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If the cylinder head is NOT attached to the engine, for instance during a rebuild, we recommend machining a slot in the spark plug counter bore to allow the sender to sit flat on the lower plane of the spark plug hole. Done correctly, the slot will not harm the head in any way. We prefer this method because it prevents the sender from spinning when you remove the spark plugs. The slot may vary slightly from the photo depending on cylinder head type. For instance, the plug counterbore for a 914 2 litre head is different from all other type IV cylinder heads.
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The type IV head has a deep recess for the spark plug which can make installing the sender difficult.
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If the engine is in the vehicle, use one of the pre-bent senders or bend it yourself. The bend may vary depending on what kind of cylinder head your engine uses. We recommend using NGK spark plugs, as they are slightly smaller above the threads than Bosch, giving extra room for the sender in the plug recess. We also recommend enlarging the hole in the sender by appoximately 0.03" so the ring terminal will slip over the plug threads more readily.
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Remove the #3 plug and cut off the crush washer so the plug will reach into the combustion chamber correctly. The soft copper sender acts as the plug sealing ring
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Barbed clip used to secure the sender wire to the cylinder head. This is modified automitive trim clip.
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If you are able to, secure the sender wire to one of the head cooling fins with a barbed clip. The germansupply kit contains a clip for this purpose. Be extremely careful installing the sender so it will not move during installation or removal of the spark plug.
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