2. Cut the original wires, shown as blue in diagram. This is done so if any heat shrink were to ever wear off, there would be no contact of exposed wires. Use a wire stripper to strip and expose about 1/4" of wire on each new wire end. Cut heat shrink tube into (10) 1/2” long tubes.
3. Now cut (5) new strands of 16-‐ gauge wire, each 18” long. Strip and expose about 1/4” for all wire ends.
4. Mesh each new wire (shown as red) to each original wire (shown as blue) on both sides.
5. For this whole sensor, there will be (10) soldering points; they are shown in grey on the diagram.
MAKE SURE THE HEAT SHRINK TUBES ARE ON ALL WIRES BEOFRE SOLDERING.
6. Solder each point and then slide the heat shrink tubes over for each newly made connection. Shrink them by using the heat of the soldering utensil.
7. Slide on protective wire tubing, spanning the whole length of the newly extended O2 sensor.
8. Repeat steps 2-7 for the other O2 sensor.
Instructions for O2 sensor installation:
1. Start by screwing in each sensor probe in the bottom part of the long tube headers with the 7/8” wrench and tighten.
2. Reconnect the now extended O2 sensor with the sensor plug behind engine; do this for both sides. Note: make sure to loop around driver side wire around gear selector arm (auto trans) so there is no contact or rubbing.
3. Zip-tie each extended wire to a near-‐ by wire to keep them secured.
4. Repeat steps 1-3 for the rear O2 sensors; these connections are up along transmission.
5. Finally, reconnect the negative battery cable.
6. Installation is now fully complete!
7. To get car back on the ground, pump jack up so chassis is a few inches off jack stands. Remove jack stands and make sure top of car ramps are aligned with both front tires. Clear area and lower jack by slowly turning the release valve handle until car is fully resting on ramps.
8. Be sure to check that all sensors are connected, all bolts and nuts are tightened and that all connections are solid before starting up.You can now fire it up and roll off the ramps!!
- When first running, the exhaust will be smoking from the grit inside the tubing from manufacturing. This is normal and smells a bit, but this will wear off very soon.
- Drive it around for a few miles and make sure there are no unusual sounds and/or responses from the engine.
- Setup will sound a little noisier at first and will take a few hundred miles to break in for a nice deep, raspy growl.
- A good 20 horsepower is added with this system with stock mufflers.
- Even more power can be added with a custom written tune (highly recommended) and also with free-‐ flowing axle-‐ back mufflers.
Below are a few pictures of the new set-‐ up after a few hundred miles of use: