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O2 sensor bursting into flames!

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Old Jul 11, 2006 | 12:14 AM
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Default O2 sensor bursting into flames!

I recently installed some coated long tube headers. Instead of purchasing O2 extenders I just went ahead and spliced in some extra wire from the harness to the plug. This worked fine for about a month untill the extra wires got too close to the headers and they melted together blowing the engine sensor fuse. The melted parts of the wire corespond to the plastic burns on the headers so i'm sure heat caused them to melt together. I replaced the fuse and the melted wires with new ones and as soon as I turned on the car, the leads comming off the O2 sensor burst into flames. This time I went ahead and wrapped the headers and the wire in heat tape so heat is not the cause of the fire.
The wires that I spliced in worked without any problems before they melted together and blew the fuse. I replaced the wires exactly like the way they were before but as soon as I put in the fuse the O2 sensor lead glows red. What could be wrong? I'll take any suggestions.
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Old Jul 11, 2006 | 12:25 AM
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Buy NEW sensors and just spend the $$$ on extensions
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Old Jul 11, 2006 | 12:26 AM
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sounds like you possibly have wrong wires connected, there are two brown wires and if you mix those up im sure it will **** stuff up.
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Old Jul 11, 2006 | 12:45 AM
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Wired wrong or still shorting out. The O2 sensors have a HEATER that I can imagine draws quite a bit of current.
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Old Jul 11, 2006 | 01:22 AM
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As soon as I fix the problem I will be purchasing the O2 extensions. I have traced the individual wires from where I cut to make sure that all the colors are running to their origional connection and are not cross wired. I think it might have shorted out further up from the wiring harness but isn't that what a fuse is suposed to prevent?
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Old Jul 11, 2006 | 10:20 AM
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it would prolly be best just to buy new 02 sensors, those might be done for and something could be wrong with the sensor itself.
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Old Jul 11, 2006 | 10:27 AM
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I thought it might be a bad snesor, maybe the connection was draging on the pavement, but I tried a second O2 sensor and it did the exact same thing.
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Old Jul 11, 2006 | 10:32 AM
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are you pluggin them in the right spots?? b/c there have been some guys on here that plugged them into the rear spots not knowing the plugs are deep in the engine bay.
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Old Jul 11, 2006 | 05:41 PM
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Yes they're plugged into the correct harness if that's what you're asking. The plugs for the rears are just tucked up under the car for now.

The wiring colors match on both ends when I looked at it, I'm at a loss as well.
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Old Jul 11, 2006 | 10:11 PM
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Ok I fixed the problem! The female harness had an internal short. It must have happened when the wires melted and started to drag on the ground. I had to hard wire the O2 sensor but that should fix the problem untill the O2 extensions arrive.
THANKS TO ALL WHO REPLIED AND TRIED TO HELP ME!!!!
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Old Jul 11, 2006 | 10:19 PM
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I wish we could have seen a vid of this happening.
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Old Jul 11, 2006 | 10:53 PM
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hell yeah that would be a first to see 02 sensors burst into flames lol.
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Old Jul 12, 2006 | 12:28 AM
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No vid, but here's some pics of the crispy sensor:

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Old Jul 12, 2006 | 12:41 AM
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thats what mine looked like when it fell down and sat on the header and melted. i blew my engine sensor fuse also and just replaced the sensors with bosch sensor. got my old ones still and they work great but just wanted new ones.
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