Cummins Intake Heater Problems: Reasons and Solutions

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If you own a Cummins engine, you might encounter issues with the intake heater. One common problem is when the Cummins intake heater fails to work properly. This can lead to difficulties starting the engine, especially in cold weather conditions. The intake grid heater in Cummins engines plays a crucial role in preheating the incoming air, ensuring optimal combustion and engine performance.

When facing intake heater problems, check the wiring connections. Faulty or loose connections can disrupt the proper functioning of the intake heater. Inspecting the wiring and ensuring a secure connection is essential for resolving the issue.

Some Cummins owners opt to disable the intake air heater, usually in an attempt to enhance engine performance or address specific modifications. However, it’s crucial to note that disabling the intake air heater may lead to adverse effects, particularly during cold weather starts.

For Dodge Cummins owners, the intake heater can also pose challenges. It’s important to address any intake heater issues promptly to avoid potential engine starting problems or reduced performance.

In some cases, Cummins owners may consider aftermarket intake heater options for their Dodge vehicles. Aftermarket solutions can provide alternative or upgraded intake heaters, offering improved functionality and performance.

Cummins Intake Heater Problems: Reasons and Solutions

Faulty Intake Heater Relay

Reason: The intake heater relay, which controls the current to the intake heater, can malfunction. This can lead to the heater not receiving the necessary power to function correctly.
Solution: Test the relay for continuity using a multimeter. If it’s faulty, replace it with a new one.

Damaged Heater Grid

Reason: The heater grid, which warms the air before it enters the engine, can become damaged or worn out over time. This can result in inefficient heating.
Solution: Inspect the heater grid for any visible damage. If found, replace the grid to ensure optimal performance.

Inadequate Power Supply

Reason: The intake heater may not receive sufficient power due to issues with the vehicle’s electrical system. This can cause the heater to underperform.
Solution: Check the vehicle’s battery and alternator for any issues. If necessary, replace or repair these components to ensure a steady power supply.

Faulty Heater Plug

Reason: The heater plug, which ignites the fuel-air mixture, can become faulty. This can lead to the heater not functioning as intended.
Solution: Test the heater plug for proper operation. If it’s not working as it should, replace it with a new one.

Blocked Air Intake

Reason: The air intake can become blocked with debris or dirt, restricting the flow of air to the intake heater. This can cause the heater to work inefficiently.
Solution: Regularly clean the air intake to prevent blockages. If the intake is severely blocked, it may need to be replaced.

Faulty Wiring

Reason: The wiring that connects the intake heater to the vehicle’s electrical system can become damaged or worn. This can lead to the heater not receiving power.
Solution: Inspect the wiring for any signs of damage. If any is found, replace the wiring to ensure a steady flow of power to the heater.

Troubleshooting Dodge Cummins Intake Heater Issues

The intake heater grid in Dodge Cummins trucks helps improve emissions and efficiency during cold starts. Troubleshooting intake heater issues involves a systematic process of inspection, testing, and repair.

First, inspect all wires for cracks, breaks, or corrosion. Damaged wires are a common cause of intake heater failure. Check wire connectors for loose or corroded terminals. Clean or replace as needed.

1. Test the intake heater relay with a multimeter to confirm it is operating properly. A faulty relay is a major reason for an inoperable intake heater.

2. Check for diagnostic trouble codes related to the intake heater circuit. Codes can point to issues with the control module, wiring, or heating elements.

3. Test resistance across the intake heater grid elements. Specifications are provided in the repair manual. Values outside specs indicate faulty elements.

4. Replace the entire intake heater grid assembly if the elements are damaged. The grid is designed as a single replacement unit.

Learn More: Car Heater Smells: An In-Depth Analysis

FAQs

How To Diagnose Cummins Intake Heater Problems?

Diagnosing Cummins intake heater problems begins with inspecting wires for damage, testing the relay and control module, and checking for diagnostic trouble codes. The intake heater grid elements can also be tested to determine if they are faulty.

Is A Faulty Relay A Common Cause Of Cummins Intake Heater Issues?

Yes, a faulty intake heater relay is a common cause of Cummins intake heater problems. The relay controls power to the heating elements, so if it fails in an open or closed position, the intake heater will not function properly.

What Are Common Symptoms Of Cummins Intake Heater Problems?

• The intake heater fails to activate during cold starts, even when the control switch is turned on. This indicates a fault with the relay, wiring, or control module.

• The engine takes a long time to warm up after the cold starts. This suggests the intake heater is not preheating the air entering the engine.

• The check engine or glow plug light illuminates, and diagnostic trouble codes related to the intake heater circuit are present.

How Do You Replace A Faulty Cummins Intake Heater Grid?

You replace a faulty Cummins intake heater grid by removing the intake ducting, disconnecting wiring connectors, and removing mounting bolts to access the grid. The entire grid assembly is then removed and a new one installed, reconnecting all wiring and ducting.