A friend of mine calls them
Morphiedite (sp?) systems, as they do not follow logic and they do not follow the normal physical laws of physics or the universe.
If the leak is leaking only tiny amounts of liquid at a not quite tight enough hose clamp, or a spot deep inside the radiator core (not visible), the bottle volume would not change, but the pressure and temperature would. Also radiator and system pressure tests are nomally done at ambient conditions, not while driving, and not while the engine is running. They are typically a static test so they could miss a hot operating, intermitent, sometimes self sealing leak. Keep in mind that one of the ingredients in antifreeze is designed to dry and seal very tiny pin hole leaks as it leaks out of the very tiny pin hole.
Can you run the pressure test on the system itself, and run it while running the engine? If so I would try that, then stick it in drive with the A/C running and the parking brake on while idling and watch to see if the pressure drops a little everytime the temperature spikes or eases up some suddenly.
Perhaps the sealing surface on the bottle, that the cap seals on is not sealing perfectly (I doubt this one as would expect to see the liquid volume in the bottle increase as you pointed out, but offer it as possibility).
Be sure and use the temperature tester to look for hot spots and temperature gradients in the engine and the radiator.
Blaine B. said:
I have the closed system. I did try another cap.
We also pressure tested the system. It held pressure, minus the stupid gasket on the tester nozzle.
If my system was leaking pressure - wouldn't the amount of coolant in the overflow bottle increase? Perhaps not, I'm not sure......it would if the pressure leak was the radiator cap, but besides that, I'm not sure.
I'll be able to use the contact thermometer tomorrow. I'll test it when it's registering warmer than usual and see if I can't get it back into the redzone and then read it again!
Thanks!