I always use the 'sniffer' test, a liquid that changes colour when exhaust gas is present in the coolant. Bare in mind the engine needs to be properly warm, small cracks in the head close up unless its properly hot, and won't show up when tested. If the motor has passed a pressure test then you must have a small leak somewhere. The level in the expansion tank can vary up or down, I just keep a little in the bottem. Then the motor can suck it back as the coolant cools so you arn't short or coolant next time. The expansion tank is just that, it gives the coolant somewhere to go when it gets hot enough to excede the capacity of the cooling system and rad cap valve rating. You shouldn't be checking the coolant level by the expansion tank, always check it at the filler cap, when cold.
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