OK I managed to get the new plug in. Besides lubing with dish soap I fitted a bar snuggly (in this case a 5.5 mm wrench) in the castled end of the plug. Then I could grab both ends of the bar and pull the plug towards me into the hole. Having the bar in there also allowed me to controll and oscillat...

No. I am trying to insert it with the smaller diameter first. The other side (with the castling) is way too big.

OK so my V90 came from the previous owner with 205/65/15 tires on all four. He also gave a set of 2 Blizzack 195/65/15 and I have a set of 185/65/15 snows from my now deceased 740. My inclination is to put the 185's on the rear and the 195's in the front. I am assuming the PO was using the Blizzack ...

Thanks for all the help so far. The old and new plug are the same size, neither will fit into the grommet once it is installed without more force that I have been willing to apply. The # on the grommet is:1378869 642 Fo 6857-11. Here is a link to a pic of the new grommet and plug. http://www.faceboo...

Yes grommet first. Tried installing with the plug already in the grommet but that does not seem possible. Grommet fits nice. I just cannot get the plug in after.

Yes , it is the white plug near the top. Has a rubber grommet and a (phenolic?) plug. I tried freezing the plug and lubing with dish soap. Still no go. It's possible this radiator is from another model as the Volvo parts guy said he had to look under a different model. Maybe it's the wrong size?

The old plug leaked due to the grommet deteriorating. I purchased a new grommet and plug. I can't get the plug in. I assume the grommet goes in first. I've tried pushing, rotating and even hammering the plug in. Right now the plug is in the freezer. I hate to lubricate it with something that will hu...