EDIT: SOLVED - noticed no leakage around thermostat, coolant ball, all belts were dry, and upper radiator dry. In the end it was the radiator.
run a mk4 secondary rad.
I will will just add that I have a 2L 16V running no oil cooler and an early Mk1 radiator with built-in overflow tank, two pin thermostat, short 5th gear, and the car does fine in a traffic jam and with spirited driving.
90 16v Passat rad fit just fine in my mk1 Jetta with a single fan mk1 (which mounted to the rad just fine) you can cut the wires and set them up for how ever you like.
I personally I have used a Denso radiator for my Mazda protege and it been working fine for almost 30,000 miles
Regarding our 1997 Jetta GLS that we've had since it was brand-new, I was topping off the original G11 with G12+ since about 2000, without any problems. A few years ago we had the radiator replaced, and the coolant was all changed out to G12 -- that is, the current G12.
I replaced the coolant tank, blue resevoir cap, thermostat, water pump and coolant but didn't help. Problem was my radiator was partially blocked. I replaced my radiator this spring and it's run like a champ.
VR6 Passat *works for an A3 radiator but will need modifications
If your going to use a fox radiator becareful cause it will hang pretty low. I ought one and thought it will work but it sits really low if you just drive on streets it should be ok, but mine is a track car so I was worried about going off and possibly hitting it on somehting and causing some problems.
I traded my mk8 GTI (early Canadian model) for a mk7.5R recently because my mk8 GTI was so problematic: the rad fell out at speed and left me stranded (this should no longer be an issue on these cars)
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