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Looks like Nissens beat me to it. Nissens radiators now come with the requisite rubber adapter and plastic plug in a parts bag inconspicuously buried under the rad behind a cinched piece of cardboard. There's no hint of their existence on the packaging that these are included. There's certainly no hint in any on-line catalogues or pictures that these are now included (except perhaps the official Nissens catalogue which I don't have access to). Many catalogues mention a need for the plug and some even give part numbers, but my local supplier couldn't find any in stock -now I know why.
In any case, I apologize for casting aspersions on Nissens. They're certainly one of the most popular aftermarket brands. Just hope their rads last as long as the Volvo ones (apparently made by Blackstone which are difficult to source in the aftermarket). The Nissens installed some years ago by the P/O in my 940 turbo is still looking good. There is no sensor hole in the later Nissens turbo rads.
I must say that the Nissens fitment was perfect, right down to the trim attachment screw holes. There's also a drain plug on the bottom just below the main outlet hose. In the good old days you sometimes had to disconnect the lower hose to drain the rad.
As for installing the plugs in the rad sensor hole, I'll offer a few notes here in case this helps someone (this may later be found in the FAQ). The plug is simply a friction fit, but a tight one and would not likely be the first thing to blow if the rad pressure went abnormally high for some obscure reason. The rubber adapter/grommet/sleeve pushes easily into the sensor hole. Then you push the plug into the rubber adapter. The plug has a rough surface to hold it in place. It's virtually impossible to push it in by hand, although with a suitable tool and enough force you may be able to twist it into place. I've heard of someone using a hammer to set it in, but I don't think that's a great idea as it's hard to get the plug started straight and you risk damaging the rad in any case. The proper way to install it would be with a press. For me, it was quite easy just using a largish C-clamp with a block of wood on the back side of the plastic tank for protection. Upside down in a bench vise or even in a workmate would also work fine. Very large pliers would work, but you'd have to be careful to protect the tank. Install everything dry -there should be no need for RTV or any other sealant with a new installation. If you really are worried about the plug popping out then I heard one suggestion to use a zip-tie around the tank -the plug has a wide slot in the face that would be perfect for holding a tie in place.
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Dave -940's, prev 740/240/140/120 You'd think I'd have learned by now
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