Hi Everyone,
Well.. The thermostat replacement job failed!
I managed to remove the hoses from the old thermostat housing with loads of twisting and pulling and some WD-40. Took a good 20 minutes each but was happy when they were finally off because that was the only thing that stopped me in my tracks last sunday.
I carefully cleaned all the connecting hoses ends and where it connects to the block. All was good. I applied silicone grease as directed and proceeded to install the new thermostat and piping. All went in well. I reversed my steps and rebuilt the top and made all the right connections. I was pretty pleased that everything went back together and every bolt, electrical connector and screw went back in exactly as it came out. The only things that were broken were the PCV hose and one other vacuum hose so I carried on anyway thinking I could at least get the engine started without these. Not that I would have run it for long but I wanted to see if the job actually worked before spending out more on hoses.
So.. all rebuilt.. I filled the expansion bottle to the line then opened the valve at the back to make sure there were no air locks. As soon as water started to escape I closed the valve and topped up the water. I went to start the engine... and it made an awful scraping-like sound! I went back to the engine bay and noticed I somehow managed to damage the fuel rail because it was leaking where the pipe meets the actual U shaped section. Also, water was running out on to the floor just like before so when I looked into the 'V' I could see water filling around the thermostat area so game over.
I don't know what's gone wrong as I followed all the instructions to the tee.. And the thermostat connections were good and all new O-rings were used. Bummer! Oh well. I tried! Even though it hasn't worked I'm glad I had a go because I learned more about how these things work. I really did think it would have worked because every step was by the book.
I'm going into hospital next sunday evening ready for surgery the following day and then I'll be out of it for three weeks (not even allowed to drive) so as soon as I'm on my feet again I'm not going to bother trying to fix what I have, I'm going to get the new engine fitted by professionals and everything done properly!
Thanks for your help everyone anyway!