DIY - Lengthen Oxygen Sensors For JHM V1 Headers B6/7 S4

If you have the JHM V1 headers, you’re going to need to lengthen your oxygen sensors so they fit. Definitely an easy job, but at the same time you want to take your time and do everything in the right order. You’ll see what I mean.

Here’s the final product vs. a factory sensor.

Some tools to get you through this DIY.

  • 22 gauge wire (about 25 feet)
  • 20 heat shrink butt connectors
  • heat shrink wrap
  • wire sheathing
  • wire cutters
  • wire strippers
  • crimper or some pliers/vice grips
  • heat gun

I chose to use butt connectors vs. soldering because I’ve heard from multiple electrical engineers that you can affect the resistance if you leave lumps in the connection.

I chose some really high temp (1200 degrees Fahrenheit) sheathing which is not necessary so get what you feel like.

The first thing you’re going to want to do is make your first cut through all 5 wires. I chose near the plug.

After the cut the wires you want to make sure you slide your new sheathing on. I forgot it the first time and ended up cutting the butt connectors off so I could get it on. Because they were already crimped they were garbage. Slip the heat shrink wrap over the wires. Then 1 by 1 add the butt connectors to the end of the wire and crimp it on there. Take 2.5’ of wire and add it to each wire using the butt connectors. Add another 5 butt connectors to the end of the newly added 2.5’ of wire. Then make the connection to the plug and hit the connectors with your heat gun.

Then slide your heat shrink over the connectors and shrink those with the heat gun too.

Spread the heat sheathing out so it goes up to the plug and down over the stock sheathing and you’re done.

Now you just need to go and cut all the zip ties holding the wires in different locations, run the new sensors, and zip tie them to all the same locations, if you can :wink:

Here’s JimmyBones’ DIY for instructions on the rest.

Any questions? Don’t be afraid to ask.