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Wow, I'm glad it's not me having this trouble!
I must admit that I am losing the plot a bit, as lots of things have changed. Is it right to presume you now have:
(1) New radiator
(2) New top and bottom radiator hoses
(3) New green pressure cap
(4) New heater core
(5) New head gasket
(6) No thermostat
(7) No loss of coolant problems since the head repair
(8) no leakage of oil or combustion gases into the coolant
(9) Cooling fans that always kick in and out on demand
(10) Good water pump delivery
And despite this, you still have overheat problems. You do not say in your message whether the overheating occurs while driving steadily along the highway or whether it only occurs when moving slow or stopped in traffic. The reason I mention this is that at reasonable speed, the natural airflow thru the radiator should be enough to keep things cool without assistance of the fans.
Also, if the temperature is behaving erratically when all other things (like driving conditions, speed, etc) are unchanged, it points to a rather strange or intermittent (or both!) problem.
What I don't understand is whether you have a flow problem or, like you say, you may simply have a problem with your temperature measurement/display system. What is the best way to resolve this? Possibly replacing the sender and checking the integrity of the temperature gauge circuit is one. Maybe this is the next step.
If there is another problem, and it is indeed related to the cooling circuit itself, then it points to some sort of intermittent obstruction to the water flow (or a very badly behaving thermostat if you have one in at the moment).
I struggle to think of what could cause a flow obstruction. It would need to be something in the water circuit that occasionally "gets in the way". Is it a coincidence that this problem has only appeared after the intial radiator/head gasket problem? I know it is a long shot, but is it possible that here is something rattlng around in the outlet tank of the new radiator that occasionally partially blocks the outlet?
Hey, I seem to be asking more questions than offering answers, but it is a real puzzle.
Wolfgang
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