I added a catch bottle to my overflow. Great way to monitor any pressure issues. In most case without it, coolant evaporates faster than you can see it.

 

Okay,

So what I am gathering is…

I need to verify I am not leaking coolant out of the pressure relief barb.

I am going to rig up a Miller High life Overfill catch flask fill it up and check it out.

I figured that by removing some of the hoses for the inline mod the overall volume of coolant would be less but I was hesitant to think it would be that much volume.

Why would filling up more liquid in a closed system after reducing the volume of the overall system cause it to spontaneously pressurize out?

I would be stoked if it is not the gasket. Pressure checking the system will verify that correct?

 

Still enjoy the Highlife but use a see through plastic bottle with a decent heat tolerance. That way you can just look when the hood is open. I zip tied it to some other thing near by.

 

Update.

The system was pressure tested to ~15 psi, lo and behold the heater core return and supply at the firewall pipe stubs were leaking. The spring clamps weren't doing much at all. The spring clamps were replaced with hose clamps. That was leak that was dripping down the heat shield and on to the passenger cats. The radiator vent return to expansion tank connection was hissing a bit.

After the clamps were replaced and tightened the system was pressurized via the tester and the system didn’t maintain pressure. It dropped relatively slow however, I am hoping the pressure testing unit and the adapter wasn't forming a great seal as I could hear it pissing out the pressure gently.

In addition, I replaced the Carr4x4 cap with the Duralast 7520 14psi cap.

I was unable to start it up as I want to visually verify the elbow coolant connection, the heater pipe intake connection, the intake hose nipple to throttle body connection, and the radiator vent nipple connection.

It was late and I was getting bit up so I was satisfied with identifying the leak.

If the system passes pressurization and holds I will be looking into the allisport expansion tank to replace the carrs4x4 tank.