Originally Posted By: EdwardC
I believe I found the answer!
My Mityvac cooling system tester arrived today, turns out it has a cap tester adapter too, so I was able to test the cap. It worked perfectly, letting out pressure right at 16lbs on the dot. I was able to use the tester pressurize the radiator a bit. Before I did that, I refilled the radiator with distilled water to help see where the water exits.
Turns out, I was wrong that the coolant was escaping from the seam under the fan mounting tab. With it full of water and slightly pressurized, I could see a stream of water coming out the front of the radiator, in the fin section.
Looks like there was a prior accident. The condenser was bowed inwards similar to the original radiator. The mounting brackets were pressing on the fin and hitting it, over time, it broke through.
This is very common when the front bumper cover gets even a minor hit.
On this Honda (my current project) it had a small coolant leak, look familiar?
The culprit..
Make sure the brackets are not twisted! As soon as i started tightening it the thing was heading right back into the fins.
Check the clearance and make sure the radiator is free to move in the mounts. The clamps you got are great, i only use those or OE spring type.
Plastic hose connections will leak when those cheap screw clamps get cold (NE winter) and loose tension, repeated tightening only damages the hose.
Those things are one of the worst automotive products ever foisted on the public, they should be melted down.
I know i should paint the bracket but its going on the block or to the auction depending on how i feel about it once i start driving it. Its not a keeper for me.
BTW the new radiator is OE.