It's fixed itself. After all that head-scratching, taking stuff to bits, putting it back together again, and sheer bafflement, the bloody thing's fixed itself. It must have been airlocked . . . .
One of those 'shake your head' moments
Now tighten all those jubilee clips, take it for a run, check for leaks, and leave it all alone lol...
With jobs like this, it's nice to know the club are supportive and behind you.
Now what Antifreeze have you put in, :nenau as the system takes 10 litres?
I flushed mine several times dropping the bottom rad hose, and running the engine in between, now, this way, you can only get 5 litres out, so I bought 5 litres of concentrate, which should be diluted 50/50 that went in... and bingo, you have a clean system, with the correct concentration good for a tough winter lol...
PS I didn't try to unscrew the drain plug on the engine block.... I had an idea that might just shear off, then you have another big problem lol..
When I did it that way, I didn't get any airlocks.
Hope it helps,
Rustic