loosing anteefreeze

You put 110 psi into the cooling system? That's one strong radiator and heater hoses.

 

Bad EGR valve?

 

Were you loosing coolant before doing all this work to the engine? Did you have a blown head gasket before? You could have dropped a liner causing the head gasket to blow putting the coolant in the cylinder. If its a 96 model you should have a 5EK. They are bad about dropping the liner to the rear of #6. If you had somebody doing it the work that does'nt know much they probably missed the block needing cut. JMO

 

We take our Cheetah tire inflator and put it on the edge of the cap. Success rate varies but cuts down on that manual pumping.

 

Good luck. Let us know how it turns out.

 

Did you ever fine the problem? I would like to know if you did

 

If I remember correctly KW had a problem internally in their radiators and that was causing the radiator to improperly maintain flow and push water out the over flow. A customer of mine that I did engine rebuilds on had his radiators rebuilt everytime for this same issue. Another remote issue is a air operated heater controller that would allow air pressure into the cooling system.