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[RobG]

C/C ON warm air when heat is called then alloy pipes go cold and stay cold.

Both pipes? I was looking for a big temperature differance as an indication of poor flow due to a partially blocked matrix.

If there is no large temperature difference between the aluminium pipes then I would tend to focus on the HBV or look for a blockage in the coolant bridge area or look for more general causes of poor circulation (air lock or faulty pump etc)

Passenger at the footwell end of centre console, if I pull the end back slightly I can see a sort of bung type thing wrapped in grey/black sponge that is dripping fluid

I wouldn't be surprised to find condensation on the A/C pipes in this area. My last car used to make the carpet wet if I used it a lot in very warm humid weather. Does it smell of antifreeze?[/quote]
Both pipes go cold. Brand new HBV all connected as should. Does the 2.0 have a coolant bridge? Water pump is OK. Tried "burping" the system for 15mins. Can`t understand why I`m getting coolant dropping to sender level then when the cap is released the coolant rises midway between sender level and normal fill line. Having to keep topping up. Fluid pass. side is clear, no smell (condensate?)

[Andy H]

Both pipes go cold. Brand new HBV all connected as should. Does the 2.0 have a coolant bridge? Water pump is OK. Tried "burping" the system for 15mins. Can`t understand why I`m getting coolant dropping to sender level then when the cap is released the coolant rises midway between sender level and normal fill line. Having to keep topping up

Sorry, I should have read your profile properly. I don't know where the heater hose connects to on a 2.0, (it connects to the coolant bridge on the V6).
Your symptoms are quite perplexing. Firstly it is unlikely that a new component should be faulty but not unheard of so the new HBV might be at fault. It might have been plumbed in wrongly (it is not easy to see what is what at the back of the engine). The water pump might be faulty or the cambelt tensioner might have lost all tension and stopped turning the water pump or the headgasket might be starting to fail and causing coolant loss and system pressurisation.

I think I have reached the limit of what I can diagnose from a distance. I think you need advice from somebody more knowledgeable (and nearer)

[RobG]

Thanks for your input Andy. As you say the symptons are quite perplexing. I`ve tried all options and still can`t fathom it out. :-/