P2609: Diesel intake air heater system performance fault
Intake Air Heater System Performance
Severity: Inspect soon
The intake air heater helps a diesel start and run cleanly when cold, so a fault means hard cold starts and white smoke. FCA says the heater cable can overheat, so it should be inspected soon.
P2609 in short
P2609 means the computer found the intake air heater, which warms incoming air on a diesel, is not performing as expected. On 2012-2016 6.7L Cummins Ram trucks, FCA says to replace the heater grid and relay as a set and inspect the cable for overheating. Cold starts may be hard.
A diesel engine can be hard to start in cold weather. An intake air heater warms the air entering the engine, and the computer commands it through a relay and watches its current.
P2609 sets when the heater does not perform as expected. KBB lists the heater element, relay, wiring, a fuse and the control module as causes. For the 6.7L Cummins in 2012 to 2016 Ram trucks, FCA says intake heater issues or P2609 and P0542 call for replacing the heater grid and relay as a set and inspecting the cable for overheating.
Skipping the cable inspection can leave a damaged cable behind, so have the whole circuit checked rather than swapping one part.
Most likely causes
Cause 1: Failed intake heater grid or relay
Supported by vehicle data- Why it ranks here
- FCA bulletin 68210071A on 2012-2016 6.7L Cummins says to replace the heater grid and relay together for these symptoms, and KBB lists both as causes.
- What would change this
- Rises on a covered Ram with hard cold starts and white smoke. Falls if heater current and relay output are normal.
Cause 2: Overheated or damaged heater cable
Supported by vehicle data- Why it ranks here
- The FCA bulletin says to inspect the cable for overheating.
- What would change this
- Rises if the cable or terminal is discolored or melted. Falls if it is intact.
Cause 3: Blown fuse or wiring or connector fault
Common general cause- Why it ranks here
- KBB lists a fuse and wiring or connector problems as common causes.
- What would change this
- Rises if the fuse is blown or the circuit has damage. Falls if power reaches the relay.
What to test first
Start at step 1. Each result tells you what it means and where to go next.
Step 1: With the engine off, inspect the heater fuse, relay, cable and terminals for burning, melting or loose connections.
Warning:The heater circuit carries high current. Disconnect the battery before touching its cable.
IfThe cable or terminal is discolored or melted
It meansCable overheating is the cause.
IfThe fuse is blown or the wiring is damaged
It meansFix the wiring cause before fitting a fuse.
IfEverything looks normal
It meansTest heater current and relay output.
Step 2: Have a shop command the heater and measure the current draw and relay operation with a scan tool and clamp meter.
Warning:The heater circuit carries high current; do not touch its cable or terminals while it is energized.
IfLow or no current, or the relay does not click
It meansThe grid or relay has failed; FCA says replace both.
Symptoms
- Check engine light on
- Hard starting in cold weather
- White smoke at cold start
How to fix
Step 1: Have the intake heater cable, relay and grid inspected, and ask your Ram dealer about bulletin 68210071A.
Parts and cost context
- Engine control module (ECM / PCM):The intake air heater and relay are not in our components list. FCA says replace the grid and relay as a set on covered trucks. Labor varies; get a quote.
Labor varies by vehicle and shop; get a quote before you approve a repair.
Compare used part prices on PartPriceGuideOn your vehicle
RamYour car
2013–2016 · 2500 · 6.7L Cummins
Supported by vehicle dataFCA bulletin 68210071A covers 2012-2016 6.7L Cummins trucks with intake heater issues or P2609 and P0542: replace the heater grid and relay as a set and inspect the cable. Whether it is current is not verified.
68210071AStatus unverified
Intake heater issues or P2609 and P0542: replace heater grid and relay as a set; inspect cable
2013–20162500, 3500 · NHTSA 10121737
Replace the heater grid (05187880A) and relay as a set and inspect the cable for overheating on 6.7L Cummins trucks.
We couldn't confirm whether this bulletin is still current, so it doesn't count as confirmation.
Related codes
No curated relationships for P2609 yet.
P2609 questions
Why replace the grid and relay together?
FCA bulletin 68210071A tells technicians to replace both as a set on 6.7L Cummins trucks and to inspect the cable for overheating.
Sources and review
- P2609 Code: Intake Air Heater System Performance
- FCA 68-21-00-71A: intake heater issues or P2609 and P0542 on 2012-2016 6.7L Cummins (replace heater grid and relay as a set)
- Last reviewed
- Written by
- Saurabh K.
- Editorial review
- Pending
- Technician review
- Technician review pending
This page explains what a code usually means; it is not a substitute for a professional inspection. How we source and review · Report an error