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can i fit a smaller header tank to my mk1 1.8 tddi without adverse effect

not without causing issues the tanks that size for a reason make it smaller you then change the pressure in the pipes which prevents the coolant from boiling as you have a smaller space in the header if you want hassle free driving ide leave alone smaller tank youll need a cooler opening thermostat

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Why would you want or need a smaller header tank?

old one broken been given a smaller that fits and need to know if it ok to fit in place of original

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I agree with the guys above, you risk too much fitting a smaller part, too little pressure and the car will just cut out, speaking from experience - its not very fun at X0 MPH on the motorway in the outside lane, in the dead of night!

As well as that, if you have too little fluid, that wont help with keeping the engine cool!

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