Smart O2 Simulator Installation Manual.

Typical exhaust system for 4, 6 and 8 cylinder engines.

Typical vehicle oxygen sensor locations are shown on diagram above. Four
cylinder engines would have one primary (upstream) and one secondary
(downstream) oxygen sensors. Smart O2 Simulator connects between one
primary and corresponding secondary oxygen sensor. Six and eight cylinder
vehicle requires two O2 Simulators, one for each bank.

1. Locate primary and secondary oxygen sensor(s).

2. Determine primary oxygen sensor type: Zirconia, Wideband, Tatania or AFR. Most cars
would have Zirconia type oxygen sensors (wires: white-white-gray-black). Wideband sensors
would have 5 or 6 wires. If you have problem determining sensor type check our site
Installation Documentation section or contact us.

3. If you have Zirconia or Tatania type sensors use wires marked on O2 Simulator board as
SI (Standard Input). If you have Wideband or AFR sensor use wires marked as WI
(Wideband Input).

4. For Zirconia or Tatania type sensor splice O2 Simulator wires to primary oxygen sensor.
Wire (blue) marked as S splice to sensor signal wire and wire (green) marked as G splice
to sensor ground. Use only sensor ground not chassis ground !!!
5. For Wideband or AFR sensors determine signal wire. Bosch Wideband oxygen sensors
(wires: red-yellow-black-white-grey-green) signal wire is red. For AFR sensors check our
website Installation Documentation section or contact us. Cut oxygen sensor signal wire and
connect wire from the sensor to O2 Simulator wire marked as S. Connect other end to O2
Simulator wire marked as C. For AFR sensor installation cut O2 Simulator white wire loop
and insulate wires with electrical tape.
6. Locate secondary oxygen sensor and determine sensor signal and sensor ground wires. If
you are installing two O2 Simulators make sure you have located secondary oxygen sensor
from the same bank. Cut sensor signal wire. Connect end going to ECU to O2 Simulator wire
(brown) marked as S. Splice oxygen sensor signal ground wire to O2 Simulator wire (grey)
marked as G.
7. Connect O2 Simulator power wires (black and red) to switching +12V power and ground.
Secondary oxygen sensor heater wires can be used for +12V source. Do not use heater
ground as it is switched on and off by ECU during engine operation.
8. Repeat above instructions if installing two O2 Simulators.
9. Turn the ignition on and verify O2 Simulator LEDs (light emitting diod) light up.
10. Set O2 Simulator to appropriate primary oxygen sensor. O2 Simulator default set to
Zirconia type primary oxygen sensor. To change O2 Simulator sensor type perform the
following steps. Use provided magnet and get it closer to wires on LED side of the O2
Simulator. Once you get close enough additional green LED will light up acknowledging
presence of the magnet. Hold the magnet in that position. As soon as you see green LED strip
blinks remove the magnet. O2 Simulator will go into configuration mode. One red LED will light
up indicating sensor type configuration mode. Green LEDs will also light up. The number of
green LEDs determines primary oxygen sensor type O2 Simulator is set to. (One LED
Zirconia, two LEDs Wideband, three LEDs AFR and four LEDs Tatania sensors). Use
magnet to change sensory type. Get magnet close to the device until additional green LED
lights up and move it away. Affectively you are pushing a button by getting magnet close to
O2 Simulator circuit. Every time you bring magnet close to the device green LED strip will turn
one extra LED. Once you set number of green LEDs according to the sensor type save
configuration by moving magnet close to the circuit and hold it until LEDs start to flash. Once
LEDs start to flash move magnet away. You just saved oxygen sensor settings into internal
flash memory. O2 Simulator will move to the second parameter and two red LEDs would light
up. Green LEDs will be set to four. Do not change this configuration unless advised by our
support staff. Power off O2 Simulator to exit setup mode. If you are not sure to what
parameters you set O2 Simulator to, just perform steps above again. To return O2 Simulator to
factory default settings, get magnet close to the circuit so additional LED lights up and hold it.
Green LED strip will start to flash faster and faster. Once it stops flashing, remove the magnet.
O2 Simulator parameters will be returned to factory default.
11. Start the car and verify O2 Simulator properly connected and correctly set to primary
oxygen sensor type. LED strip marked IN will start cycling up and down. You might not see
any movement until oxygen sensor warms up. If your primary oxygen sensor is wideband,
cycling of green LEDs might not occur. Give it little gas and you should see cycling of LEDs.

Please fill the table below updating color of the vehicle sensor wires simulator connected to.
It will be very useful later if you need to contact support.