Thanks for the ideas pwpanas. I've basically concluded that there is something corroding in the cooling system, just not sure what. I would prefer to replace it before it fails leaving me on the side of the road in a green puddle. Options are; radiator, hoses, pipes, water pump, block, head, heater core, thermostat, heater switch.
I think you might be on the right track with the coolant pipes around the engine. There seems to be several, one that runs the length of the engine under the exhaust manifold.
The car is due for a timing belt in a few weeks. While I've got it stripped I'll be checking all the pipes and water pump etc, hopefully that will solve the problem.
Thanks again!
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