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Dear Metallo,
"I checked all the hoses to the radiator, no leaks, but the level of the fluid went to the min"
--> You noticed this when then engine has cooled down 8 hrs? With no visible leaks from the hoses this could only meant one thing - I suspect faulty headgasket.
"With the old grey cap, I had leaks at the radiator hoses, and did not warp the tank"
--> The old grey cap could be faulty and couldn't relieve excess pressure so the water had to go out somewhere ie. at the hoses (I interpret this as leaking at the clamps, not anywhere along the hoses as that would clearly indicate faulty hoses). With pressure relieved, the tank didn't warp.
New green cap has double the pressure capacity than the old grey (green cap 150 kPa, grey cap 75kPa). With excess pressure vented out, the hoses didn't leak (plus you could have tightened the clamps by this time around). But the residual pressure inside tank still doubles than what was there before, so the tank warped. I also suspect the current tank could be of aftermarket quality (thin walls). If its original tank (thicker walls) it shouldn't warp as whatever excess pressure should've been vented out by functioning cap leaving only the residual pressure which still within the design capacity of the tank. Where this excess pressure came from? I suspect faulty headgasket.
Amarin
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