. I was getting worried. I have all my new powdercoated goodies back, about to mask the engine to paint and in the back of my mind I have this small yet very annoying 02 issue lol. "Hopefully" between your info and my geeky tech guy, we'll get it sorted without any issues. I agree, I'm glad this happened as everything else is soldered and taped that I've had installed so this is good that it's happened, I can get to it and do it properly. Thanks again mate, if you were local it'd be my shout on the pints for sure!!


:cheers:

Carl, no problem. If you need the wiring diagrams, PM me your email address. Also, I travel quite a bit internationally as part of my job. I keep trying for a trip down under but it just doesn't seem to work out. :dontknow: But I keep trying nonetheless. If I make it down to ya, I'll drop ya a note.

 

[Carlwalski]

For sure!! :rock: Thanks again John. Yes, please email me the diagrams. He may think it's better to attack them further up for a cleaner more positive fix? I have no idea how those guys think but I'd like to have the diagrams available for him if possible, unless you know the page number in the manual? [email protected]


Thanks!!

 

[FastRam]

Carl, I'll email ya the diagrams later today. I have to run to a off site meeting. But, the diagram can be found in section 9, page 1616.
Cheers

 

[Carlwalski]

Eeek, I must have a different manual. No worries mate, no rush, he'll be here in 5 days so if you could get it to me before then that's all I need.

 

[FastRam]

Eeek, I must have a different manual. No worries mate, no rush, he'll be here in 5 days so if you could get it to me before then that's all I need.

You have mail...

 

[Carlwalski]

Thanks mate!!

 

[Carlwalski]

OK, had my electrician around and we tidied up the bay - yehaaw! However, he said he'd only be guessing trying to re-install the 02 sensor I have. Which, in turn, is a Toyota unit!?! The wiring is completely different and I don't want him wasting his time, then me re-installing it/the headers to find it's wrong. So, does anyone have the part # to the right hand side (YOUR passenger, MY driver) 02 sensor, the 1st one in the header. That would be awesome. That way the wires are color coded and it's a simple, connect, solder, tape and wrap!



Thanks,
Carl

 

[FastRam]

A Toyota O2 unit, LMAO. And it worked without throwing a code, wow! If you're going to swap out one O2, I would change them all out. That way you have a matched set, all new for PCM happiness.

From the 2006 Parts manual, here are the part numbers:

Before Cat, right side: 56028995AB
Before Cat, left side: 56028997AA
After Cat, right side: 56028996AA
After Cat, left side: 56028997AA

I would also give your VIN number to the parts guy to double check the part numbers noted above. Sometimes a manufacturer will enact a mid-year parts change that may not be reflected in the parts manual but reflected within the VIN. Using the VIN to attain part numbers is a good back check to verify the parts book. My old Chevy 4x4 proved this when I swapped cats for hi-flows and it took three tries before we found the correct rear O2's with the proper connecting plugs.

 

[Carlwalski]

LMAO! I know, oh well, could have been worse (for me), like a Mazda! Cool, I will source these bad boys ASAP.



Cheers and Merry Christmas John.

 

[FastRam]

LMAO! I know, oh well, could have been worse (for me), like a Mazda! Cool, I will source these bad boys ASAP.



Cheers and Merry Christmas John.

Carl, same to you, Merry Christmas!