You must have air in the system somewhere, have you bled at the rad, the heater, the jiggle valve and on the steel pipe? Are you also sure the pump is Ok? Chacking this is not much fun, and I would have maybe changed it with HG?
I have heard of people refitting the main front to rear pipes the wrong way round?
My wifes mgf had both fans running constantly when we bought it - after a battery off job it then decided not to run them at all, so they had a bug in the code somewhere, but it doesn't sound like you have this problem.
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