Sorry to go a bit off-topic, but I thought I might add to this:
carbully wrote:Also, this may sound strange, but not running a t-stat can actually make a car run too hot. You guys will propbably flame me for that statement, but I am an ASE certified technician with over 21 years of experience. The thermostat serves an importaint role in regulating the speed coolant flows through the radiator. Having coolant flow too fast through the radiator does not give it enough time to dissipate enough heat into the air. So, if you have say 200deg coolant coming in to the radiator, and it passes through the radiator in only 2 seconds it has only had enough time to get rid of "x" number of BTU of heat, leaving the radiator at say 175deg.
Slowing down the flow, it spends more time in the radiator. So let's say now it spends 4 seconds iflowing through the radiator that's going to get your outlet temp down to say 160 deg. Make sense? To some of you it won't, becuase I have this argument even with other technicians. All I know is that I have seen it and fixed it by simply installing a missing thermostat.
I'm not going to say it's impossible for an engine to overheat without a t-stat, but your explanation leaves out a few important variables.
The assumption that coolant will be at 200deg in both cases seems to ignore that the coolant will have less time to absorb heat from within the engine. Hence, the coolant in an engine without the T-stat should have a lower temp before it reaches the radiator. One might then argue: "The lower coolant temp proves that the engine is retaining more heat!" This, too, would be incorrect. Since the velocity or mass flow of coolant is greater, you're still absorbing roughly the same amount of heat. You'd probably get more heat into the coolant since the heat exchange in the t-stat-less engine will have a higher temp differential throughout the entire engine.The above will carry over to the radiator. If coolant is flowing through the radiator twice as fast, twice as much coolant will run through the radiator, dissipating about the same amount of heat over time.
The most logical explanation for cases where people claim adding a thermostat fixes an overheating issue would be an inefficiency with the coolant pump. If, by some chance, the coolant pump cannot support the volume flow of an empty thermostat housing, the pump might cavitate or acheive less overall flow.
From experience, this is not the case with a 240sx.
To the OP:Run an expansion tank. Coolant expands when it's hot. This expansion dumps coolant into the expansion tank (hence the name). When the engine is turned off, the coolant contracts. This contraction creates a vacuum due to less coolant being in the system. The check-valve in the cap then sucks coolant in from the expansion tank. Without it, you'll just suck air back in, and we all know that air doesn't belong in your coolant galleys.
My bet for your initial problem is a damaged or gouged freeze plug, either on the hole or plug. Take care when replacing them. If they're all installed correctly, they won't leak, regardless of other issues. If they were damaged, it wouldn't take much for them to dump coolant out under pressure.