Well the rego has been paid and I am going to have another go at replacing the thermostat housing. I have found instructions to get the plenum off which is as far as I got last time, but at least I won't have the worries about not been able to get it all back together. the egrs have been turned off and I found blanking plates at the end of the coolers so I am going to see how easy it is to bypass these as I gather they are also known to leak. I bypassed the egr cooler on my bt50 after having the egr turned off without any problems arising.
John


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youll find the more you take off the easier its gets


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