OXYGEN SENSORS

NTK Oxygen Sensors manufactures and supplies over

half of original equipment (OE) oxygen sensors.

 




    
 
 

  

  
  
 

  
  !
   


Dual-coated Platinum element Water resistant connector

Increases longevity and ensures Protects against water
quickest response time contamination related failures

3-stage element overcoat Fast light-off times

Provides superior protection Reduced time spent in open-loop
against element contamination mode: decreases emissions,
increases fuel economy

Variety of protective sheathings Pure alumina ceramic

Resists high temperatures with variety of Protects the sensor element
   
 
  exhaust gas

99.5% VIO COVERAGE

ngksparkplugs.com/ntk
Tech Support: (877) 473-6767 ext. 2
 TECHNOLOGY

TITANIA
T WIDE BAND ZIRCONIA
(5-WIRE)
 !! • The most
require outside • NTK is one of common
reference air the pioneers of sensor and is
wide band sensor usually found
• Features a technology downstream of
smaller element the catalyst in
to shorten • Wide band newer vehicles
light-off time sensors monitor
the air fuel • Available
• Available ratio to a in 18mm
in 12mm higher degree thread size
and 18mm of accuracy to
thread size provide precise
ratio control

TESTING &
MANUFACTURING

NTK Oxygen Sensors must pass extensive

testing procedures and quality checks to
 
 


• Mechanical vibration testing

• Thermal shock testing to -40°F
• 

   

manufacturing facility
• 




10-0822171

ngksparkplugs.com/ntk
Tech Support: (877) 473-6767 ext. 2
SS-0817-OS2
Questions and Answers on Oxygen Sensors
 Q1 Q: What is an Oxygen Sensor?

A: An emission control component that senses the

presence of oxygen in the exhaust stream.

2
Q: Why is an
Oxygen Sensor needed?
Q2
A: Vehicles are one of the leading causes of air pollution in the
world. As a result, government legislation has enacted regulation in
many parts of the world to reduce vehicle emissions and increase fuel
efficiency. By more closely controlling a vehicle’s air fuel ratio, fuel
efficiency can be increased, while tailpipe emissions are reduced.

The oxygen sensor functions as the eyes and ears for the ECU.
Its role is to communicate with the ECU whether a vehicle is running
rich or lean. The goal is to have the engine run close to 14.7 parts of
air to 1 part of fuel. 14.7:1 is known as the Stoichiometric Point. At this
point, optimum combustion under normal conditions occurs and the
least amount of harmful gases are produced.

Smog filled skyline due to air pollution

3
 Q3 Q: How does an
Oxygen Sensor work?

A: The sensor becomes operational at approximately 350˚C (650˚F).

At this point a chemical reaction occurs producing a

high or low voltage based upon high or low levels of
oxygen in the exhaust stream.

The oxygen sensor generates 800-1000 mV when the

exhaust gas air/fuel ratio is rich. It will generate
100-200 mV when the exhaust gas air/fuel ratio is lean.

Output Voltage vs. AFR

800 - 1000 mV

Voltage
[mV]

100 - 200 mV

RICH LEAN
(Low Level of Oxygen) (High Level of Oxygen)

14.7:1

4
Q: Does my vehicle
have an Oxygen Sensor?
Q4
A: Most vehicles produced for the North American market after
1981 have at least one oxygen sensor.

EPA laws required the introduction of oxygen sensors to

decrease vehicle tailpipe emissions and improve fuel efficiency.

Early 1 Wire Sensor Design

5
 Q5 Q: Where are
Oxygen Sensors located?

A: Vehicles produced before 1996 (OBDI) will have one or two sensors upstream of
the three-way catalyst (catalytic converter). Vehicles produced after the 1995 model
year (OBDII) will have oxygen sensors both upstream and downstream of the three-
way catalyst.

To explain the sensor locations as found on a scan tool, you must first find the
#1 cylinder location. Bank one (1) will always be the side of the
engine with the #1 cylinder. Sensor one (1) will always be upstream
of the three-way catalyst, while sensor two (2) will be downstream.

To determine left and right, as this is how the sensors are cataloged,
you must first establish the front and rear of an engine.

Front will be the side of the engine with the accessory drive belts for
alternator, air conditioning, power steering, etc.

The left side of the engine will be the side to the left of the accessory drive belts when
standing behind the engine. The right side of the engine will be the side to the right of
the accessory drive belts when standing behind the engine.
B1 S1
(Bank 1 - Sensor 1)

B1 S2
Exhaust Bank 1 (Bank 1 - Sensor 2)
Cylinder Bank 1

V6 / V8 / V12 Catalyst Tail Pipe

Exhaust Bank 2
Cylinder Bank 2

B2 S1
(Bank 2 - Sensor 1)

6
Q: Where are
Oxygen Sensors located?
L4 Cyl. Engine
Q5
1 B1 S1
(Bank 1 - Sensor 1)
B1 S2
(Bank 1 - Sensor 2)
Exhaust Bank 1

2 Catalyst Tail Pipe

3
4

B1 S1 B1 S2
(Bank 1 - Sensor 1) (Bank 1 - Sensor 2)

Catalyst Tail Pipe

Exhaust Bank 1
Cylinder Bank 1

V6 / V8 / V12
Exhaust Bank 2
Cylinder Bank 2

Catalyst
Tail Pipe

B2 S1 B2 S2
(Bank 2 - Sensor 1) (Bank 2 - Sensor 2)

7
 Q6 Q: What are “Open Loop”
and “Closed Loop” modes?

A: Open loop mode is the period of time before the oxygen

sensor becomes operational, usually at vehicle start up. It is
also the default mode should a sensor problem occur.

Closed loop mode is the desired mode where the oxygen

sensor is operational. At this time AFR and exhaust emissions
are being controlled.

ENGINE
OXYGEN
Closed loop OBD I

CONTROL
UNIT SENSOR

AIR FUEL THREE

MIXING ENGINE WAY EXHAUST GAS
SYSTEM CATALYST
FUEL

FUEL INJECTORS

INTAKE AIR
via Throttle Position

ENGINE
Closed loop OBD II

Air / Fuel
Mixture
AFR
Adjustment

t
en
tm
us
j
Ad

OXYGEN SENSOR
UPSTREAM THREE WAY
CATALYST
Controls
AFR
EXHAUST

ECU
OXYGEN SENSOR ,
(ection of CAT deterioration
DOWNSTREAM ,

AFR compensation

8
 Q: What are the components of
a Zirconia type Oxygen Sensor?
Q7

Silicone Varnished
Hexagon size Silicone Rubber Glass Sleeve
Protector Tube 22mm Grommet

Gasket Connector
Thread size
18mm
Typical Completed Unit

Wiring Harness and

Heater Element

Sensor Body

Metal Cap Talc Ring Shell with Zirconia Protector

Hex Element Tube

Typical Components
Note: The images above represent a typical oxygen sensor and its components. Each
oxygen sensor part number is unique in its own way and the image’s appearance and
component vary based on the part numbers specification.

9
 Q8 Q: What are the different types
of Oxygen Sensors?
Zirconia Titania
A: Zirconia Heated AFR Se
ns
Unheat e
ed Wide B or
w ir and
1,2,3 ,4
s Most popular (90% of the market)
s 1-4 wire configuration
s Heated or unheated
s Thimble or Planar type
s 18mm thread size
s Requires reference air

1 wire (unheated sensor)

s Signal wire
s Ground achieved through sensor body (earth ground)

2 wire (unheated sensor)

s Signal wire
s Ground wire (ground achieved through case or isolated ground)

3 wire (heated sensor)

s Signal wire
s Ground achieved through sensor body (earth ground)
s Two heater wires

4 wire (heated sensor)

s Signal wire
s Ground wire (ground achieved through case or isolated ground)
s Two heater wires

10
 Q: What are the different types
of Oxygen Sensors?
Q8
Titania

s Always heated (3 or 4 wire)

s Requires no reference air
s Typically 12mm but some 18mm thread sizes

Q Are Zirconia and Titania sensors interchangeable?

A NO - Zirconia produces a voltage (less than 1v) while Titania require a
voltage. Resistance is then measured and AFR is controlled accordingly.

AFR Sensor (4 wire)

s Similar structure to conventional

(switching) type Zirconia oxygen sensors,
but uses limiting current characteristics to measure AFR.
s ECU creates voltage variance across the sensor’s electrodes-the potential
difference is 300mv and current will be generated as needed to maintain a fixed
voltage of 300mv. This limiting current is used for O2 sensing and is linearly
proportionate to the amount of oxygen present.
s Thimble or Planar type
s Free of reference air
s Measures air/fuel ratios from 10:1 to 18:1

Wide Band Oxygen Sensor (5 Wire)

s Monitors AFR to a higher degree of accuracy- provides precise control of AFR.

s Wide Band sensors require a controller which is pre-programmed to control AFR
at desired point (usually Stoichiometric point)
s Wide Band controller then sends signal to ECU for fuel trim adjustment
s Measures air/fuel ratios from 10:1 to 18:1

Q Are AFR sensors and Wide Band oxygen sensors interchangeable?

A NO

11
 Q9 Q: What are the obvious signs
and impact of worn Oxygen Sensors?

A: The most obvious sign an oxygen sensor is failing or has failed is a

check engine light. Vehicles are designed to inform the driver if there is
a problem with the emissions system. A check engine light may point to
a problem with the emissions system but does not necessarily mean the
oxygen sensor is faulty.

Other signs of worn oxygen sensors are increased fuel consumption and an
increase in vehicle emissions.

12
Q: How can I check my Oxygen Sensors
to ensure they are working properly?
Q10
A: There are three (3) ways a sensor can be checked to see if it is
functioning properly.

A professional repair shop will have scan tools to check sensor operation.

Advanced shops may have a tool called an oscilloscope. This tool will graphically
display oxygen sensor output as it switches voltage from high to low.

Removed from the vehicle, a oxygen sensor can be checked using a common
multi-meter to check for heater resistance. In the case of a faulty heater
element, the resistance will read as an open circuit.

Scan Tool In Use

13
 Q11 Q: What can shorten the life
of an Oxygen Sensor?

A: Common causes for oxygen sensor failure are poisoning

from substances such as engine coolant, silicone gasket
materials or soot.

Often these problems can point to other mechanical issues

with an engine.

Thermal shock from raw fuel or moisture in the exhaust can also cause a sensor
heater element to crack.

The root cause of the problem should be addressed along with replacement of the
oxygen sensor if needed.

PROBLEM - PROBLEM - PROBLEM -

Lead Poisoning Excessive Carbon / Soot Deposits Silicone Contamination

SYMPTOM - Shiny deposits are SYMPTOM - Thick soot deposits lead to SYMPTOM - White deposits are
evidence of lead in the fuel. Lead blockage of the sensor protection tube evidence of silicone poisoning.
attacks the precious metal of the and have a negative effect on reaction Silicone based adhesives/products
sensor element & the catalytic time. Causes can be a mixture that is too will contaminate the sensor element.
converter. fuel-rich or the result of damage to the
sensor heater. SOLUTION - Sensor must be removed
SOLUTION - Sensor needs to be and replaced with new sensor; care
replaced and care taken to use only SOLUTION - Sensor must be replaced in must be taken to use ONLY “oxygen
lead-free fuels. all cases with new sensor. sensor-friendly” products.

14
Q: What can I tell from visually
inspecting an Oxygen Sensor?
Q12
Problem Solution

Wires melted Replace with new

by contact sensor and route
with exhaust without touching
the exhaust

Frayed or broken Replace with new

wires sensor and make
sure there is some
slack in the wires

Wire Grommet is Replace with new

loosened water may sensor and make
enter the sensor sure there is some
slack in the wires

15
 Q12 Q: What can I tell from visually
inspecting an Oxygen Sensor?

Problem Solution

Sensor is bent Replace with

new sensor

Soot deposits are Diagnose and correct

blocking the openings fault. Note: Excessive
of the protective deposits of soot and oil
sleeve, due to on the protective sleeve
fuel-rich mixture or are not caused by the
high oil consumption sensor itself
because of wear on
engine or valves and
leaks in the exhaust
system

Water in the connector Replace with new

sensor. Check electrical
connections to connector
seal and also the
connection between
the sensor and the
engine control unit

16
Q: What is a Universal
Oxygen Sensor?
Q13
A: Universal oxygen sensors are designed to work on several applications,
thereby reducing the number of stocking units needed.

Universal oxygen sensors do not have factory matched connectors and

need to be spliced into place using the connector from the old sensor.

The use of universal oxygen sensors are not recommended as compatibility

and installation issues often prevent the sensor from performing as well as
an OEM matched unit.

Improper Universal Sensor Installation

17
 Q14 Q: What are the advantages of using
a Direct Fit Oxygen Sensor over a
Universal Oxygen Sensor?
A: A direct fit oxygen sensor has been engineered to ensure the
operating parameters are the same as the OE sensors.

Direct fit sensors will have the correct connectors, hardware and

wire length to ensure proper form, fit and function.

OE Aftermarket

Aftermarket sensor programs may have small

variances to the OE sensor to provide wider
coverage. For example, the picture above
illustrates the elimination of the mounting flanges
and allows the aftermarket version to be utilized
on both the left and right banks versus having two
Aftermarket part numbers, as is the case with the
OE part.

18
Q: How do I install an
Oxygen Sensor?
Q15
A: Sensor installation will first require the proper tools. A specialty oxygen
sensor socket is recommended for removal of the old sensor and installation
of a new sensor.

1. Disconnect the battery.

2. Disconnect wiring harness from the old sensor.

3. Remove any hardware or clips if applicable.

4. Use the oxygen sensor socket (shown below) to remove the old sensor.

5. Apply anti-seize compound to the threads of the sensor

(if not already pre-applied).

6. Use specialty socket to install the new sensor to the recommended torque.

7. Put in place any hardware or clips if applicable.

8. Connect the wiring of the new sensor to

the existing vehicle wiring.

9. Reconnect the battery.

19
 Q16 Q: What is the expanded role an
Oxygen Sensor plays in
OBDII vs. OBDI ?
A: In OBDII equipped vehicles there is a sensor downstream of the three-
way catalyst to monitor catalyst function and can also assist in controlling
AFR by adjusting fuel trim.

If a catalyst has failed or there is a problem elsewhere in the system, the

downstream sensor may trigger a MIL light or check engine light to warn of
a possible problem.

In OBDII, the ECU is also monitoring the condition of the sensor signal
response time, heater light-off time and heater resistance.

Downstream Oxygen Sensor

20
 Glossary
Q: What does the future hold for
Oxygen Sensors?
Q17
A: As future emissions standards become tougher for all engines, even non-
automotive applications, NTK is further developing sensor technologies to
help provide cleaner, more efficient commercial and recreational engines.
In the future, legislation will mandate emission controls on all engines. Today,
many motorcycles, snowmobiles, marine and outdoor power equipment
applications are using oxygen sensors to limit emissions.

21
 Glossary

Term Definition
AFR (Air Fuel Ratio) The measurement or ratio mixture of air to fuel for internal combustion
engines.
AFR Sensor Air Fuel Ratio Sensor. A linear 4 wire oxygen sensor which actually
measures air fuel ratio rather than producing a switching voltage. In
this type of system, a constant voltage is applied to the sensor to get a
desired AFR result.
Three-Way Catalyst Emission control component designed to convert harmful poisonous
(Catalytic Converter) gasses by heat & chemical reaction to non-poisonous environmentally
friendly gases.
s Converts - CO (Carbon Monoxide) to CO2 (Carbon Dioxide)
s Converts - HC (Hydro Carbons) to H2O (Water)
s Converts - NOx (Oxides of Nitrogen) to N (Nitrogen)
Closed Loop Condition after oxygen sensors have reached operating temperature,
AFR is controlled and emissions are reduced.
Direct Fit Sensors Oxygen Sensors that include the wiring connector.
Downstream Term referring to oxygen sensor position beyond the three-way catalyst
located in the exhaust pipe to monitor catalytic converter output.
DTC (Diagnostic Trouble Code) Code # downloaded from ECU by means of a scan tool identifying
emissions related problems.
ECU (Electronic Control Unit) A vehicle’s on-board computer module responsible for controlling
and adjusting multiple systems in real time such as fuel management,
braking, ignition, etc.
EPA
US governmental agency responsible for federal emission laws &
(Environmental Protection
mandates.
Agency)
HC (Hydrocarbons) Emission pollutant resulting from incomplete fuel combustion & fuel
evaporation.
Lean Condition of AFR. Too much oxygen is present in the exhaust. AFR is
greater than 14.7:1
MIL (Malfunction Indicator Lamp) Also known as Check Engine Light, a warning lamp on a vehicle’s
instrument cluster that informs the driver of possible emissions related
problem.
NOx (Nitrogen Oxides) Formed when fuel is burned at high temperatures. Vehicles are the
highest producer of NOx

22
 Glossary

Term Definition
OBDI Federal emissions standard prior to 1996 model year vehicles. Usually
vehicles have one or two oxygen sensors upstream of the catalyst.
OBDII Federal emissions standard after 1995 model year mandating stricter
emission control. Use of downstream oxygen sensors is required.
Open Loop Condition at start up or wide open throttle where AFR is defaulted to
rich, emissions are at its highest. AFR is not controlled by the sensors.
Oscilloscope Instrument used to measure fluctuations in electrical current where
amplitude is graphed as a temporary waveform on a fluorescent
cathode screen.
Oxygen Sensor Vehicle emission control component that senses the presence of
oxygen in the exhaust stream.
Rich Default condition of AFR in open loop mode & also the default condition
of an emission related problem. Little oxygen is present in the exhaust.
AFR is less than 14.7:1
Stoichiometric Point Measurement of AFR - where optimum combustion occurs & the least
amount of harmful poisonous gases are produced. AFR mixture at this
point is 14.7:1
Titania Sensor Narrow band oxygen sensor made of titanium dioxide that requires
a voltage rather than producing one and changes its resistance in
response to the oxygen content present in the exhaust stream.
Universal Oxygen Sensor An oxygen sensor that lacks a wiring connector. Commonly used in the
past to reduce SKU count and inventory costs.
Upstream Term referring to oxygen sensor position in front of the three-way
catalyst located in the exhaust manifold or Y pipe.
Wideband Sensor A linear 5 wire oxygen sensor which measures air fuel ratio. This type of
sensor produces a voltage from 0-5V to the ECU. The voltage produced
corresponds with a definite air fuel ratio.
Zirconia Sensor Narrow band O2 sensor made of zirconium dioxide based on an
electrochemical fuel cell that produces an output voltage at its two
electrodes comparing the amount of oxygen present in the exhaust
stream to that of the atmosphere.

23
 NGK Spark Plugs (U.S.A.), Inc.
46929 Magellan Drive, Wixom, MI 48393
(877) 473-6767 s ngksparkplugs.com

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