Installed an aftermarket water temperature sensor. Perhaps I should be making a new "DIY" thread specific for it instead of posting the details on here:
Parts I used:
1. aftermarket a-pillar gauge holder (optional)
3. temperature sensor
4. hose adapter (advice: purchase one with a 'grounding screw')
7. two radiator hose clamps
Tools I used:
1. appx. 1/16" diameter rod, 16" long (clothes hanger will work)
2. Electrical tape
3. Solder or electrical butt connectors
4. Knife or a saw (to cut through the radiator hose)
5. two ring terminals (for the ground wire)
6. a drill (if using an after market a-pillar gauge holder, to make holes for the wires)
7. bucket to catch the coolant
8. rag (to wipe off spills)
9. screw driver
11. zip ties
12. plumbers tape
Step 1: Disconnect the battery.
Step 2: Drain the coolant by removing radiator plug at the bottom of the radiator. Once the coolant begins to drain, remove radiator cap to help it drain quicker.
Step 3: remove upper radiator hose clamps, remove the hose and cut it in half :
Step 4: Install water temperature sensor adapter and secure it with clamps:
Step 5: connect the aftermarket water temperature sensor to the adapter using plumbers tape, re-install the radiator hose.
Step 6: install a ring connecter on one end of a new 5 foot long wire and connect it to the newly installed aftermarket water temperature sensor.
Step 7: run the other end of this wire towards the firewall and secure it with zip ties to the existing wire harness (use common sense). Continue running it along the firewall to the driver side using the same technique.
Step 8: using electrical tape connect the end of this wire to the 1/16" metal rod and gently push it through the firewall (use the center of the existing black rubber grommet). Just don't force it. Insert it only 12 inches or so:
Step 9: go inside and try to locate it under your dash using a flash light. In my opinion this is the most difficult part of this task. You may have to ask for someone to help by shaking the rod from the outside so you could search for it with your hand instead of getting a visual on it. Once you have it in your hand, carefully pull it down and towards you and disconnect 1/16" rod from it (you will need that rod again later).
Note: Steps 10-14 are for the folks who will be using an after market a-pillar gauge holder
Step 10: place the aftermarket a-pillar over an oem a-pillar to identify the exact height where you want your gauge to be. Using a pencil mark the bottom end of an aftermarket a-pillar on the oem pillar.
Step 11: remove OEM a-pillar cover by pulling the top first. Its clipped and should easily come off.
Step 12: align both a-pillars using the reference line you drew with a pencil. Use electrical tape to secure them together. Now drill two 1/16" holes at the top and at the bottom of the aftermarket a-pillar cover to be used for the screws to be able to later secure an aftermarket a-pillars to the oem a-pillar.
Step 13: drill 1/4" hole through the oem a-pillar so that you could pass the gauge wiring through it. The hole shall be visible through the round gauge opening of the aftermarket a-pillar and shall be big enough to pass 3 wires through it.
Step 14: use 3/8" short screws to secure both a-pillars together. gauge pod to the a-pillar cover.
Step 15: remove ash tray and the two screws behind it (do not remove the center screw) and pull the 9v outlet assembly out.
Step 16: locate 2 wires coming from the bulb that illuminates the ash tray. RED w/black stripe is a negative (ground wire), solid RED is a positive wire. Connect a new 5' long red wire to existing solid red ash tray bulb wire. Then connect new 5-foot long black wire to the existing red w/black stripe ash tray bulb wire. Best is to use a solder. If you don't have one, or don't know how to use one, just use electrical butt connectors and electrical tape.
Step 17: run both new wires behind the dash, above the pedals, towards the a-pillar. Use zip ties to secure new wires to the existing wire harness (use common sense). You don't want new wires to hang low and to accidently step on it while pressing pedals. Once you both ends of new wires reach as far as the fuse box (under the dash) go to the next step.
Step 18: using 1/16" rod, carefully insert it from above where the dash meets the a-pillar. Using the flashlight you should be able to see it, if not, ask someone to shake the rod from above while you search for it with your hand. Once you are able to locate the rod, pull it just enough to be able to secure all 3 wires using electrical tape. Yes connect 3 wires. The third wire is the one you ran through the firewall earlier.
Step 19: pull the 1/16" rod from above to get 3 wires connected to it out. Once the wires are out, disconnect them from the 1/16" rod.
Step 20: run these 3 wires through the oem a-pillar using the 1/4" hole you drilled earlier.
Step 22: install the oem a-pillar cover, bottom first.
Step 23: run the 3 wires from the back of the after market a-pillar through the round gauge opening.
Step 23: attach the aftermarket a-pillar to the oem a-pillar by using 2 screws.
Step 24: connect the wire from the new water temperature sensor to the gauge's green wire. Connect positive ash tray bulb wire to the gauge's red wire. Connect ground ash tray bulb wire to gauge's black wire.
Step 25: install radiator plug and fill-up radiator with 50% antifreeze 50% water. Start the car and bleed coolant as necessary to get all air bubbles out:
Step 26: Enjoy