Here's my original post (full thread is at http://www.brickboard.com/RWD/index.htm?id=1057595):

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"Last try before I admit defeat:

1984 245 water-cooled turbo. Coolant was drained when I replaced the exhaust manifold gaskets, coolant temp sensor and sender.

Put everything back together again, car started up, dash temp gauge crept up as expected but then just kept slowly creeping up to the red! Radiator not hot. Upper radiator hose not hot. Tried burping suspected air pocket by rapidly squeezing the upper radiator hose, but no luck (All told, I've tried this probably 15 times now over the last couple of months.) Purchased a new thermostat, checked it's operation on the stove, and installed--still no flow. Took the radiator to a shop, they checked it and said it was flowing fine. Replaced the water pump, upper and lower radiator hoses. Still the temp gauge creeps to red and the upper radiator hose, radiator, and expansion tank remain lukewarm at best.

Any ideas for last things to try would be greatly appreciated. I'd hate to be defeated by something that seems like it should be the easiest part of the process."
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Turns out it was a faulty temp sensor--the one that goes to the dash gauge. I think FCP shipped me the wrong one or something. It fits in the block correctly and has the same spade connector as the old one but is different in shape.

So, basically I ended up doing all kinds of things that I didn't need to do (new thermostat, water pump, pulled radiator, etc.) But you know what? I had a blast just getting into it, thinking about the system, trying things I'd never done before, learned a lot.

Thanks to everyone who replied to the original post with great advice and encouragement.

Long live Brickboard!

Corey


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1966 122s + 1984 245ti + 2000 v70glt = much to learn!