2.0l TDCI overheating problem.

[Badman]

Hi.I have a Mondeo 2,0l tdci 2006, yesterday it overheated whilst I was out and the Ecu cut power. Called breakdown service and they told me it was almost certainly the thermostat stuck closed.Today I brought a new thermostat and fitted it, topped expansion tank up with antifreeze and started engine. After running on tick over for about 5 mins the temp gauge was showing at about 60deg but there was no heat from heater, running at about 2000 rev for a further 5 mins got temp gauge showing normal temp but still no heater working. I tried squeezing all the water pipes that are accessible to see if any air was in them but made no difference. I took car on short drive, about 1 mile from home and the temp gauge went to max cooling fans were on and when I got home the rad was hot at both end,no loss of water but the heater pipes in engine were both cold. Can anyone help?. Also when I was replacing the thermostat I noticed a pipe was flopping about when I found where it was from it is a valve of some sort on front of engine above the water pump, it has something to do with the EGR system as it has 3 pipes on the body, 1 goes to EGR valve, 1 goes to the brake servo via a non return valve and the 3rd pipe disappears under the battery tray, The pipe that goes from brake servo has broken off the valve body. Does anyone know what this valve is called and how much they cost.

Thanks.

[dezwez]

sounds like air lock does it say anything in the Hayes manual about refill the coolant