[5th Gen : 08+]: Losing Coolant, No leaks
I have an 09 Grand Caravan with around 140k miles on it. In October I started noticing a coolant smell coming into the van. So far my mechanic has replaced the timing cover gasket, timing chain, water pump, and the coolant bottle. He has pressure tested it twice and put Ultraviolet dye into the coolant trying to find out where it could be leaking from. When he replaced the coolant bottle I believe he put too much in because it was on the ground and it looked like it had sprayed all over the engine around the top of the bottle. He cleaned the engine and put a new radiator cap on and I haven't seen any coolant on the ground but now it seems to be evaporating. The coolant level keeps getting lower and lower pretty quickly, but there isn't any on the ground and there isn't any sign of a leak around the bottle like before. I'm very worried that it's the head gasket but he said that it would be overheating if that was the case and it hasn't done that at all.
It could very likely be the plastic "Y" connector on the heater hoses near the EGR valve. Same thing happened on my 2010 4.0 SXT and is a common problem. It is normally evident when the "Y" heats up and you rev the engine you can see it seeping at the injection molded joint, it just spreads apart.
Try warming the engine to normal temperature and then get someone in the drivers seat to rev the engine to about 3,000 rpm while you watch the plastic "Y" fitting. You might well see a stream of coolant spray out so wear glasses just in case.
Try warming the engine to normal temperature and then get someone in the drivers seat to rev the engine to about 3,000 rpm while you watch the plastic "Y" fitting. You might well see a stream of coolant spray out so wear glasses just in case.


