I've pumped the tool by itself, will keep an eye on it. Finished reassembling, started up and seems to be running okay. No leaks so far. It did start to overheat after about 10 minutes, but I was expecting that because I haven't refilled the coolant properly yet. Will try tomorrow and see how...

20 minutes later and it's holding at around 14 psi. Maybe a very small variance from where it was at the start

Found a leak, water pump hose clamp. Tightened and pressurised to 14 psi again, fingers crossed.

Nearly 3 hours later, the pressure is down to 6 psi. Seems I've got some more digging to do

I've reassembled everything that's in the cooling circuit and pressurised to 15 psi. First attempt sent water everywhere because I didn't tighten a hose clamp properly. I've left it to dry and set the pressure at 15psi again, how long should the system hold this pressure before it starts to...

It has mostly gone well. New gasket is on and manifold is in place, with 11 out of 12 bolts in. The last bolt (5 in the tightening diagram, one before the left rear) is cross threaded, so it's become a pain. I didn't force it any further, it's a problem for tomorrow. It's got the fuel rail next...

Cheers, I'll have a go at that. And it's 17NM for the seal clamp bolts, right?

Remind me before I fit this new valley gasket: 1. Do I need to use RTV around the intake ports or just the coolant ports 2. Do I need any RTV on the rubber seals Thanks

I'm sure the pipe from the radiator to the expansion is correct because I can blow through it and hear bubbles, hopefully that means the other pipe is in the right place too

Ah I was hoping to leave the fan alone. Someone before me has nicely butchered the nut on it

It was a bit rusty coloured at first, then eventually ran clear. I'll take the rad off tomorrow - is it a pain to get out?

Perhaps tomorrow I'll remove the rad completely and try and give it a good blasting. Any ideas what this noise in the video could be? It might be a red herring, but I didn't hear it before the strip down

I broke my bucket :( This is the flow out of the drain plug with the hose in the top pipe - I couldn't turn the pressure up very high because it would just blow back out the top. I gave the bleed pipe a good blow from the rad side, and I could hear the bubbles in the expansion tank

To the best of my knowledge, it was good before I stripped everything down I will try this now.

This is what comes out of the bleed pipe with the engine running and when revving: It starts with a steady spill when idling, then as I rev it seems to increase to a steady stream before stopping altogether. I am not sure, should I undo the drain plug and stick a hose in the top pipe?

Just tried it again after leaving it for a while. Tried filling via radiator top hose, but it was already full. The metal pipe on the other end that goes to the block was also full. Started it up, ran for a few minutes before coolant was being pushed out of the expansion tank. Turned it off and...

When you say fill the radiator, do you mean fill it directly through the top hose?

Before filling the system, I stuck a hose in the top of the radiator and removed the drain plug to try and flush as much crud out as I could

Just tried to test for exhaust gases again. Coolant started to get pushed up through the device before I could give it enough time to let the liquid change colour. Something is causing the coolant to overflow pretty consistently. Cabin heater still not blowing warm.

Just ran it again until it started going in to the red. Coolant still gushing, heaters on full blast max temp. Noticed that radiator feels cold all over - no hotspots on the top or bottom (from the limited places I could feel it anyway)