F17560 Force HEAD ASSEMBLY

Recommended Actions
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
Diagnostic Codes
Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continuing with this procedure.ECM Parameters
Ensure that the problem is not a parameter that has been incorrectly programmed.
Use the electronic service tool to ensure that the correct mode was selected.
Use the electronic service tool to verify that the correct engine rating has been provided.
Use the electronic service tool to verify the maximum engine speed limit.
Use the electronic service tool to reset the parameters to the OEM specifications.
Ensure that the repairs have eliminated the performance problems.
If the repairs have not eliminated the faults proceed to "Electrical Connectors". Electrical Connectors
Check for correct installation of ECM connectors at the following locations:
J1/P1 ECM connector
J20/P20 Machine interface connector
J40/P40 Fuel injection pump connector
J100/P100 Engine coolant temperature sensor connector
J103/P103 Intake manifold air temperature sensor connector
J200/P200 Intake manifold pressure sensor connector
J201/P201 Engine oil pressure sensor connector
J401/P401 Speed/timing sensor connector
Refer to Troubleshooting, "Electrical Connectors - Inspect".
Use the electronic service tool to check for the following logged diagnostic code: 253-02 "Personality Module erratic, intermittent, or incorrect". If this diagnostic code is logged, proceed to Troubleshooting, "Electrical Power Supply Circuit - Test".
Inspect the battery wires from the ECM back to the battery compartment. Inspect the wires and the power relay. Check the power and ground connections to the ECM. Refer to Troubleshooting, "Electrical Power Supply Circuit - Test" for more information.
Check the P40 VP30 fuel pump connector. Refer to Troubleshooting, "Fuel Injection Pump Circuit - Test".
Repair any faults and check that the fault has been eliminated. If the fault has not been eliminated, proceed to "Electronic System". Electronic System
Turn the start switch to the ON position.
Use the electronic service tool to verify that the intake manifold pressure is 0 kPa (0 psi). Check the 5 V sensor supply for the intake manifold pressure. Refer to Troubleshooting, "5 Volt Engine Pressure Sensor Supply Circuit - Test".
Use the electronic service tool to verify the throttle position status.
Run the engine until the speed is equal to the maximum no-load speed.
If the maximum no-load speed can not be obtained refer to Troubleshooting, "Throttle Switch Circuit - Test" and Troubleshooting, "Mode Selection Circuit - Test".
If the engine speed is erratic refer to Troubleshooting, "Analog Throttle Position Sensor Circuit - Test" or Troubleshooting, "Digital Throttle Position Sensor Circuit - Test".
Repair any faults and check that the fault has been eliminated. If the fault has not been eliminated, proceed to "Air Intake and Exhaust System". Air Intake and Exhaust System
Check the air filter restriction indicator, if equipped.
Ensure that the air filter is clean and serviceable.
Check the air intake and the exhaust system for the following defects:
Blockages
Restrictions
Damage to the air intake and exhaust lines and hoses
Make all necessary repairs to the engine.
Ensure that the repairs have eliminated the fault.
If the fault has not been eliminated, proceed to "Valve Lash". Valve Lash
Check the valve lash and reset the valve lash, if necessary. Refer to Systems Operation, Testing and Adjusting, "Engine Valve lash - Inspect and Adjust".
If the repair does not eliminate the fault, proceed to "Turbocharger (if equipped)". Turbocharger (if equipped)
Note: The turbochargers that are equipped on 1100 Series engines are nonserviceable items. If any mechanical fault exists then the turbocharger must be replaced.
Ensure that the mounting bolts for the turbocharger are tight.
Check that the turbocharger drain is not blocked or restricted.
Check that the turbocharger housing is free of dirt and debris.
Check the turbocharger for worn bearings. If any mechanical fault exists then the turbocharger should be replaced.
Check that the turbine blades rotate freely on the turbocharger.
Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect".
Make all necessary repairs to the engine.
Ensure that the repairs have eliminated the fault.
If the fault has not been eliminated, proceed to "Fuel Supply". Fuel Supply
Check the fuel pressure. Refer to Systems Operation, Testing and Adjusting, "Fuel System Pressure - Test".
Ensure that the fuel system has been primed. Refer to Systems Operation, Testing and Adjusting, "Fuel System - Prime".
Check the diesel fuel for contamination. Refer to Systems Operation, Testing and Adjusting, "Fuel Quality - Test".
Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, "Air in Fuel - Test".
Check that the fuel lines are tight and secured properly.
Check for fuel supply lines that are restricted.
Check the fuel filters.
Visually check the fuel tank for fuel. The fuel gauge may be faulty.
If the engine has a water separator, check for water in the fuel.
Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
If the repairs do not eliminate the fault, proceed to "Low Compression (Cylinder Pressure)". Low Compression (Cylinder Pressure)
Perform a compression test. Refer to Systems Operation, Testing and Adjusting, "Compression - Test".
Make all necessary repairs to the engine. Examples of low compression are shown in the following list:
Loose glow plugs (if equipped)
Mechanical problem
Faulty piston rings
Worn cylinder bores
Worn valves
Faulty cylinder head gasket
Damaged cylinder head
Ensure that the repairs have eliminated the faults.
If the repair does not eliminate the fault, proceed to "Individual Malfunctioning Cylinders". Individual Malfunctioning Cylinders
With the engine speed at a fast idle, loosen the high pressure fuel line to the fuel injection nozzle of number 1 cylinder. Note if there is any reduction in engine speed. Tighten the high pressure fuel line to the fuel injection nozzle.
Individually repeat this procedure for each fuel injection nozzle.
If there is no reduction in the engine speed, proceed to "Fuel Injection Nozzles". Fuel Injection Nozzles
Remove the fuel injection nozzles from the cylinder head. Refer to Disassembly and Assembly, "Fuel Injection Nozzles - Remove".
Visually inspect the fuel injection nozzles. If any fuel injection nozzle has a suspected fault, replace the fuel injection nozzle.
Install the fuel injection nozzles into the cylinder head. Refer to Disassembly and Assembly, "Fuel Injection Nozzle - Install".
Ensure that the repairs have eliminated the fault.