INTAKE AIR HEATER RELAY CIRCUIT
CUMMINS
FAULT CODE: 381
PID: S237
SPN: 626
FMI: 11
Intake Air Heater Relay Circuit
DESCRIPTION
The intake air heater improves starting and white smoke control in
cold ambient conditions. The ECM controls relays that switch
power to the air heater. There are two heating coils in the heater
that are individually controlled by the ECM.
- These faults could also indicate the intake air heater circuits are
shorted to battery (+). This would command the grids to be on full
time. This will drain the batteries, burn out grids, and/or destroy
intake gaskets.
- The intake air heater circuits will only activate when intake
manifold temperature is below 19°C [66°F], when the key switch is
in the ON position.
COMPONENT LOCATION
The intake air heater is located at the air inlet connection into the
intake manifold. The location of the heater relays will vary with the
OEM.
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TROUBLESHOOTING STEPS
Step 1A) Turn key switch OFF and disconnect the OEM harness from the ECM. Disconnect the intake air
heater relay. Inspect the OEM harness, intake air heater relay, and ECM connectors for the following:
• Loose connectors
• Corroded pins
• Bent or broken pins
• Pushed back or expanded pins
• Moisture in or on the connector
• Missing or damaged connector seals
• Dirt or debris in or on the connector pins
• Wire insulation damage
• Connector shell broken
• Damaged locking tab connector
No damaged pins?
Yes - Go to 1B No - Repair or replace the OEM harness, ECM, or
intake air heater relay, whichever has damaged pins
Go to 2A
Step 1B) Turn key switch OFF and disconnect the OEM harness from the ECM. Disconnect the OEM
harness from the intake air heater relay connector. Check for an open circuit in the relay enable circuit.
Measure the resistance from the intake air heater relay pin in the OEM harness connector to the harness
side of the heater relay connector. Refer to the following to determine the correct pins to check for each
fault: OEM harness connector pin 41 to heater relay 1 (pin A).
Less than 10 ohms?
Yes - Go to 1C No - Replace the OEM harness
Go to 2A
Step 1C) Turn key switch OFF and disconnect the OEM harness from the intake air heater relay connector.
Check for an open circuit in the relay and relay ground. Measure the resistance of the relay and its ground
on the pull-in-coil-side of the relay.
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Open circuit in the relay and relay ground?
Yes - Refer to the OEM troubleshooting and repair No - Replace relay or ground circuit. Refer to the
manual for specification OEM troubleshooting and repair manual.
Go to 1D Go to 2A
Step 1D) Turn key switch OFF and disconnect the OEM harness from the intake air heater relay connector.
Disconnect the OEM harness connector from the ECM. Check for a short circuit to ground in the intake air
heater relay circuit. Measure the resistance from the intake air heater relay pin in the OEM harness
connector to engine block ground. Refer to the following to determine the correct pins to check for each fault:
OEM harness connector pin 41.
More than 100k ohms?
Yes - Go to 1E No - Replace the OEM harness
Go to 2A
Step 1E) Turn key switch OFF and disconnect the OEM harness connector from the ECM. Disconnect the
intake air heater relay connector from the OEM harness. Check for a short circuit from pin to pin in the intake
air heater relay circuit. Measure the resistance from the intake air heater relay pin in the OEM harness to all
other pins in the OEM harness connector. Refer to the following to determine the correct pins to check for
each fault: OEM harness connector pin 41.
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More than 100k ohms?
Yes - Go to 1F No - Replace the OEM harness
Go to 2A
Step 1F) Disconnect the OEM harness from the ECM. Turn key switch ON and check for a short circuit to
battery. Measure the voltage from pin 31 and 41 in the OEM harness to the block ground.
Less than 1.0 (+) VDC?
Yes - Go to 2A No - Replace the OEM harness
Go to 2A
Step 2A) Connect all components. Turn key switch ON and disable the fault code. Start the engine and let
idle for 1 minute. Verify Fault Codes 381 are inactive.
Fault Codes 381 inactive?
Yes - Go to 2B No - Return to troubleshooting steps or contact local
Cummins Authorized Repair Location if all steps
have been completed and checked again
Go to 1A
Step 2B). Connect all components. Turn key switch ON and clear the inactive fault codes using the
diagnostic tool.
All fault codes cleared?
Yes - Repair is complete No - Troubleshoot any remaining active fault codes
with appropriate troubleshooting steps.
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