Thanks again, Ed and Stan,
I did warm up and fill the car with the cap off. I topped it up a couple of times. I added maybe 1.5 gallons of coolant after the radiator install, and it did not want to take any more. If I had waited an hour or two, I think I could have added more fluid and avoided much of my trouble. For some reason, my system did not burp very quickly. Eventually I added may 1.5 additional gallons, and seem to now have a working system.
I will still check for HC's in the coolant this weekend to verift HG OK.
Thanks again,
Dave

 

Hi again,
I tested for CO2 in the coolant gases with an indicator type head gasket tester and I AM OK! I will repeat the test again, but so far I have to go with either a malfunctioning radiator cap or manufacturing defect in radiator end cap as my original problem.
I am finally getting good heat out of the vents, so I think I have finally filled my coolant system.
Thanks,
Dave

 

How about just taking the car for a spirited drive and be done with it?

 

That sounds like a good plan.
Thanks,
Dave

 

BTW if your radiator looked like mine did in the first picture, I think you would be cautious in the recommission.
Dave

 

I just replaced my Behr radiator yesterday due to a cracked right side tank. Filling for me was simple, I filled the engine block completely with the left hose disconnected from the radiator. Then topped off the radiator by removing the hose connected to the thermostat. After that I filled the reservoir completely and ran the car until it was up to operating temperature with the cap off. The system completely self bled itself of air.

 

Yeah, Christian. That sounds like a good idea. My hoses are not that accessible with a supercharger installed. BTW, the factory says to just fill from the coolant reservoir, and keep adding fluid as the air bubbles allow. I just did not allow enough time for all that air to dissipate.
Thanks,
Dave

 

yes, I only fill from the coolant res as well; I know others like the hose method however

 

What type of tester is being used for checking for CO2 from exhaust gasses in the coolant? I'm having what appears to be exhaust gasses leaking into the coolant of a Neon and this tester would help greatly. I'm almost ready to tear the car down for a head gasket job but would love to be able to verify before digging in.

 

Hi Brad
I used Uview 560000 Combustion Leak Tester, from Amazon:


Good luck,
Dave

 

Thanks for the quick reply good sir!

Bit more than I can spend right now but I may look at some local alternatives. (Doubtful I'll find a better deal though, that's how online shopping is.)

Also how recently does the engine have to be run to test for the CO2?

 

I think it has to be a running car. You run it, let it come to temp, squeeze the hoses, shut it off. Let it cool enough to be able to remove the coolant cap. Then the test device will sniff the gas mixture above the coolant in the reservoir. If the blue fluid turns yellow, that indicates CO2 in the coolant system.
They may have a cheaper version online.
Good luck,
Dave

 

The car runs but will boil the coolant with what appears to be a lot of pressure behind it. So I think this tester would be a nice option. Thanks again.