"Sounds like something major" = get ready to pay us big money to fix something you could fix at home for $25. In fact, an experience like that is why most of us are here.
The cooling system on these is simple. You could replace the radiator, every cooling line, the water pump and thermostat in a Saturday afternoon for less than $500. That said, we could also keep guessing or we could do some smarter troubleshooting. The fact that the upper radiator hose isn't getting hot would not be uncommon in colder temperatures. Where are you located?
I'm more concerned with why the fans are running at 100% duty cycle and why you're not getting a gauge reading on the dashboard. If the cause were mechanical, you would still be getting a temp gauge reading on the dash. With that, I believe the problem is still electrical.
Did you also replace the pigtail on the coolant temp sensor? It's common for them to need replacing at the same time - so much so that many sensors include a new pigtail that you can splice in.
if you did replace the pigtail, do you have access to a bidirectional scanner? We need to know: coolant temp as the computer sees it, and what the computer is commanding the fans to do. We also need to know if there are any other codes set. The shop manual (alldata) has a troubleshooting chart that explains what different parameters will trigger the fans to 100% duty cycle. Troubleshooting starts with this:
Circuit/System Verification
- Ignition ON.
- Verify that DTC P0480, P0691, or P0692, is not set.
- Verify the scan tool Cooling Fan Motor Command parameter is 0 %.
- Verify that the G10 Cooling Fan Motors are not operating.
- If a G10 Cooling Fan Motor is operating
Test or replace the appropriate G10 Cooling Fan Motor.
- If the G10 Cooling Fan Motor is not operating
- All OK.
If P0480, P0691, or P0692 are present, then:
Circuit/System Description
The engine control module (ECM) commands the speed of the cooling fans based on cooling requirements. The ECM controls the cooling fan speed by commanding the cooling control module. The cooling fan control module supplies separate power and ground circuits for each cooling fan. The ECM sends a pulse width modulated (PWM) signal to the cooling fan control module. The cooling fan control module interprets the signal and operates the cooling fans at the commanded speeds.
Conditions for Running the DTC
- The ignition voltage is 11 volts or greater.
- The engine speed is 400 RPM or greater.
- The ECM driver transitions from ON to OFF or from OFF to ON.
- DTCs P0480, P0691, and P0692 run continuously once the above conditions are met.
Conditions for Setting the DTC
The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds.
Action Taken When the DTC Sets
- DTCs P0480, P0691, and P0692 are Type B DTCs.
Conditions for Clearing the MIL/DTC
- DTCs P0480, P0691, and P0692 are Type B DTCs.
Diagnostic Aids
- A delay or ramp up of approximately 12 seconds may occur before the cooling fan activates or changes speed when being commanded with a scan tool.