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Looking for some mechanical advice for a 2007 registered T5 1.9 TDI BRS. Have been having ongoing coolant issues, where on a long drive, especially in hot weather, the red engine cooling system warning light comes on. Pull in, check expansion bottle and right enough the level is well below the minimum mark on the bottle. Once you open bottle cap, the coolant fizzes back up well above the max level. This went on for a while with various fixes tried to no avail until eventually one day on a test run the engine temperature guage went well beyond 90. So decided to take the hit and have just had my engine remanufactured, new water pump fitted, new thermostat fitted, new DMF, new clutch, timing belt etc. First long run yesterday to get the engine run in and back at square one with the coolant system warning light and subsequent low level of coolant in the bottle, light came on after 170 miles of easy driving yesterday. Has anyone any ideas? Cheers.
 

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Is the expansion tank grubby, as that would indicate head gasket failure meaning the cooling system is getting pressurised, which results in the coolant being pushed out the bottom of the expansion tank - stuff a cloth under there, go for a spirited drive then check if it's damp.
 
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