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Stolen cat: new Denso 02 won't plug in to receptacle

Discussion in 'Gen 2 Prius Main Forum' started by Gen2BlueStripes, Dec 13, 2023.

  1. Gen2BlueStripes

    Gen2BlueStripes Junior Member

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    Stolen cat on our 2004 Prius. I bought ebay item 193690871378 and amazon item B000C5WCUO per recommendations on this site. (Thanks a million, all y'all!) (Not allowed to post links, sorry.)

    I didn't like the "for Calif. Equip" part of the O2 sensor description on the Amazon listing because I don't have a CA Prius, but it worked for AndyFromWI, so what the hey? (I also didn't like that the description says "Square Plug Harness" while the image is of a rectangular plug.) It arrived and the plug is square, as is the existing receptacle. Sounds like a win. Unfortunately, the plug and the receptacle will not mate. Insertion is possible, but there is no click connection and the depth of penetration doesn't seem adequate for physical contact between the two parts. Any idea what gives?

    Additional info: it seems the thieves forcibly yanked the cat with O2 away, rather than snipping the sensor's wires. The plug at the end of the original O2's wires was separated from the receptacle, with some of the plastic snapped off. I'm not certain, but some plastic on the receptacle end might also have broken.

    What are my options for getting my vehicle back on the road?
     
  2. mr_guy_mann

    mr_guy_mann Senior Member

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    It's certainly possible that the body harness connector was damaged.

    If the connectors fit together enough that the sensor can work, then I would use zip-ties (length-wise) to keep them in place.

    Ideally, you would use a scantool to check O2 sensor function (the signal varies from 0.0 to 1.0V as you drive).
     
  3. Tombukt2

    Tombukt2 Senior Member

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    There are O2 sensors that come with a universal plug or several plugs in the kit that split and the pins go in and you close the two halves of the plug together and that's that so I'm not sure without pictures what you've got going on I understand the cat was ripped out of the car along with the wires to the O2 sensor that were just left and something got ripped apart You can follow the wire and it goes under the seat somewhere like that and there's a plug You could replace that section or something along those lines there should be a lot of videos on YouTube about universal O2 sensor replacements regarding Toyota in particular I know there were several I don't know what's out there today for exactly this model but I'm sure they're covered.
     
  4. TMR-JWAP

    TMR-JWAP Senior Member

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    EVERY Gen 2 Prius in the US is a "California Equip" model.
    If you purchased a DENSO, it should be model 2344623 and is an exact fit. These are available from ROCK AUTO for $52. I'd bet a coke that anything DENSO you buy on Amazon is likely counterfeit.

    Whan a connector breaks, it's usually the retaining clip, so it may never actually click into place again. As mentioned, plug it in as you normally would and either ziptie it or tape it together.
     
  5. Gen2BlueStripes

    Gen2BlueStripes Junior Member

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    Thank you, mr_guy_mann; good suggestion and good data to have. Looking at it in daylight I've reversed my thinking that it wasn't inserting far enough to make contact, so I'll try the zip-ties and hope for the best.
     
  6. PriusCamper

    PriusCamper Senior Member

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    Last cat theft gen2 I worked on the thief was able to pull on O2 sensor plug wire so perfectly that it came unplugged. Could that of happened with you, but the plastic tab that holds plug in was broken?

    But, in general, I'm confused because you said it doesn't fit, but you also said it did fit, just no click.

    The real question is: Did they sell you the exact same plug or not?

    Maybe post some pictures of both plugs?
     
  7. Gen2BlueStripes

    Gen2BlueStripes Junior Member

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    [​IMG]
    Image credit: Amazon (Error message trying to use "Upload a File," so none of my own pics yet.)

    I know for a fact a small bit of the square plastic connector on the stolen sensor broke off. Quite possibly something also broke on the car side connector; I just can't be positive yet. It certainly doesn't snap together. I made one unsuccessful zip tie attempt today (had to move the vehicle before I could finish). I'll have another try when I have daylight again.
     
  8. Tombukt2

    Tombukt2 Senior Member

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    You'll figure it out can't be that complicated without any pictures and nobody can see anything I know what all the plugs look like I even have some laying here on the floor but I don't know what you've got.
     
  9. Gen2BlueStripes

    Gen2BlueStripes Junior Member

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    Apologies, the title was supposed to say "won't fully plug in;" I don't see a way to edit the title.

    I zip tied the two pieces together, as suggested.
    [​IMG]
    I have a P0037 that returns within seconds of clearing it, so I cut the cable ties to try again, and to take photos.

    [​IMG]
    [​IMG]
    On this side view photo, I'm assuming that is the release on the left. (It depresses a bit.) On the new part there is what looks like a corresponding lip that would be the other side of the click connection. The pieces won't press together far enough for the car side piece to grab onto the piece at the end of the 02 wires.
     
  10. Frontporch

    Frontporch Member

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    Its a long shot but make sure that the pins on your new sensor are not bent. I trust things leave the factory without defects, but I don't always count on being the first person to install a part with today's liberal return policies.

    I also had my O2 sensor wire yanked out but was happy to find that the OEM harness side was not damaged and the O2 sensor must have unclipped itself before any wires were damaged.
     
  11. Tombukt2

    Tombukt2 Senior Member

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    A lot of times if your cat hasn't been stolen yet it's a good idea to break the tab on the O2 sensors clip or tang that locks in to the cars provided plug this way here if somebody cuts and yanks it breaks away free leaving the cars wiring intact It's kind of like knowing somebody's going to do this before they do You could put a dab of goop if you think this thing is going to come unplugged or a piece of black tape soon as they yank it it'll just slide apart rather than pull out the pins or do any craziness this happens a lot to halogen light plugs that have gotten overheated from years and years of well usage a lot of time those little locking tabs will break off the first time you push down on them but it doesn't matter because it's not like the headlights are going to come unplugged on the fly.
     
  12. Gen2BlueStripes

    Gen2BlueStripes Junior Member

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    Thanks for the suggestion, Frontporch. It does feel like the pieces are not aligning properly, but no particular part is visibly bent. Could the car side part be damaged instead? I've thought about ordering that piece as a way to check.

    Never having seen a mated pair, I'm unsure whether I've identified things correctly. Here's a new photo that I've marked up with my guesses:
    [​IMG]
    I think the area circled in green is where I would press to release a mated pair; the bump circled in blue is what the car side piece needs to grab; and the edge that the yellow arrow points to is what the bump needs to slide under. This picture shows how far away the bump is from where it needs to go, at the point the O2 connector hits solid resistance.
     
  13. Frontporch

    Frontporch Member

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    At first it didn’t look right to me but now I think it just needs a little finesse. How about put pressure on it and rock a little to see if it’s hung up on something? It does still have a way to go before it clicks and locks. Once it starts to move give it a good push until it clicks. Not sure why it’s resisting I wouldn’t think you need to depress the green lever to get them together but that wouldn’t hurt to try either

    In 2022 I bought the Prius that had the O2 sensor yanked from the harness. This sensor from amazon worked and was in my purchase history

    Denso 234-4623 Downstream Oxygen Sensor with 23” 4-Wire Square Plug Harness for Calif. Equip
    https://a.co/d/ej0z7t8
     
    #13 Frontporch, Jan 3, 2024
    Last edited: Jan 3, 2024
  14. Gen2BlueStripes

    Gen2BlueStripes Junior Member

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    Thank you, Frontporch.

    As mentioned in the OP, Amazon item B000C5WCUO, "Denso 234-4623 Downstream Oxygen Sensor with 23” 4-Wire Square Plug Harness for Calif. Equip" is what I purchased and am trying to install.
     
  15. Frontporch

    Frontporch Member

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    Seems like you should be good to go. Can you share a picture of your O2 sensor end showing the pins?
     
  16. Gen2BlueStripes

    Gen2BlueStripes Junior Member

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    Hard to get a good picture of the plug; best I have so far:
    [​IMG]
     
  17. Gen2BlueStripes

    Gen2BlueStripes Junior Member

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    Another attempt:
    [​IMG]

    I've ordered this $10 pigtail:
    [​IMG]
    Image credit: amazon.com

    If my 02 sensor won't plug into the new pigtail, I'll assume the sensor's plug is defective and I need to return the sensor.
     
  18. Gen2BlueStripes

    Gen2BlueStripes Junior Member

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    The pigtail was clearly not the correct piece, so I've ordered a different one.

    Per a suggestion above, I ordered a Denso O2 sensor from Rock Auto. It's exactly the same as the one from Amazon and also doesn't fully connect to the car side.

    Here is a head on image of the car side connector:
    [​IMG]
    To me it looks odd in that the red or orange rubbery part is visible on three sides, but on the fourth side (where the presumed latching mechanism it barely visible at all; instead I see the hard gray plastic. Should the rubbery thing be visible on four sides, three sides, or not at all?
     
  19. Frontporch

    Frontporch Member

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    You found your problem. There was a part of the old connector wedged in there still. Pull out with some pics and celebrate

    I looked back on the other pictures and nothing was as clear as that last picture. Hopefully you can return the Amazon O2

    the orange is a gasket to make it moisture proof and should seal all around to the new O2 sensor connector
     
    #19 Frontporch, Jan 10, 2024
    Last edited: Jan 10, 2024
  20. Gen2BlueStripes

    Gen2BlueStripes Junior Member

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    Thank you, Frontporch!!! Now it all makes sense, including why it felt like something hard was blocking full insertion of the new plug.

    It took a few tries to figure out a technique to dislodge the piece that stayed behind, but here it is:

    [​IMG]

    The O2 sensor is finally plugged in! Now I can clear the P0037 and do a bunch of fingers crossed driving that I don't get a P0040.

    The Denso O2 sensor from Amazon was already installed in the cat; I'm not going to remove it to return it to Amazon. I'll have to resell or return the one from Rock Auto.