Installation Of Universal Oxygen Sensor (07.4/03)

Publication date: 1998-04-01
Reference number: 07.4/03

INSTALLATION OF UNIVERSAL OXYGEN SENSOR

TECHNICAL SERVICE BULLETIN

Reference Number(s): 07.4/03, Date of Issue: April 1998

ENGINES 110.984/985, 116.960/961/962/963, 117.982/983/985/986, INSTALLATION OF UNIVERSAL OXYGEN SENSOR

Model(s): Mercedes-Benz

Group: 07 - Engine Combustion

Bulletin No.: SI-MBNA-07.4/03

Date: April 1998

SERVICE INFORMATION

The original oxygen sensor for the above referenced engines is no longer available. Engines can be equipped with shielded and unshielded oxygen sensors. An unshielded universal oxygen sensor is available as a replacement and before installation must be modified as described below. Should the replacement oxygen sensor be installed in a vehicle where the previous sensor was shielded, an additional test step must be performed. In this case please refer to step 4.

Remove old oxygen sensor from vehicle.
Measure 2 1/2" (63.5mm) from the end of the oxygen sensor and cut the pigtail at that point. Retain the pigtail and discard the oxygen sensor (Fig 1 ).
Strip approximately 1/4" (6mm) of the insulation from the pigtail using a wire stripper. Care must be taken not to damage wire core (Fig 2 ).
NOTE: Perform step 4 only if vehicle was equipped with a shielded oxygen sensor.
Strip approximately 1/2" (13mm) of plastic insulation protecting the shielding mesh with a sharp instrument such as a knife. Strip 1/2" (13mm) of the shielding mesh and carefully trim away with sidecutters.
NOTE: Do not damage the wire core (Fig 3 ).

CAUTION: Use extreme care when stripping the plastic insulation to avoid injury.
Remove new oxygen sensor and heat shrink tube from package. Slide heat shrink tube over end of oxygen sensor connector (Fig 4 ).
Insert end of pigtail into splice connector of oxygen sensor (Fig 5 ).
Crimp splice connector using crimping tool (Fig 6 ).
Slide heat shrink tube over splice connector. Heat shrink tube must cover and evenly overlap splice connector (Fig 7 ).
Apply heat using a heat gun (arrow, Fig 8 ) and shrink tube evenly over the connector. The heat shrink tube must make a watertight seal. Care must be taken to avoid burning the shrink tube. The thread of the oxygen sensor is pre-greased with "anti-seize" compound. Do not wipe off! Install oxygen sensor into exhaust system and connect lead to vehicle harness.