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Sounds like you may have a headgasket starting to fail - it would be worth testing the water system for the presence of exhaust gas.

Yeah as above. Get a sniff test first to rule that out before you do anything else.

air con is separate from the water. it sounds like a head gasket blow. you don't want the pipe to be rock hard because that means it has too much pressure in it and why the relief valve in the cap opens up and pushes it out behind the headlight. If it is only intermittent it may be a small blow due to the heat expanding stuff in the engine. if you have the time and money get all the water hoses changed to samco ones if they are still the factory fitted black ones (they go hard and crack), try a new water pump, is it remapped? if the problem is still there after changing them and getting it mapped, bite the bullet and get new head gaskets fitted.

The fmic does not block the rad as such.

hope that helped M8 Webby

Cheers for replies yeah it's been mapped but I don't have any details on what map etc as it was by previous owner also it has most of the hoses are silicone samcos if it was head gaskets wouldn't it be more permenant rather than intermittent ? Only seems to do it after a long run

Silly question maybe, You've heard or seen the radiator fans cutting in?

Exactly HOW did you "bleed it"?

Iv seen the fans cut in yeah , and I out the in car heaters on hot with the blower on full on the windscreen setting removed top hose at rad end and used as a funnel to fill block then attatched it back to the rad and removed at block end to fill the rad then filled header tank and started it up slowly topping it up as the level dropped untill the stat opened and it was all the way round the system also took off the return pipe off the top of the rad to the header to make sure it had a smooth flow of water no air