Hi,
Welcome to the P38 overheating club - i know what you're going through - i have a yr 2000 4.0L petrol and sorry to say suffer the same problem.
This what i have fitted:
Had new head gasket
new o rings on matrix
new water pump
new radiator
new hoses
3 x new thermostats
OEM new expansion vessel cap
checked,double checked,triple checked quadruple checks for air locks - all removed
new viscious fan
Condenser fans do work - ive seen them turning - nothing to do with cooling
No leaks
This is what i did the other day:
Filled radiator from top hose, filled system and bled completely of air.
started and allowed her to warm up
internal heater chucking out hot air (very hot) with fan on full (air con off)
allowed to trick over for 55 mins - all ok
revved to 2500 rpm and kept there for approx 5 mins - done this on a couple of occasions during the aforementioned 55 mins - all ok
water level stayed same throughout test dropping only 1 cm during who time - not due to leak - most likely due to removal of a small amount of air.
top of rad hot - bottom of rad cold
top of thermostat hot - bottom of thermostat cold
heater matrix flow and return hot
top hose pressurised but still could be squeezed a bit by hand
expansion hose from thermostat to expansion tank hot and could be squeezed
radiator bleed pipe hot, not blocked
no unusual noise ie tapping/knocking from slipped liner etc
temperature needle stayed dead in middle and did not move
viscious van speed increases with engine revs
throttle housing flow and return hot
no leaks anywhere
not overheating at all
Took her on a gentle run around the local streets - managed to go for approx 3 miles then bugger me she overheated - this is what i found
Expansion cap releasing pressure & water
bottom of radiator cold
bottom of thermostat cold
top of rad hot hot
Since the above, i have had from this forum zzr1200 come round, see for
himself the problem, pressure tested this system (results ok) and suggest a new OEM thermostat and exp cap - in the mean time until i can get one to run the engine with the thermostat wedged in the open position. Drove for 75 miles+ and she did not miss a beat and no overheating.Rad hot all over - obviously circulating throughout car - temp gauge at approx 1/3 of the way across - yippee i thought - problem found - another faulty thermostat!
Tested thermostat in saucepan to confirm operation, fitted OEM thermostat and OEM expansion tank cap and with 3 miles she overheated as before. Top of rad hot bottom cold - what F*&k is going on?
Don't know what to do next nut whatever it is sounds like the same as your problem.
only thing i know is that when i drive the car she overheats, i can only assume that i have a crack in block/head that opens up when driven - is this possible ?

