JC55

Has this happened to any one?
My truck is a 2006 and is stock exept cold air intake and smarty jr after a 2 1/2 hour trip over the Sierra's this weekend check engine light came on when truck was warming up PO541. Intake heater must have stayed on after I got home and draned the battery, cooked the wire from battery to relay, and discolored the intake elbow from heat. What could have caused this? When I charged the batterys and conected the cables the intake heater warmed up with the ignition off. I disconected the power to the relay, ohmed out the relay thinking it was stuck closed but it was open . Could it be the Smarty Jr. I just installed?
HELP!

mq105

Are you saying that there is no voltage to the heater with the relay trigger wires disconnected? In other words, the relay is working properly and the trigger wires have voltage with the ignition off?
Put your meter on the relay trigger wires. Are they energizing the relay with the ignition off?
If this is the case, then you need to find the source of the voltage to the trigger wires. Hopefully a battery-hot wire is rubbed through and touching.
If something is signaling the relay to energize then you have a TIPM or other box-type thing happening. I wouldn't know where to start on that.

JC55

Heater disconected relay apears to work ok when ingnition is turned to on. Relay closes and then opens as it should. Now showing a p0541 again and P2609. When I got home yesterday I did smell somethig burning and whished I would have checked it out. Too late now!

mq105

So when the ignition is off, there is no voltage to the relay trigger wires? Also, no voltage to the grid heater wire?

If so, the relay may be going bad and somehow it stuck closed, or you have an intermittent source of power to the trigger wire. Any wear on the trigger wires? Any power source that could be touching?

Codes are due to the fact that the heater is not plugged in.
P0541 Intake Air Heater Relay 1 Low
P2609 Intake Air Heater System Performance

JC55

With ign. off .065 V to triger wire ign. on & no call for heater 4.28 V. Is it a 12vdc coil on the relay?
Relay open still no wire from batt. to relay. From load side of relay to batt. (-) is 0.7 ohms that would be about 18 amp draw on heater dose that sound right? Just not sure what would make intake over heat. looks like it got pretty hot to discolor elbow like it did.

gadget

My two cents? You live in California - take it out! : )