Yeah as it's not pressurised with the cap off, as soon as it gets close to boiling point and the water is expanding, it just coughs and spits water out. Just top it up to max now and put the filler cap on. You should have cleared any air locks in there. Looks like you've hit a brick wall mate, get the matrix changed. As I said, I ran a hose through mine initially and got water back out, it all seemed fine but changing it actually made the difference. Don't think there is anything else you can change now so it's the only thing remaining.