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Thanks guys, I knew I was being stupid. I just put some more coolant into the expansion tank and that sorted the thermostat level. The level in the expansion tank is higher that I remember but it's been off the road for a while so maybe im just miss remembering.

I did that when I was replacing the coolant and it was fine, but now when I took the thermostat plug out to double check it's level it isn't full and if I try to top it up it just runs out and goes into the expansion tank.

Probably a stupid question but on a 300tdi should the thermostat housing be full of coolant? Also should the top radiator hose be full too? Thanks in advance.

Yeah definitely needs replacing. Disintegrating just looking at It.

Anybody have any recommendations for a new radiator?

Apologies for the bad quality photo, but that just came out the front of my radiator, looks like the fins have corroded. Not sure it will solve the getting up to temperature too quickly problem but replacing it should help with running cooler.

Haven't checked the pump or thermostat yet so I'll definitely take a look. Hater is working fine, no coolant use, and it's a factory 300tdi.

Hope not I've had the head off twice in the last year. It's been a issue for a while so dont think it's head related.

I've got to change my power steering pump so I'll be taking the fan of then, should give me good access.

Thanks I'll give that a go. Easier say than done with a full width intercooler though.

My 300tdi defender is running slightly hot, about a quarter before the red. It also gets to temperature very quickly, within a couple of miles. It never gets to the red but I definitely dont want to keep running it hot. Just looking for some ideas before I start digging into it properly. Thanks.

That's a great idea, thanks.

Just about to cut the old crossmember off, I was just going to cut the wiring loom and solder it back together. But wondering if anyone has a better plan for the loom? Cheers

I cant see any other damage. It looks almost like somthing has hit the nut in the middle of the turbine.

I’ve taken the cartridge out and there looks to be some damage to it. Do you think this is whats causing my problems?

With the actuator arm off I can move the wastegate by hand and it feels like its opening and closing correctly.

Yes I've checked all the pipes. Im at a real loss as to what the problem is, I think I'm going to take the turbo cartridge out and see if the exhaust turbine is damaged. If its not then I have no idea what the problem is.

The pipe to the wastegate actuator.

Ok, I double checked the wastegate actuator this morning and even with 20psi the arm doesn't move. But the gate seems to be stuck in the closed position, so from what I understand I should still be getting more than 6psi of boost pressure when Im driving?

Ive driven it with the pipe from the back of the air box disconnected so I think that would bypass any blockage in the induction system. Im getting a lot of black smoke when I accelerate so I think im geting enough fuel, but im happy to be told I'm wrong. I'll check the turbo to injector pump...