I would still do a leak down test. That might answer everything.




Dave

 

Well I finally got back to the cooling fan issue. (Not a daily driver so repairs are done as time allows) After replacing every fuse sensor and thermostat, some twice, I decided to pull the fans and do a bench test. As I was removing the connector to the left fan I felt some roughness on the bottom of the yellow and orange wire. There was about a 1/2" strip of wire insulation missing. Not a single strand of twisted wire was broken just corroded enough to prevent proper current flow. Totally invisible unless you removed the connector from the fan and turned it over. I spliced in a new 2" piece of 10 gauge wire, wrapped and water proofed it turned on the car with A/C = Two fans turning great.

 

Well - it appears (GULP) that the cooling issue and excess pressure issue is resolved. After getting the cooling fans working properly by replacing a 1" section of corroded wire on the left fan connection the issue seems to be gone. I have put the car through a few test (translation = no revenue enhancement agents in site) and it passed with flying colors. Interesting note on the cooling gauge (idiot light equivalent), I have noticed that it now fluctuates slightly at the below 1/2 point position. Previous to the repair it was always holding steady at slightly above the 1/2 point. Now driving it at least once a week and have no issues since repair.
Thanks to all for your input.