02 Sensor Wire Question (Header & Hi-flow Cat Install)

[9864ever]

Hi all, I just ordered a set of headers and high flow cats for my 2003 S.
I will need to extend the 02 Sensor wire a bit.
Does anyone know what gauge wire to use and any specifics would be great.

If anyone has done this before would be curious to know how it went and if you had any issues with thrown codes. Though I would imagine it could just be inaccurate readings due to the hi-cell cats (if that's the route you took)

[pilot4fn]

Originally Posted by 9864ever

Hi all, I just ordered a set of headers and high flow cats for my 2003 S.
I will need to extend the 02 Sensor wire a bit.
Does anyone know what gauge wire to use and any specifics would be great.

If anyone has done this before would be curious to know how it went and if you had any issues with thrown codes. Though I would imagine it could just be inaccurate readings due to the hi-cell cats (if that's the route you took)

Here's from my previously made post regarding the connectors and cable extensions.

"Here's the part numbers I used to hunt the connectors:
Bosch 1-928-403-453
Bosch 1-928-403-736

Each cable needs one of each plug.

I purchased these from UK, since I'm in Finland (no customs etc issues) - at least untill the brexit kicks in
Here's the link where I ordered those both connectors:
https://www.auto-click.co.uk/1928403453
Same can be purchased from all continents.

On top of the cables I have the white 8mm heat resistant sleeve. This size fits real well over the wires."

...and the actual post for the same:
What did you do with/to your Boxster today?

Hopefully this is helpful

Also, here's the link to post I did after installing the cable extensions and having driven a bit:
What did you do with/to your Boxster today?

[9864ever]

Originally Posted by pilot4fn

Here's from my previously made post regarding the connectors and cable extensions.

"Here's the part numbers I used to hunt the connectors:
Bosch 1-928-403-453
Bosch 1-928-403-736

Each cable needs one of each plug.

I purchased these from UK, since I'm in Finland (no customs etc issues) - at least untill the brexit kicks in
Here's the link where I ordered those both connectors:
https://www.auto-click.co.uk/1928403453
Same can be purchased from all continents.

On top of the cables I have the white 8mm heat resistant sleeve. This size fits real well over the wires."

...and the actual post for the same:
What did you do with/to your Boxster today?

Hopefully this is helpful

Also, here's the link to post I did after installing the cable extensions and having driven a bit:
What did you do with/to your Boxster today?

Thanks for replying.
Why would you need new connectors though? I've seen a video where the cable was cut and a wire was joined somewhere in the middle to make the desired length.
I do like the clean look of your finished cables though - they look great!

[9864ever]

I think the Euro spec might be different from my car too which is a US car. My oxygen sensors only have one connector.

[pilot4fn]

Originally Posted by 9864ever

I think the Euro spec might be different from my car too which is a US car. My oxygen sensors only have one connector.

My car is US spec. Sold originally in San Diego.

[BYprodriver]

Originally Posted by 9864ever

Hi all, I just ordered a set of headers and high flow cats for my 2003 S.
I will need to extend the 02 Sensor wire a bit.
Does anyone know what gauge wire to use and any specifics would be great.

If anyone has done this before would be curious to know how it went and if you had any issues with thrown codes. Though I would imagine it could just be inaccurate readings due to the hi-cell cats (if that's the route you took)

I have the whole kit I used when I had headers on my Boxster including heat shielding to cover the O2 wires. I'll sell it for $ 35.

[9864ever]

Originally Posted by pilot4fn

My car is US spec. Sold originally in San Diego.

I think I understand now what you did. For each connector that you made, one end clips to the clip end of the 02 sensor and then the other end to the car. Is that correct?
If so I never thought of it that way as I always imagined the wires had to be cut and spliced in hence my confusion.

[9864ever]

Originally Posted by BYprodriver

I have the whole kit I used when I had headers on my Boxster including heat shielding to cover the O2 wires. I'll sell it for $ 35.

Do you have any pics of this setup? I'd consider it.

[maytag]

Originally Posted by 9864ever

I think I understand now what you did. For each connector that you made, one end clips to the clip end of the 02 sensor and then the other end to the car. Is that correct?
If so I never thought of it that way as I always imagined the wires had to be cut and spliced in hence my confusion.

When I first did mine, I simply cut-n-spliced the wires on the o2 sensors to lengthen them. That was all fine-n-dandy until I had a sensor fail, and then the next sensor I put in was either bad out of the box (it was a Bosch, so unlikely) or i damaged it when extending the wires.

So I built the extension cables, the way pilot4fun did. (In fact I think I used his part numbers to order the connectors?!) Now I don't have to worry about suspect solder-joints creating impedance that throws-off the sensor. AND - I can simply replace the O2 sensor with a new one next time, rather than have to extend wires again.

It's worth it, in my opinion, to do the extension cables the first time.

[9864ever]

Originally Posted by maytag

When I first did mine, I simply cut-n-spliced the wires on the o2 sensors to lengthen them. That was all fine-n-dandy until I had a sensor fail, and then the next sensor I put in was either bad out of the box (it was a Bosch, so unlikely) or i damaged it when extending the wires.

So I built the extension cables, the way pilot4fun did. (In fact I think I used his part numbers to order the connectors?!) Now I don't have to worry about suspect solder-joints creating impedance that throws-off the sensor. AND - I can simply replace the O2 sensor with a new one next time, rather than have to extend wires again.

It's worth it, in my opinion, to do the extension cables the first time.

Agreed. At first I couldn't wrap my head around it based on the picture he sent and then it just clicked. One of THOSE days I guess.
I like this idea much better as the sensors don't get butchered and can be swapped out easily.

[pilot4fn]

Originally Posted by 9864ever

Do you have any pics of this setup? I'd consider it.

The only picture I have of the install is from the after cat where you can see the black cable of OEM O2 sensor going up and connecting to extension plug (far-) behind the exhaust hanger on here.


I used zip-ties to keep the cables away from the exhaust and attached tidy at the car undercarriage.

[9864ever]

Originally Posted by pilot4fn

The only picture I have of the install is from the after cat where you can see the black cable of OEM O2 sensor going up and connecting to extension plug (far-) behind the exhaust hanger on here.


I used zip-ties to keep the cables away from the exhaust and attached tidy at the car undercarriage.

Looks good. I am convinced this is the right way now. Only issue is that 1-928-403-453 seems to be on backorder from the sites i've visited. Still searching...

[maytag]

Originally Posted by 9864ever

Looks good. I am convinced this is the right way now. Only issue is that 1-928-403-453 seems to be on backorder from the sites i've visited. Still searching...

Well check out what I've got sitting in my garage..

Send me a pm, we'll figure out how to get them to YOUR garage....



Sent from my SM-G970U using Tapatalk

[9864ever]

[QUOTE=maytag;619849]Well check out what I've got sitting in my garage..

Send me a pm, we'll figure out how to get them to YOUR garage....


PM sent

[BYprodriver]

Originally Posted by 9864ever

Do you have any pics of this setup? I'd consider it.

Here it is 2 brass anti-foulers, more wire heat shield than you will need & a old o2 sensor to mock up were you want to position everything.