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Mechanic Help needed

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They replaced the cap, checked the heads, and did a pressure test. No leaks. No smell inside the car, just intermittently outside.

So your leaking cooling system has no leaks as per your shop.

Find another shop.

As mentioned, cracked plastic WILL hold pressure until it is under load at operating temp.

Your pressure in the cooling system comes from thermal expansion in a sealed system. Once you develop a leak and the radiator does not draw coolant from the reservoir as the engine cools, you get air. The system then pressurized from heat of expansion of the air (Boules law),as well as thermal expansion of the remaining coolant.

As it pressurizes, more coolant is lost. Air does not transfer heat as well as liquid and you will overheat.

Once pressure escapes, your leak will stop until the next Te you cold start the engine and you repeat the pressurize-leak cycle.

S trick to limp home with a known leak is to depressurise the system by loostening the cap and driving home or to shop. This only works with pressurized leaks, if you have a hole below the waterline, all coolant will escape down to the level of that hole.
 
Check the water pump weep hole for coolant residue

The wife's Honda did this. Only leaked hot, no drips at all. Weep hole next to firewall, behind engine. Would drop straight down to road, no sign at all except for losing some water everytime driven more than 10 miles. No wet spots anywhere on engine, rad, or hoses.
 
1 get a bottle of colored coolant Leak detector and a black light slash light. Available at most auto parts stores, with the engine at operating temp the light will show leaks that are hard to find. It glows when the light hits it. The detector also shows up when it dries. The color stays on metal AND plastic
2.) IF you take it to the KIA dealership, be prepared to have them “disqualify” your problem for warranty. KIA is notorious for claiming the problem is a result of neglect / abuse
 
This gets better and better.

The wife is at the dealership now. They're telling her the coolant is not circulating properly through the engine and it needs a new engine.

Warranty has expired, and they're not offering anything except a $6,000 new engine.
 
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