The jap spec 97 300tdi has finally got back to roadworthy status and been for MOT,only failing on a little sill/pillar weld. The engine seems to run lovely since the cylinder head was replaced properly,oil flushed and radiator and cooling system clean without and within.

However,the first time I got it up to temp the top rad hose leaked.Fair enough,it had been on when the head went and filled the cylinders with coolant so it wasnt a surprise. Then I ran it on the road and the heater matrix went.Fine,as above and it had been sitting for nearly a year so I could understand that. Then I took it for MOT,the matrix bypassed by linking the heater hoses with metal pipe.On the way home I got a coolant smell and a puff of steam from under the bonnet as I pulled into the drive. The heater hose that is jubilee clipped to the head had blown apart at the join. Fair enough,it was an old hose,had suffered a lot and was in poor shape so on its own, I wouldnt be worried.
At no time did the gauge show any overheat and the header still had some coolant as did the rad and engine.

So,is this just the coolant finding the weakest points in this system , taking into account the previous overheat and gasket failure ,plus the standing unused for nearly a year ?

Or is it symptoms of a more serious problem ? There is no oil/water mix,the header cap doesnt blow out any coolant.....everything LOOKS fine.....

Could the header cap be blocked? So failing to release excess pressure from heating. More likely if coolant slightly overfilled. Cheap `n` easy to get a new `un.
Not a definate fix but worth a punt.

No overfill but will try another lid , bound to have one somewhere . Thanks mate.

Any more for any more ? I wont be going to the vehicles location til tomorrow so get it while its (too darn) hot

Closed thermostat might give similar, was the engine flushed properly to clear any muck and gunge.

Engine was flushed WAY beyond properly,hosed through from every angle until water ran clear,rad likewise,for 45 minutes. But closed 'stat ? Water seemed to be getting around in that when any pipe was squeezed there was overflow from the valve installed on top of 'stat housing.....even so,for the price of a new one,got to be worth a go ! Thanks mate.

Anyone else ? I want to take this vehicle on a caravan holiday on tuesday.....so I would like to get this sorted and forgot ! Otherwise I have to use the 98D1 which isnt so nice a drive.