Bosch_Oxygen sensor

Tools required to perform installation:

Oxygen sensor removal tool or 22mm

f wrench (see manufacturers instructions) Tape measure f Wire cutter

f Wire stripper (18-20 gauge)

f Contents of OE SmartLink Oxygen Sensor Connector Kit:

OE SmartLink Oxygen Sensor (Qty. 1)A. Posi-Lock Terminals (Qty. 4)B. Cap (Qty. 1) C. Body (Qty. 1)D. Wire Seals (Qty. 8)

E. Please read these instructions carefully before removing the installed oxygen sensor from your vehicle.

Do NOT cut wires while removing the existing sensor from the vehicle. f Do NOT solder wires. Soldering wires will lead to early sensor failure.

f Before removin

g the existing oxygen sensor from your vehicle, make note of the location of the

f connectors joinin

g the oxygen sensor and vehicle wiring. Also note the routing of the existing sensor to ensure the OE SmartLink oxygen sensor is routed the same way.

OE SmartLink kit assembly will add approximately 25 – 30 minutes to the complete installation

f time.

D

E

C

B

A

4-Phase Installation Process

Do not cut the wiring while removing the existing sensor from the vehicle, as it is necessary to utilize a portion of this wiring on the OE SmartLink oxygen sensor.

1) Lay the existing sensor and the OE SmartLink sensor next to each other on a work surface, with

the sensor bodies at the same end.2) Using the wire cutters, cut through the leads and insulation sleeves of both sensors at the

same location. Discard the sensor end of the existing sensor and the excess lead end of the OE SmartLink sensor.

Phase II – Sensor Preparation

1) Remove the existing sensor from vehicle. Oxygen sensors

can be located in a manifold or exhaust pipe.

Phase I – Sensor Removal

Existing Sensor Example A

Existing Sensor Example B

Existing Sensor Example C

A (cut)

(cut)

C (cut)(cut)

B (cut)

(cut)

Bosch OE SmartLink Sensor

A

1) Slide the insulation sleeve off the wire

leads far enough to cut 1 ?” from the length of the insulation sleeve, and slide the insulation sleeve back towards the existing connector.

2) Install the cap (C) on the wires

by inserting the wires into the designated holes. 3) Slide the wire seal (E) over each

wire. The un-ribbed, smaller

diameter end of the seal should face the cap.

4) Strip 3/8” of insulation from the ends

of each of the wire harness leads. Use proper tools to ensure that you strip only the insulation.

Phase III – OE SmartLink Connection

Prepare the individual segment(s) for connection.

Assembly for Existing Connector Segment

C

E

C

E

Cut 1?"

Slide sleeve

1?"

1) Slide the insulation sleeve off the

wire leads far enough to cut 1 ?” from the length of the insulation sleeve, and slide the insulation sleeve back towards the OE SmartLink sensor body.

2) Install the body (D) on the wires

by inserting the wires into the designated holes. 3) Slide the wire seal (E) over each

wire. The un-ribbed, smaller diameter end of the seal should face the body.

4) Strip 3/8” of insulation from the

ends of each of the wire harness

leads. Use the proper tools to ensure that you strip only the insulation.

Assembly for OE SmartLink Sensor Segment

Phase III – OE SmartLink Connection (Continued)

E

D

E

D

Cut

1?"

Slide sleeve

1?"

Use the “Wire Color Reference Table” to determine the proper wire connection.

1) Identify the two “heater” wires first (2 wires that are the same color) and match

them with the OE SmartLink white wire.2) Identify the signal wire. Match the signal wire with the OE SmartLink black wire.3)

Identify the ground wire. Match the ground wire with the OE SmartLink gray wire.

Wire Color Reference Table

Phase III – OE SmartLink Connection (Continued)

Phase III – OE SmartLink Connection (Continued)

1) Unscrew the ends from the center of

the Posi-Lock terminals (B).

Connect the two segments using the Posi-Lock? terminals.

Using the Posi-Lock terminals

5) Follow the wire color reference table

to match the appropriate wire colors on the existing connector segment to the OE SmartLink sensor segment.6) Align wires so that the appropriate

matching color wires are straight across from each other. Avoid crisscrossing the wires.7) Repeat the steps above for using the

Posi-Lock terminals (B).

B

2) Insert the wire through the end caps.3) Keeping slight pressure on the wire,

hand tighten the male (threaded) end into the center section (barrel end) of the Posi-Lock connector.4) Repeat this process for all wires on the

OE SmartLink sensor segment.

Assemble the OE SmartLink Connector

1) Push the wire seals (E) against the

Posi-Lock terminals (B).

2) Insert the seals (E) and Posi-Lock

terminals (B) into the body (D).

3) Push the cap (C) onto the body until

both tabs on the cap lock into position.

The OE SmartLink connection is now complete. Phase III – OE SmartLink Connection (Continued)

The OE SmartLink oxygen sensor is now ready

to be installed on the vehicle. Route the OE SmartLink oxygen sensor in the same way as the existing sensor, utilizing any clips and grommets attached to the wire harness. Remove the plastic cap from the OE SmartLink oxygen sensor protection tube and re-install onto the vehicle.

It is critical to locate wires away from sources of

extreme heat and possible abrasion. Phase IV – Sensor Re-Installation