O2 sensor wire "extension?" E70 X5M

[Molez93]

So the Racing Dynamics down pipe I just had installed required some creative machining to fit. Along with that challenge, the driver side (I think) O2 sensor wire isn't long enough to attach to their bung.

Anyone know of any off the shelf solutions for extending the oem wires so that sensor/bung can be connected? I'm hesitant to have the shop solder such wires.

Thanks!

BTW- The Velos tune I'm running feels great post DP install...MUCH better than when I was running their set-up for free flow DPs yet with stock pipes. Haha.

[Molez93]

So... it turns out Racing Dynamics offers an O2 connector extension. Apparently it will add ~4". Shop says I'll need 8-12 to make it work so I'm still hunting if anyone thinks of a source. I don't really want the stubby bolt extension ala Racing Dynamics anyway. Truly hoping for a wired alternative.

[philly42]

Bosch does sell a universal version of the o2 sensor used for the cat. The wiring is longer than normal.

[Molez93]

Cool. That possibility dawned on me later last night, although I hadn't found one online yet.

[m5james]

You still have to piece meal this together with as much as they charge? So much for not getting what you pay for.

[Molez93]

True. I figured there was a reason their DPs were ~$1500 less than competing products ($500 vs $2k) Velos suspected there would be fitment problems. Even another $500 for long cord/wire sensors works out OK.

[Molez93]

Small update in case anyone else faces the same challenge...
-The tune from Velos requires an O2 signal from the exhaust stream. Generated dual rich errors without the sensors connected.
-Racing Dynamics wasn't much help. They pointed me to their website for those extended bung connection fittings. That was nowhere close to what kind of length the wires needed on their own DP. grrrr
-Found no off the shelf solutions to extend things. Perhaps I'm just bad at using the interwebs and the google. ;-)
-Local shop spliced in some O2 wire they had lying around (needed ~10" each to make the connection) $450 for 4 hours and $50 worth of supplies.

Net cost? $500 DP + $450 jury-rig labor instead of the $1500-2000 for alternative choices from other vendors.
I'm ok with that, but wish I knew all this when I first placed the order with Racing Dynamics four months ago. Long effing time...

[frankenm]

Super cheap for down pipes considering other options ... you can always just splice some wiring together to extend it, I had to do this with my m3 since the o2 wires I had were about 2 ft to short any hardware store would have wiring.

What kind of machining was needed to make these fit as how is actual build quality?

Looking at the pics it is really poor place for post cat o2 and pipes appear to be resonated but for the price ...

I have gutted oem cats but might try these out when it comes time to swap again after inspection considering the price

[Molez93]

When new in the box, the RD down pipes looked to be pretty solid and cleanly manufactured pieces. I didn't get details on exactly how much machining the shop needed to do- and where- to make it fit. Pretty sure it was "just a little" based on the discussion at the time and their hours for that install were unchanged from their original estimate.

[greddy91]

It's just a sensor with wires that lead to a connector...

Measure the length you need.
Cut similar guage wire to that length.
Put some heat shrinking covers on both sides of the new wire.
Cut one wire at a time and solder your extensions in.
Move the heat shrink over the soldered leads and hit it with a heat gun.

10 minute fix. No errors here.

[greddy91]

On fitment...

The rear o2s aren't really even close to the factory locations... We just clearanced the stock heat shield with new and appropriately placed holes. (Clearanced is a verb now btw.)

[Molez93]

@greddy91
Good to know, makes sense now- would have been real helpful to understand months ago...like from them when I bought the downpipes. ;-)

At least this might serve others some hassle.

[NicksM]

Hey Molez93 I wish I would of came across the thread a little sooner, I installed mine about 3 weeks ago and left the o2 uninstalled from down pipe and got the car tuned and I guess that's why the check engine light keep coming back for secondary 02 sensors just be glad Velos did the install. the mayor issue was tightening the bolts on the driver side with the drive shaft in the way and almost no way to hold the bolts from the back of it, also I had issues with the flange that mates to the turbo not being in the correct angle, and not being close enough. I'm currently looking into a universal 02 sensor from Bosch part number 17025 that might work if not ill be extending the wires with cable.

[Molez93]

Originally Posted by NicksM

Hey Molez93 I wish I would of came across the thread a little sooner, I installed mine about 3 weeks ago and left the o2 uninstalled from down pipe and got the car tuned and I guess that's why the check engine light keep coming back for secondary 02 sensors just be glad Velos did the install. the mayor issue was tightening the bolts on the driver side with the drive shaft in the way and almost no way to hold the bolts from the back of it, also I had issues with the flange that mates to the turbo not being in the correct angle, and not being close enough. I'm currently looking into a universal 02 sensor from Bosch part number 17025 that might work if not ill be extending the wires with cable.

Yeah... kinda blows. While Velos didn't do the install, the rep I spoke to when buying the tune stated "Sure. Basically any DP solution will work, but you might have some fitment issues with them [Racing Dynamics]." That was a respectful warning which made sense at the time and was even more appreciated once my indy shop did encounter issues. [Hey they cautioned me. I made the choice.]

I too looked for universal O2 sensor options because driving with a CEL/SES light alone was annoying. In discussing the issue with Velos, they made it clear the O2 wires need to be receiving a reading for the vehicle to run right. I assumed the ECU would be sensing a lean situation all the time without function O2 sensors. As a result I also figured it would only be a matter of time before running without the O2 sensors hooked-up/functional would lead to failed Cats from so much extra fuel [combating the lean conditions "detected"] and all the fun which comes with replacing cats on an M vehicle.

[NicksM]

I found some 33'' O2 sensor wire extensions on Bimmerworld currently under the E9x M3 platform they look like the same connectors and they are also used for the secondary O2 sensors i just bought them last night and when i get them and install them ill post here updates.

[philly42]

Molez93, the O2 sensors for the cats do not regulate air/fuel ratio, so you don't have to worry about your cats getting damaged. Keep in mind running rich is a lot safer than lean. I'd rather replace cats than a headgasket

This is why I suggest getting bosch universal sensors cats. I would caution you to use the universal sensors for up-stream (pre-cat) unless you are really good with electrical wiring and use a multi-meter to test the resistance.

Racing Dynamics probably placed the bung further down to achieve proper emission readings to not throw a CEL.

[Molez93]

Originally Posted by philly42

Racing Dynamics probably placed the bung further down to achieve proper emission readings to not throw a CEL.

Given my rather annoying, drawn-out experience in with their sales and service, I find it impossible to believe it's their engineers who have their s#%t together while the rest of the organization seems "fly-by-night." My guess at why their bung was placed where it was? Incompetence. ...or at a minimum insufficient on vehicle testing which would *still* look a lot like incompetence.

[philly42]

Originally Posted by Molez93

Given my rather annoying, drawn-out experience in with their sales and service, I find it impossible to believe it's their engineers who have their s#%t together while the rest of the organization seems "fly-by-night." My guess at why their bung was placed where it was? Incompetence. ...or at a minimum insufficient on vehicle testing which would *still* look a lot like incompetence.

Agree...they could of at least include a wiring harness of some sort with the DP. Nobody likes surprises when they are in the middle of installing a product...Especially name brand.