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Dear Blindboy,
Hope you're well and stay so. Put the black rubber grommet in hot tap water and let it sit. That softens the rubber slightly. Take some dish-washing liquid soap and coat the outer edges of the grommet. Then press the grommet into the radiator's side-tank opening. It is OK to use a small, flat-blade screwdriver (1/8"-wide tip) to press the grommet into the opening.
Once the grommet is seated, clean the sensor's side with steel wool (if you're replacing the in-service sensor). Then, coat the sensor with dish-washing liquid soap and press the sensor into the grommet. This will take some finger power!
Once the sensor is seated fully, you need to wire the sensor in place, so it doesn't work loose. First, drill a 1/16" hole in the corner of the radiator fin closest to the engine. Then take 12" of brass wire. Run the brass wire through the hole in the radiator fin and then between the sensor's contacts. Make sure the brass wire does not touch either contact.
Then, wrap the brass wire around the brass hex fitting on the radiator's side tank (the hex fitting below the just-installed temp sensor). Bring together the two ends of the brass wire near to the radiator fin with the small hole in it. Twist both ends of the wire, using a pliers, to snug the wire. Finally, cut-off extra brass wire and file the cut ends, to smooth them. This will ensure the sensor stays in place.
Hope this helps.
Yours faithfully,
Spook
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