Technical Support: O2 Dash Sensor Light Hook-up

At Acme, we like using as much of the stock Suzuki platform as possible for a consistent swap personality. So, when it came to replicating the Rabbit, Jetta or Golf glow plug light, we decided to convert the Suzuki O2 dash sensor light for use as the VW diesel glow plug light.

In order to convert the Suzuki O2 sensor light to the VW glow plug light, the first thing you need to do is to take out your dash gauge pod assembly. The easiest way to do it is to take off the lower plastic cover under the dash on the steering wheel side and proceed to unbolt the torx bolts that hold up the steering column to the frame. You need to unbolt the steering column so it will hang low enough to clear the gage pod from the emergency flasher light switch. Once the steering column is hanging, perform the following:

1. Unscrew the service engine light small switch from its mount. Switch is located right next to the steering column and tube frame. It has a blue, red and white wire soldered to the back of it.
2. Unscrew the 4 Allen head screws holding the gauge pod in the dashboard. Unplug the left and right electrical connectors at the back of the gauge pod.
3. Unplug the speedometer cable.
4. Take out the gauge pod assembly and put it on a working surface. At this time, it’s a great idea to clean the plastic surfaces from dust and stains. Unscrew the Phillips screws and carefully clean up and polish the plastic or glass lenses and collateral parts. We have found that the Meguiar's line of plastic polishes works great for this.
5. Cut the engine service switch wires (small red, blue, and white wires) next to the little plastic wire support. As an alternative you can also disassemble the speedometer unit and remove the micro switch with the wires, figure 1.
6. On the front of your gauge pod, locate the O2 sensor light. The O2 sensor location is different based on whether you have a tach or non-tach gauge pod. After locating the O2 sensor light, look on the backside of the gauge pod and find the O2 light socket that sits on the film circuit with copper traces. You can do this using a flashlight shining the light through the bulb socket when removed. The goal is to separate the O2 sensor light from the other dash lights. If you don't separate the O2 sensor light, two other lights will light up along with it.
7. Cut the copper traces on the back of the circuit film with an razor blade to make the O2 socket independent from the rest of the circuit board, figure 2. Again, the location of the traces will be different based on a tach or non-tach model gauge pod.
8. Scrape away the green coating and solder a wire on each copper trace. Solder a wire close to the light socket but not so close as to disturb the twisting action of the black plastic light socket. You need a wire soldered on each side of the copper trace, figure 3. Caution: don't allow your soldering iron to heat up the copper traces enough to melt away from the plastic film. Solder quickly and cool it down by blowing on the connection. Note: make sure you make your glow plug/O2 sensor light wires nice and long. Doing so will enable you to take out your gauge pod in the future with out ripping them off as you disassemble the gauge pod.
9. Connect one side to the glow plug relay (Black/yellow wire from the "L" pin). The remaining wire gets connected to the stock Suzuki 15 amp switched ignition at the fuse box. If you don't hook the glow plug light up this way, the relay will not work correctly and you will not be able to start your diesel motor properly.

Figure 1, Cutting the red, blue and white wires

Figure 2, Cutting the copper traces at the O2 sensor light

Figure 3, Wires soldered in position ready to be hooked up

Diesel VW glow plug relay and wiring hook-up