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Through that whole description, I didn't see one actual temperature value. First off, you need a monitor.

I'm with the other poster on plugging the EGR valve back in. The jury is out on its contribution to the fan strategy. Can't hurt plugging it in.

Regarding the leak that you know that you have... until you fix it, I don't see much point in trying to overanalyze anything else. I get your point about air bubbles, but there weren't four gallons worth of air bubbles.

Last thing... by diluting so much, there is no telling what your current boiling point is. ...but I bet that it's a bit low. I'd work to get it 50/50 again and then top off with 50/50 in the future.

Good luck.
 
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