Not Ranked
Dan,
You mention system had 16 pounds pressure but because the cap was rated at 16LBS and leaking, right. I think you just have a bad cap or maybe a POS between the sealing surfaces.
16 PSI is a lot of pressure and more than would allow cap removal without some effort and a big mess. If you just removed the cap on the top hose and watched it would fluid keep coming out? I think there is just a leak on your lower cap to tank.
If overflow tank cap is lower than rest of system it will seek its own level of course but what if you throw a jack under car to lift front end till the cap is the high point and watch without a cap in place or can you swap with the other cap?
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