Have you replaced the pressure cap? If it doesn't release pressure the symptoms you describe are a sure thing. Even if head gasket is breached due to poor surface preparation you shouldn't have more pressure than 15psi in the system.
You need to do a compression gases check on the coolant to determine whether head gasket is failing again.
Kits are available with a special dye which changes colour when hydrocarbons are present in the coolant. Not cheap but it's the only way to be certain. Posters on this forum have indicated they are available for hire.
high pressure cooling system
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precopster
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difflock54
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Could bad air locks be playing a part in this problem?
When the coolant was replaced the system may not have been burped correctly.
The 2002 S40/V40's have a red colored plastic relief valve installed in the lower radiastor hose, approx' midway specifically to help with this problem but alternatively, gently squeezing the hoses with the coolant cap off and the coolant, (not too hot) forces the trapped air to rise up to the expansion tank. Bubbling is visible.
When the coolant was replaced the system may not have been burped correctly.
The 2002 S40/V40's have a red colored plastic relief valve installed in the lower radiastor hose, approx' midway specifically to help with this problem but alternatively, gently squeezing the hoses with the coolant cap off and the coolant, (not too hot) forces the trapped air to rise up to the expansion tank. Bubbling is visible.
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