OK... i started the motor for the first time after the re-build (d15b7 in a eg hatch)....i let it warm up for like ten to twenty minutes, bothe hosses are hot and it was at normal temp.....then the upper hose started to swell....

things i have tried to solve problem:

1 flushing from upper hose without thermo and it came out clean and fast
2 flushing the heater core and its good too.
3 flushed all of the tiny hoses on manifold and it's good too..
4. brand new water pump
5. brand new hose


questions about it...

1. how much coolant does it take to fill entire motor, heater core and radiator?
2. if the water pump is as hot as the hoses then it should be working fine, right?
3. could it be alot fo air in the system the makes it hot enough to swell...(the first time it inflated i opened the radiator cap and no coolant spewed out)

 

Fill up the motor with like 3/4 of a gallon. and then when the motor is running. Add the coolant until it tops off. then let the car warm up to operating temperature (still without the radiator cap on.) then watch for bubbles. then let it run another 5-10 mins after the motor has reached operating temperature just be sure the bubbles have stopped. and keep adding coolant til it reachs the neck of the radiator cap. once the bubbles are gone and coolant is full put ur cap on and go for a drive.

 

you could need to do a few things..

A) bleed the system a few times
B) the upper radiator hose could be bad... sometimes the layers in the hose can rot or go bad and then it will cause the hose to swell

 

new hose....