amp draw on intake manifold air heater? - Dodge Cummins Diesel Forum

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post #1 of 13 (permalink) Old 01-20-2012, 11:32 PM Thread Starter
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amp draw on intake manifold air heater?

just wondering if anyone knows what each grid on the intake manifold air heater is supposed to be drawing.. I got about .5 ohms resistance on each grid, the math says about 25 amps for each x 2 grid heaters = 50amps total?

can anyone confirm these numbers?
(a wiring schematic would be a bonus!)


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post #2 of 13 (permalink) Old 01-20-2012, 11:54 PM
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The manual says approx 95 amps from each cable.
Here it is.
OPERATION
The air heater elements are used to heat incoming
air to the intake manifold. This is done to help
engine starting and improve driveability with cool or
cold outside temperatures.
Electrical supply for the 2 air heater elements is
controlled by the Engine Control Module (ECM)
through the 2 air heater relays. Refer to Intake Manifold
Air Heater Relays for more information.
Two heavy-duty cables connect the 2 air heater elements
to the 2 air heater relays. Each of these cables
will supply approximately 95 amps at 12 volts to an
individual heating element within the heater block
assembly.
Refer to the Powertrain Diagnostic Procedures
manual for electrical operation and complete description
of the intake heaters, including pre-heat and
post-heat cycles.

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post #3 of 13 (permalink) Old 01-21-2012, 09:09 AM Thread Starter
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Quote:
Originally Posted by waywardtravel View Post
The manual says approx 95 amps from each cable.
Here it is.
OPERATION
The air heater elements are used to heat incoming
air to the intake manifold. This is done to help
engine starting and improve driveability with cool or
cold outside temperatures.
Electrical supply for the 2 air heater elements is
controlled by the Engine Control Module (ECM)
through the 2 air heater relays. Refer to Intake Manifold
Air Heater Relays for more information.
Two heavy-duty cables connect the 2 air heater elements
to the 2 air heater relays. Each of these cables
will supply approximately 95 amps at 12 volts to an
individual heating element within the heater block
assembly.
Refer to the Powertrain Diagnostic Procedures
manual for electrical operation and complete description
of the intake heaters, including pre-heat and
post-heat cycles.
higher draw then i thought..thanks for the info. I think my relays are shot

2003 5.9 2500 / Auto / AFE intake / 4"lift / Magnaflow 4" /
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post #4 of 13 (permalink) Old 01-21-2012, 09:37 AM
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not your relays, there is a fuse link between the + side of the battery and the relays. it is not very easy to spot because it looks like insulation on the wire. just short across the top of one of the relays, if you get lots of sparks the fuse is good. the motor does not need to be turned on to do the test. you do not need the heaters, if the fuse is bad just do not wait to start and it will not throw a code.

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post #5 of 13 (permalink) Old 01-21-2012, 11:08 AM
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actually do need the heater with ambient air temps below -10d F.
speeds up engine start, warm up and cly/piston/ring raw diesel washdown at extreme cold temps.

the Dodge ECM on the Cummins overfuels badly at temps below -10d F, too much condensed cold air with rich oxy mix that the intake air temp sensor and ECM can't calculate. worst at cold idle and cold run.

guys in Minnesota, N. Canada and Alaska can give you examples

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post #6 of 13 (permalink) Old 01-21-2012, 06:50 PM Thread Starter
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im in northern canada, last week it was -48 Celcius. the heaters are a must as steelhead01 said.

the reason i say it is my relays are:

battery to relay : 12v
when ignition is on wait to start is engaged, ecm sends power to engage the relay (tested the posts from ecm - have power). at this point that relay should engage and i should see that 12v on both sides of the relay, which i don't

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post #7 of 13 (permalink) Old 01-21-2012, 11:01 PM
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probably relay solenoid coil ground.

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Last edited by steelhead01; 01-21-2012 at 11:06 PM.
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post #8 of 13 (permalink) Old 01-23-2012, 10:53 PM
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Just thought I'd put in my $0.02. Tested my intake heaters. Found they pulled 125 Amps each.

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post #9 of 13 (permalink) Old 01-23-2012, 11:16 PM Thread Starter
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Just thought I'd put in my $0.02. Tested my intake heaters. Found they pulled 125 Amps each.
right on thanks for the info. out of curiosity did you measure the draw from just the heaters or is that total truck draw?

2003 5.9 2500 / Auto / AFE intake / 4"lift / Magnaflow 4" /
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post #10 of 13 (permalink) Old 01-23-2012, 11:17 PM
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Yeah I figured they are about 100 amps each, of course resistive loads have larger tolerances.

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post #11 of 13 (permalink) Old 01-23-2012, 11:58 PM
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That's on each heater positive cable coming off the pass. side bat. measured between the bat and heater sol.

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post #12 of 13 (permalink) Old 01-09-2013, 01:35 AM
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Anyone ever see one of these relays remain closed and drain your battery? I think this happened to me earlier this week. I cleaned the terminals and reacharded the batteries, and everything seemed fine - just odd that the batt drained on me.

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