Also, I changed the oil and filter, 2 days before starting my trip. So, built up condensation wasn't considered.

Yesterday, I removed the valve cover and pressure checked the
cooling system @ 18 psi. I found a very small leak @ the bottom
radiator hose to the outlet. 1 drip every 5 minutes.

The lose of coolant (1 quart from overflow bottle) and the
mayonnaise in the filler cap and PVC valve lead me to suspect
a cracked head or block..

After leaving the tester on the system all night, I still have
10 psi in the system. At this point, I'm guessing that the
Alumiseal I put in a while ago to make the heater stop stinking, may be sealing a cracked head with the engine cold.

I'll drain and refill the cooling system with straight water. Get the engine up to operating temp and then do another pressure test. 500 miles in 80 degree weather with clean oil shouldn't be making mayonnaise in the valve cover and that quart of coolant
went somewhere...No noticeable external leaks..

Last edited by Melon; 04/14/15 10:26 AM.