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Where does the air hide when you fully drain the coolant system and refill it?
When I've done it, it has taken over a week to get all the coolant back into the system, and usually that week is spent topping off about 1.5 gallons of fluid. Engine is hot, engine is cold, tubes are squeezed, degas cap is closed, opened ... doesn't matter ... it wants to take a week.
I have a coolant filter and the fumoto block plugs.
Where is the air hiding?? Could the coolant filter be affecting the purge of the air in the system?? I would have thought that with a good drive and with heaters and a/c's going and the engine up to temp and everything flowing that it would equalize pretty quickly, but it doesn't seem to.
My guess would be it gets trapped in the heads, towards the back. Being at an angle the way it is theres no other place i could think it would get trapped. Took me 2 days of driving to get my level back to where it was, but i was adding quarts, not gallons at a time.
I actually think it gets trapped in the radiator. If you look closely, you can see the degas reservoir is not the highest point in the system, the upper radiator tank is. I overfill my degas a bit initially and that helps purge the air out faster.
It takes a pretty steep angle to make much of a height difference. I've never had to add more than about a quart after the initial fill. Make sure you get it warm enough that the thermostat fully opens to purge all the air out of the block.