Water /Steam is flowing out into the car interior and flushing/rad weld has not sealed the leak. How difficult is replacement and where is the best/ cheapest place to get one. Currently I have bypassed it with a bit of copper pipe, but don't fancy leaving it that way as winter temperatures will soon be here!
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The Haynes manual does a good blow-by-blow description with photos and whilst it doesn't look easy, it doesn't involve removing all of the dash as with most modern cars. It involves stripping the area in and around the front ashtray, followed by working into the heater matrix which is located at the lowest point of the central area of the dashboard just above the hump in the carpet. For a replacement matrix try Autovaux www.autovaux.co.uk/ although you will probably find the nearest Vauxhall dealer isn't astronomically expensive.
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Thanks for the advice, I will give it a go and let you know how I get on.
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It might be worth 'phoning Autovaux rather than using their website ordering process. I find their website a bit off-putting although they are quite helpful. I see Cav radiators are "phone for price" anyway.
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