Technical OVERHEATING ! Fan ! Thermo ! Head Gasket !

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Technical OVERHEATING ! Fan ! Thermo ! Head Gasket !

Vehicle is a fiat palio active (2009 model).
I am now driving the car for 12 days after collecting it from garage - As mentioned before, I replaced (head gasket, thermostat, temp switch, water bottle, water bottle pressure cap - Palio's dont have a radiator cap), also had engineering works skim cylinder head, plus they tested the valves and confirmed cylinder head is ok.
When starting car in morning (engine cold), the car stuttered in 1st gear on day 3 to day 9, thereafter its gone (no more stuttering when cold). Only issue I still have is that when I fill water bottle from 2cm below min. to max in morning, I need to refill it next morning. Took car to radiator shop, they pressure tested the cooling sytem - no leaks. They then did a combustion test (the liquid turned yellow - meaning that there is gas (CO2) in the cooling system (so head gasket is leaking exhaust gas).
How can head gasket be blown again ?
 
Have you shimmed the head ? Probably is warped.
When you have shimmed the head you need a thicker head gasket to compensate
 
Engineering works did skim cylinder head, plus they tested the valves and confirmed cylinder head is ok.

Not sure I understand - When you have shimmed the head you need a thicker head gasket to compensate.
 
I'm in Africa where the temps rise quite a bit, and becoming sick of the intermittent workings of the radiator fans and the relays that switch them on, I fitted a manual switch which allows me to manually switch on my fans. I have become so used to it, that I drive with an eye on the temp gauge, and once on, the fans keep everything cool. You have to be the kind of person who would keep an eye on the temps though!
 
It must surely be possible to fit a manual override to the thermostatic set-up, so that the fan will still kick in automatically if your attention wanders from the temp gauge, but you can still switch the fan on manually (eg if you're stuck in traffic on a hot day and want to pre-empt the thermostat)?
 
Yes, Gar4 - I had everything 'fixed' with a new relay et al, and will be taking the car back to the auto-electrician because the automatic switch-on is not happening. trouble is, I have become comfortable with the manual switch, but of course would be silly to leave it like that.
 
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