Camaro V8-6.2L (2010)
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to
repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is
obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of
the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
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Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor
performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a
path for foreign materials to enter the sensor and cause performance problems.
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Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the
lead wire.
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Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as
the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance.
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To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Note: All wiring repairs need to be 200 mm from the heat zone. Areas of consideration would be any area located near the exhaust manifolds, catalytic
converter, exhaust pipes, and turbocharged engines.
Items Required
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DuraSeal splice sleeves to crimp and seal connections
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High temperature SCT1 shrink tubing to protect the splice sleeves
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Terminated leads or pigtails
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The correct tools to remove the terminals from the connectors
Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage
wire. Also replace any reflective tape that you remove during the repair.
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and
shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following:
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Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire.
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Replace any heat shielding that is removed.
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Cover any DuraSeal splice sleeves with SCT1 shrink tubing.
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After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source.
Identifying High Temperature Wiring
Note: High temperature areas would be areas located near exhaust manifolds, catalytic converters, exhaust pipes, and turbocharged engines.
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring
repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials
may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because
conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area
is exposed to excessive heat before making a wiring repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length
