Oxygen sensor . Splicing wires on the harness side

[commodoredave]

VTII, V6, no supercharge or turbo.

Have a kinked/cracked wire just near the connector side. It causes intermittent signal faults ( checked with multimeter).
wreckers will only sell entire looms, jaycar do not have compatible connectors nor do any of the automotive chains.
This creates a need to place new connectors and cut in some new wires to replace the cracked wire.
QUESTION The standard commodore wire is steel while the jaycar wire is ether bronze ( greater conductivity)
or steel/tin/bronze combo which again varies on ohms resistance etc. Has anyone mixed wire types ( eg steel mixing with bronze)
and has it been succesful given the sensitivity of oxygen sensor signal output to the ECM?

 

[BlackVXGTS]

The Holden VT/VX Service Manual only has special wiring repair procedures for ABS and SRS wiring repairs. That could indicate that other wiring repairs are not as sensitive.
I'm surprised that the standard Commodore wire is steel.

 

[lout]

try a different wreckers
or facebook for someone wrecking a car privately

 

[Fu Manchu]

If you are unsure about where the break is, you can use one of these to find it.

https://www.ebay.com.au/itm/1341791...VTSobbORpi&var=&widget_ver=artemis&media=COPY

The tool in use:

You would apply the same method to the circuit at hand.

You can repair the wire. As long as it’s the same gauge. I prefer crimping with a brass crimp joiner and dual layer heat shrink so it’s sealed from moisture.

You can unpin the plug and fit it to the new wire/s.

Some new split tube and engine bay tape. Better than new.

 

[Fu Manchu]

You could even get one of these and use it. Cut the end plug off, join up the wires. Dual layer heat shrink. Plug it in to the O2 sensor. All fixed.

https://www.ebay.com.au/itm/1858239...VTSobbORpi&var=&widget_ver=artemis&media=COPY

Then you also have a new plug.

 

[Drawnnite]

Yeah id go with Fu's extension loom option.

If the wiring is damaged right near the plug i would do as below.
Cut back into your loom about 100mm from the plug and probably add 200mm from the extension in.
Just make sure you have the heatshrink on ready to go before soldering Or you can always depin/repin plugs but that isnt fun.

 

[Lex]

Or you can always depin/repin plugs but that isnt fun.

Yes, l reckon it's fun (NOT).
But usually doable.

 

[commodoredave]

If you are unsure about where the break is, you can use one of these to find it.
View attachment 253710

https://www.ebay.com.au/itm/1341791...VTSobbORpi&var=&widget_ver=artemis&media=COPY

The tool in use:

You would apply the same method to the circuit at hand.

You can repair the wire. As long as it’s the same gauge. I prefer crimping with a brass crimp joiner and dual layer heat shrink so it’s sealed from moisture.

You can unpin the plug and fit it to the new wire/s.

Some new split tube and engine bay tape. Better than new.

Thank you for the guidance. gauge is same(1.5). copper has a better rate of conductivity and a different resistance to steel. The issue is mixing the two types along the same wiring line given how super voltage sensitive the sensor to ecm signal is. Hpusehold wiring wouod not give it a thought it is just the signal range that is the issue. Trying to hear from someone who has mixed the two types of wire and can declare NO PROBLEM.

 

[commodoredave]

You could even get one of these and use it. Cut the end plug off, join up the wires. Dual layer heat shrink. Plug it in to the O2 sensor. All fixed.
View attachment 253711

https://www.ebay.com.au/itm/1858239...VTSobbORpi&var=&widget_ver=artemis&media=COPY

Then you also have a new plug.

Yeh, did think about that. 2 wire though.

 

[commodoredave]

The Holden VT/VX Service Manual only has special wiring repair procedures for ABS and SRS wiring repairs. That could indicate that other wiring repairs are not as sensitive.
I'm surprised that the standard Commodore wire is steel.

Me too. I just thought it would be copper.,