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Originally Posted by maczo
First of all, the sensor is in the head, so as far as I understand, thermostat is not a factor here.
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Thermostat is always the factor, if it's opening too early engine temperature will drop significantly while driving. And it doesn't matter where temp sensor is placed. Coolant temp is similar in whole system.
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He said he connected the gauge directly to the sensor before mounting, waited for the engine to heat up and the fan to engage, and the readings were OK. Then he proceeded to mount the sensor inside the car, tapping into the wires there. So my guess is he might have tapped into the second temp sensor (both are head-mounted), the one that feeds data to ECU. Then there's resistance and voltage drop on both of them, correct? And neither works correctly, which would explain why the fan wouldn't engage when I let the engine idle for half an hour.
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That can be the factor.
You can check wiring on your own very quickly, just short a "temp gauge wire" to the mass and gauge should go crazy. You may hook up it through light bulb to not destroy it, but few seconds of pure mass won't be a problem for your gauge. Then you'll know for sure if wiring is correct.