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Update.... new firewall heater valve installed yesterday..... no change in heat problem. I am really thinking Headgasket now. Weird thing is that I have had this problem for the past 2 winters now and nothing has gotten better/worse. Putting together my own degas pressure tester this weekend. Already looking at what it going to cost me for head gaskets.... etc..... ouch!
DinoB- Can you put a manual low pressure gage(0-30 psi) teed into the small coolant line and run it up to the grab handle to watch it while you are driving? That would show you if the pressure slowly rises or jumps crazy from leaking compression from the cylinders.
Ok, looks like HGs are not the issue. Still a small amount of pressure in degas after 14 hours of sitting. Also ran the HERO test kit today. Pressure was 9-10 psi , no large spikes while pulling a hill and hammering it pretty hard. After some more troubleshooting I am concentrating on my egr delete/ oil relocation/ coolant filter setup from IPR. At idle the return line from the heater core is cool.... bump up idle to about 1200 rpm and line gets hot and heat comes in to cab. Partially closed inlet ball valve on coolant filter and outlet from heater core is hot at idle with heat in the cab. Still trying to figure out why. Both heater cores are brand new. I believe the coolant is taking the path of least resistance at idle which is sending it through the filter and not the heater core. Then when I kick up the rpms and the water pump is pushing more fluid.... it flows through the core and I get heat. So.... I manually restricted the inlet of the coolant filter slightly to see what happened..... guess what?!?.... heat in the cab at idle! Now I am trying to figure out why.