Strange cooling system issue

Evening All,

I have been having a strange cooling system issue on my 400 diesel, ever since I changed the head gasket earlier in the year.

Essentially, the coolant seems to be being pushed out of the header tank when the engine gets up to temperature.

I was having an issue where the return to header tank was becoming blocked (in the pipe stub in the header tank). However, I think that I have now resolved this, and it appears clear.

The following items have been replaced:
Water pump
Radiator
Thermostat
Various hoses
Pipe over gearbox taken off and cleaned and repainted inside and out (currently in progress)
Cap (about 5 times!)

The gauge shows an acceptable temperature at all times (cold initially, then rising to around half-way, and staying there).

I have noticed that there seems to be a very intermittent flow from the return hose going to the header tank, both when the engine is cold and when warm. There either seems to be no flow at all, or else just very short spurts.

I have also flushed the system as best I can for about 20 mins.

Any thoughts on what else to look at?

Cheers. TIA

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1999 (V) Rover 400 iXLd
1994 (L) Rover 820 Vitesse
Wanted: 400 Brooklands Green (HYF) doors, hatch bumpers and front wings.

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Strange cooling system issue