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...remember the one posting about the coolant reservior tank that, despite being molded properly, the inlet/outlet at the bottom was not drilled to let coolant pass thru. Whatever coolant was in the tank couldn't circulate into the system, and the expansion had no where to go. When you say the "coolant was barely over the minimum", a portless reservior tank is all I can think of.
You'll need to be creative in finding a method to detect if the port is there or not.
Good luck!
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