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Cummins 5.9L ISB #46659082 in a 2007 F650 Ford, has low

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power. Not building much boost...
Cummins 5.9L ISB #46659082 in a 2007 F650 Ford, has low power. Not building much boost. Found two codes. #1, SPN 103 FMI 10, Flash code 2345, Turbo speed invalid rate of change detected- Abnormal rate of change. Sensor has detected an erroneous speed value. Code #2, SPN 411 FMI 2, EGR Recirculation 1 Differential Pressure-Data erratic, intermittent or incorrect. Where do we start?
Submitted: 3 months ago.Category: Medium and Heavy Trucks
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Answered in 10 minutes by:
3/27/2018
Technician: Daniel Wilson,
 replied 3 months ago
Daniel Wilson
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Hi ,My name is Dan. I will be glad to help. We can follow up as needed on here, Give me some time to review your information and post my responses. Im not an employee of the site but I help on here as time allows in between jobs. Response time will vary depending on my work load , etc.

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Technician: Daniel Wilson,
 replied 3 months ago

Fault Code 687: Turbocharger Number 1 Speed Low – Warning Level

Code Types

FAULT CODE 687 PID 103 FMI 1 (SPN 103 FMI 18)

J1587 / J1708J1939OEM

MID 128MID

PID 103SPN 103Fault Code 687

FMI 1FMI 18***** *****ght

Code Description

Turbocharger speed sensor is a variable reluctance speed sensor. It includes a coil of wire and an iron core. A Signal is generated as turbocharger shaft spins. Target on turbocharger shaft is a ground flat in center of shaft.

With no turbocharger speed signal present, fault may come active if ECM senses boost pressure and engine speed.

Possible Causes

  • Barometric pressure sensor
  • ECM.
  • Engine harness
  • Intake manifold pressure sensor
  • Turbocharger speed sensor

Fault becomes inactive any time turbocharger speed sensor speed Signal Returns.

When calibration software phase is less than 5.0.0.0 and this fault code is active at key-ON with engine not running then there is inaccurate intake manifold pressure Signal or barometric pressure sensor Signal. View calibration software phase using Scan Tool. Data Logger/ Monitor.

When fault occurs intermittently, find causes of intermittent open circuit or short circuits in turbocharger speed sensor circuit (including speed sensor pigtail connector).

CAUTION:Before replacing ECM, ensure all other active fault Codes are inspected to avoid damage to NEW ECM.

CAUTION:Use Male Deutsch/AMP/Metri-Pack (3822758) and Female Deutsch/AMP/Metri-Pack (3822917) while taking electrical measurements to prevent damage to terminal and harness.

Effect

Engine power derate. ECM uses estimated turbocharger speed.

Wiring Diagrams

See CUMMINS in ENGINE PERFORMANCE WIRING DIAGRAMS.

Component Location

Turbocharger speed sensor is located in turbocharger center housing.

Testing

1: Inspect For Atmospheric Pressure Or Intake Manifold Pressure Sensor Faults

1A: Read Fault Codes With Scan Tool

Condition: Connect scan tool. Turn ON ignition switch.

Action: View fault codes using Scan Tool.

Specification: PID 102 FMI 3 (Fault Code 122), PID 102 FMI 4 (Fault Code 123), PID 108 FMI 3 (Fault Code 221), or PID 108 FMI 4 (Fault Code 222) active?

Repair:

If okay, see appropriate fault code troubleshooting tree.

If not okay, then operate engine and confirm that turbocharger speed fault comes active.

2: Inspect For Intermittent Fault Condition

2A: Operate Engine And Confirm That Turbocharger Speed Fault Comes Active

Condition: Connect scan tool. clear inactive fault codes.

Action: Start engine. Accelerate engine speed to high idle (100 percent) and hold engine speed at high idle for minimum 20 seconds using accelerator pedal. Return engine speed to idle. View fault codes using Scan Tool.

NOTE:This step applies even if maximum engine speed, without vehicle speed sensor, limits engine speed.

Specification: PID 103 FMI 1 (Fault Code 687) came active during engine operation?

Repair:

If okay, then inspect engine harness connector to turbocharger speed sensor.

If not okay, an intermittent fault conditions exists, then troubleshoot inactive or intermittent fault code .

3: Inspect For A Failed Turbocharger Speed Sensor

3A: Inspect Engine Harness Connector To Turbocharger Speed Sensor

Condition: Turn OFF ignition switch. Disconnect engine harness from turbocharger speed sensor.

Action: Inspect turbocharger speed sensor connector, engine harness connector, and turbocharger speed sensor pigtail harness for:

  • Bent or broken terminals
  • Broken connector shroud
  • Damaged terminals
  • Damage to wire insulation
  • Dirt or debris in or on connector terminals
  • Loose connection
  • Moisture in or on connector
  • Missing or damaged connector seals
  • Pushed back or expanded terminals

Specification: Connector pigtail harness damaged?

Repair:

If okay, repair or replace turbocharger speed sensor , then disable fault code.

If not okay, repair or replace damaged connector, then measure turbocharger speed sensor resistance.

3B: Measure Turbocharger Speed Sensor Resistance

Condition: Turn OFF ignition switch. Disconnect turbocharger speed sensor from engine harness.

Action: Measure sensor resistance . Measure resistance between turbocharger speed Signal (+) terminal to turbocharger speed Signal (-) terminal at sensor with a multimeter.

Specification: Between(###) ###-####Ohms range?

Repair:

If okay, then inspect for a short circuit to ground in turbocharger speed sensor

If not okay, turbocharger speed sensor is failed. Replace turbocharger speed sensor , then disable fault code.

3C: Inspect For A Short Circuit To Ground In Turbocharger Speed Sensor

Condition: Turn OFF ignition switch. Disconnect turbocharger speed sensor from engine harness.

Action: Inspect for a short circuit to ground. Using a multimeter, measure resistance from turbocharger speed Signal (+) terminal at sensor to ground.

Specification: More than 100k ohms?

Repair:

If okay, see inspect ECM & engine harness connector terminals

If not okay, turbocharger speed sensor is shorted to ground. Replace turbocharger speed sensor , then disable fault code.

4: Inspect Engine Harness

4A: Inspect ECM And Engine Harness Connector Terminals

Condition: Turn OFF ignition switch. Connect turbocharger speed sensor to engine harness. Disconnect engine harness connector from ECM.

Action: Inspect engine harness ECM connector for:

  • Bent or broken terminals
  • Damaged terminals
  • Damage to wire insulation
  • Dirt or debris in or on connector terminals
  • Loose connection
  • Moisture in or on connector
  • Missing or damaged connector seals
  • Pushed back or expanded terminals

NOTE:Inspect for a terminal that may not be locked into engine harness ECM connector, or expanded causing an intermittent connection.

Specification: Damaged engine harness connector?

Repair:

If okay, repair or replace engine harness , then disable fault code.

If not okay, repair/replace engine harness connector, then inspect turbocharger speed sensor circuit continuity.

4B: Inspect Turbocharger Speed Sensor Circuit Continuity

Condition: Turn OFF ignition switch. Connect turbocharger speed sensor to engine harness. Disconnect engine harness connector from ECM.

Action: Inspect sensor circuit continuity . Measure resistance between engine harness ECM connector turbocharger speed Signal (+) terminal and engine harness ECM connector turbocharger speed Signal (-) terminal with a multimeter.

NOTE:Ensure resistance of turbocharger speed sensor circuit resistance is not greater than 10 Ohms more than turbocharger speed sensor resistance.

Specification: 10 Ohms sensor resistance range?

Repair:

If okay, then inspect for a short to ground in engine harness.

If not okay, high resistance or an open circuit exists in engine harness or turbocharger speed sensor connector. Repair/replace engine harness or connector(s), then disable fault code.

4C: Inspect For A Short To Ground In Engine Harness

Condition: Turn OFF ignition switch. Connect turbocharger speed sensor to engine harness. Disconnect engine harness connector from ECM.

Action: Inspect for a short to ground . Measure resistance between engine harness ECM connector turbocharger speed Signal (+) terminal and engine block ground with a multimeter.

Specification: More than 100k ohms?

Repair:

If okay, then inspect for a terminal-to-terminal short in engine harness.

If not okay, short to ground exists in turbocharger speed sensor circuit. Inspect engine harness for a short to ground. Repair or replace engine harness , then disable fault code.

4D: Inspect For A Terminal-To-Terminal Short In Engine Harness

Condition: Turn OFF ignition switch. Connect turbocharger speed sensor to engine harness. Disconnect engine harness connector from ECM.

Action: Inspect for a terminal to terminal short circuit. Measure resistance between engine harness ECM connector turbocharger speed Signal (+) terminal to all other connector terminals except turbocharger speed Signal (-) terminal with a multimeter.

Specification: More than 100k ohms?

Repair:

If okay, then connect all components & determine if fault code reoccurs.

If not okay, inspect engine harness for a short between two terminals. Repair engine harness repaired or replaced, then disable fault code.

5: Inspect ECM

5A: Connect All Components And Determine If Fault Code Reoccurs

Condition: Turn OFF ignition switch. Connect turbocharger speed sensor to engine harness. Connect engine harness to ECM. Turn ON ignition switch. Start engine.

Action: Run engine at idle. Accelerate engine speed to high idle (100 percent) and hold engine speed at high idle for minimum 20 seconds using accelerator pedal. Return engine speed to idle speed. View fault codes using Scan Tool.

NOTE:This step is valid even if maximum engine speed, without vehicle speed sensor, limits engine speed.

Specification: PID 103 FMI 1 (Fault Code 687) comes active during engine operation?

Repair:

If okay, then disable fault code.

If not okay, replace electronic control module (ECM) , then disable fault code.

6: Clear Fault Codes

6A: Disable Fault Code

Condition: Turn OFF ignition switch. Connect turbocharger speed sensor to engine harness. Connect engine harness to ECM. Turn ON ignition switch. Connect electronic service tool. Start engine.

Action: Disable code. Accelerate engine speed to high idle (100 percent) and hold engine speed at high idle minimum for 20 seconds using accelerator pedal.

NOTE:This step is valid even if maximum engine speed, without vehicle speed sensor, limits engine speed.

Specification: PID 103 FMI 1 (Fault Code 687) inactive?

Repair:

If okay, then clear inactive fault codes.

If not okay, then read fault codes with Scan Tool..

6B: Clear Inactive Fault Codes

Condition: Connect all components. Turn ON ignition switch. Connect scan tool.

Action: Clear inactive codes using electronic service tool.

Specification: All codes cleared?

Repair:

If okay, repair complete.

If not okay, see appropriate troubleshooting steps

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Technician: Daniel Wilson,
 replied 3 months ago

Check the delta pressure sensor and harness for problems. Let me know.

Fault Code: 1866
PID: P411
SPN: 411
FMI: 2/2
LAMP: Amber
SRT:

Exhaust Gas Recirculation Valve Delta Pressure - Data Erratic, Intermittent, or Incorrect. An error in the EGR delta pressure signal was detected at initial key-on or the sensor failed the autozero test.

EGR valve actuation will be disabled

Ask Your Own Medium and Heavy Trucks Question
Technician: Daniel Wilson,
 replied 3 months ago

Likely a failed sensor or harness for the 411 code

Please take a moment to rate as that is how the site credits my time helping on the site or let me know if you need more help. 5 star and bonuses are always greatly appreciated.

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