DIAGNOSTIC ANALYSIS Section 2 .  .  .  HIGH COOLANT TEMPERATURE (Temperature above 200° F to 210° F) 1. Verify problem: a. Determine operating conditions when overheating occurs. b. Check temperature indicators for accuracy. c. Refer  to  guideline  temperature  data  in  the "PERFORMANCE DATA GUIDELINES" located in the rear of each Engine Section. 2. Verify operation: a. Operator’s habits - running improper range. b. Vehicle    specifications    -    check    guideline data if correct for vehicle and job. c. Accessory equipment - approved? 3. Engine Maintenance: a. Clean, no oil leaks, no external coolant leaks. b. Belt adjustments correct (use Krikit gauge). Refer   to   the   following   Maintenance   Manuals   for   belt adjustment specifications: Engine Manual No. DT-466  1 1 171 478 R1 DT/DTI-466B 1 171 562 R1 DT/DTI-466C 1 171 585 R1 400 Series OEM 1171 581  R1 9.0 Liter (All Model Years) 1171 584  R1 6.9 Liter (A Model) 1171 569  R1 6.9 Liter (B Model) 1171 577  R1 4. Inspect Cooling System: a. Coolant   clean   and   properly    inhibited    for season. b. Radiator caps operative.  Use pressure test kit.    Check  restriction  at  water  pump  inlet. Should not exceed 10 kPa (3 in Hg) without pressure cap and engine at high idle. c. Hoses - correct type and properly clamped. d. Radiator   clean   and   unobstructed   by   bent fins, pinched tubes, etc. e. Radiator  correct.    Check  repair  history  or use of "stop leaks." Check specifications of radiator for vehicle. f. Fan    -     proper     specification     for     vehicle, proper fit in shroud.  Properly installed. g. Shutter  control  (if  equipped)  operative  and correct set. 5. Inspect Engine: a. Water pump condition. b. Thermostat and seal - proper specifications and operating correctly. c. Engine    static    timing    and    advance    unit operation. d. Oil cooler(s) proper flow both oil and water. e. Engine power correct. f. Coolant    aeration    from    head    gasket    or nozzle sleeve leakage ("Pop bottle" test). "Pop Bottle Test" 1. Fill bucket and pop bottle with water. 2. Run engine until operating temperature is reached. 3. Immerse  filled  pop  bottle  in  bucket  of water    with    neck    facing    bottom    of bucket. 4. Insert cooling system overflow line into pop bottle neck. 5. Observe pop bottle for aeration (bubbles)    or    in    extreme    cases    the water  in  the  pop  bottle  will  be  blown out. NOTE:  Bubbles or expulsion of water from bottle indicate head gasket or nozzle sleeve leakage. .  .  .  EXCESSIVE SMOKE 1. Excessive   visual   smoke   can   occur   under   two general conditions: a. During acceleration. b. During full load operation. 2. Smoke  during  acceleration  can  be  caused  by  a malfunctioning fuel modulator or improper operation  of  vehicle.      For   example,   the   driver must    keep    engine    speed    within    the    range specified for the transmission and rear-end drive ratio  or  intake  manifold  pressure  will  drop  and allow fuel modulator to actuate. (400 Series, D-Series and 9.0 Liter only) 3. If smoke under Full Load Operation is not within recognized  limits,   follow   the   "PERFORMANCE ANALYSIS   GUIDE"   CGED-390   for   400-Series with   UTDS*   Model   100   Fuel   Injection   Pump, CGED-365    400    C-Series    with    Robert    Bosch Model MW Fuel Injection Pump or CGED-335-2 for 9.0 Liter diesel engine to determine the cause of the problem. NOTE:  A  smoke  sampling  kit  can  be  used  to  test smoke intensity as described in Section 5.  Sampling Kit is not used on 6.9 Liter. 4. Smoke color can indicate particular problems a. BLUE SMOKE - could indicate lube oil is being burned in the cylinders. *United Technologies Diesel Systems (formerly AMBAC) CGES-240-4 Printed in United States of America Page 2