Temperature gets hot .. no fans .. fans do work on AC ..
Here's the flowchart ... changed oil, flushed coolant system, installed G12 via vacuum unit, ran hot, got motivated - installed new water pump, timing belt, tensioner, transmission cooler, oil cooler, thermostat, coolant flange, temp sensor, temp switch in radiator, coolant reservoir, multiple hoses, FCM, checked all fuses, no leaks at all ...
Upper hose warms first and then the upper after running a while ...
Using OBD2 to monitor coolant temp. Fans will not engage at 96 C or any higher temp. Temp gets up to 220 F and I stop engine at that point. Ran a jumper on the harness and fans do run at low and high speeds.
Flushed radiator and water flows clean and strong. When I removed the thermal switch at the bottom, I was able to pull out several pieces of rubber gasket material. Picture enclosed. VW dealer parts department, nor local auto parts store, have any idea where the gasket material originated, nor how it ended up lodged in the radiator clogging the area by the thermal switch. But they say definitely not head gasket or valve cover gasket. They looked up all the gaskets on their computers and nothing matched the pieces you see in the pic. There is likely some still lodged where I can't reach it ... So ... there's a mystery for one of you experts !
This likely is causing a circulation restriction, prohibiting hot coolant from activating the thermal fan switch. I used a hot blower on the switch and the fans did come on.
So ... can coolant flow through the radiator, but still be restricted somewhere inside the RAD unit, preventing the switch from reaching operating temp? Replacing the radiator, and fans while I'm there, is my next step ... but that disassembly sucks ... Hoping one of you fine experts can help me complete this journey ... Much appreciate this site and all the value it provides ... Russhaus