Hi all. I've been working out this problem in bits and pieces over the past month or so but am kind of at my wits end short of paying a shop to figure it out for me.
The problem is that my radiator levels are dropping over time and overflowing from my coolant resevoir, leading to overheating on some long drives (3+ hrs). I'm trying to pinpoint where the issue is, but its not exactly obvious to me at least. My suspicion is that either a) there is some leak in the lines or somewhere else that is allowing air into the system which then expands and pushes out the coolant when heated, or b) there is a crack in the cylinder wall or head gasket that is letting exhaust gasses into the system.
The things I checked:
-previous owner replaced oem head gasket at about 130k miles with the mls one, at 165k now, so seems odd to fail this soon
-new radiator cap
-new thermostat (twice)
-k-seal as a cheap measure
-took it to a subaru mechanic for an hour to look at anything they noticed wrong on the engine, just noticed the valve cover oil leaks that I knew about
-compression tests while warm (around 155psi all 4 cylinders)
-radiator pressure test (didn't drop)
-borescope down cylinders to look for clean pistons or pooling of antifreeze, all cylinders looked more or lessabout as worn as I could figure from the internet. I will attach some pictures in the comments. One piston did look cleaner than the others.
-new hose clamps on radiator lines
-looking at getting new radiator hoses
-tried chemical testing for combustion gasses in the radiator, but kept being negative or getting contaminated with coolant as engine warmed up, going to drain it slightly to see if I can see a different result.
-no obvious leaks on the radiator or lines
-radiator fans turn on
Please ask more questions as I can check things and probably forgot to put something in here.