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Come along with Eric O. at the South Main Auto shop as he takes a look this 2002 Chevrolet 3500 with a 6.6 Duramax Diesel. The vehicle came in with an engine light and a code P0540 " Intake Air Heater Incorrect Voltage".
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50 thoughts on “Chevy duramax – p0540 intake air heater incorrect voltage”
  1. Avataaar/Circle Created with python_avatars kps gil says:

    I have same issue on volvo vnl truck. Are able share that schematic? Thanks for the video.

  2. Avataaar/Circle Created with python_avatars Bill Sanders says:

    Well if Ivan would take lessons he might not have so many come backs

  3. Avataaar/Circle Created with python_avatars richard3141592638 says:

    climbed up on that truck 60 times for the video – thanks Mr O

  4. Avataaar/Circle Created with python_avatars Appallo Kelley says:

    So I鈥檓 getting a air intake heater code/plug code. Should I just replace the relays ? I鈥檓 thinking that鈥檚 the issue.

  5. Avataaar/Circle Created with python_avatars Kenneth Franklin says:

    There was an ad every two minutes in this….

  6. Avataaar/Circle Created with python_avatars Robe Rey says:

    I think I'll just get a gas can and light my piece of shit gmc with all this bull crap ass problems and never buy another new vehicle again, I'll bring back to life my 70' chevy with a newer drive train..

  7. Avataaar/Circle Created with python_avatars Luis Mendoza says:

    Thanks, that help me alot

  8. Avataaar/Circle Created with python_avatars RP 502 says:

    that's why chrysler did away with those burdensome relays and went with trouble free tipm's馃槈

  9. Avataaar/Circle Created with python_avatars 讗诇讬专谉 eliran 住讜诇讜诪讜谉 solomon says:

    Hallo Eric , the things that caut my eye was that when u graund the relay whit the test light the test light did not became deem , thank you from isreal , great content

  10. Avataaar/Circle Created with python_avatars JetsetJoey says:

    Does anyone know the model number of the AUTEL scan tool being used???

  11. Avataaar/Circle Created with python_avatars Steve Waclo says:

    An excellent example of logical, thoughtful diagnostic procedure 馃憤馃憤馃憤. Well done sir!

    I鈥檓 on a personal crusade in regard to heater delete, and below have copied a rant I have posted elsewhere. One question that remains is when does the heater operate? I鈥檓 guessing it is independent of glow plugs. Just watched the rest of the video and you said 鈥渂elow 73F鈥, but for how long?

    Also, you should consider one of those 鈥渙ver the engine, reclining creepers.鈥 馃榾

    ********

    As an engineer myself, I must question mods or deletes on an engine which override the original intentions and motivations of fellow engineers who undoubtedly spent considerable time and effort designing various aspects of our Duramax engines. As we all know, economics of every aspect of vehicle design are an important part of decision making and unless a part is mandated by emissions regulations, I doubt anything is ever added without considerable research into the pros and cons. While I concede the heater coil no doubt causes some degree of intake restriction and turbulence, I鈥檓 confident those downsides were on the con side of the ledger, but were overridden by the benefits of better warmup characteristics during cold weather starts. Frankly, I don鈥檛 know at what ambient the heater is energized, but would be willing to bet there are benefits to warmer intake air, which may be transparent to the operator, but nonetheless contribute to better engine operating characteristics during that phase of operation.

    I also suspect that, short of dyno testing, there is little noticeable performance difference following removal of the heater, and even then, improvement is only at the margins.

    If anyone has numbers to refute my observations, I鈥檇 luv to see them.

    Delete on, homey and thanks for this otherwise well produced video. 馃憤

  12. Avataaar/Circle Created with python_avatars Trennis Wright says:

    Excellent video Eric!!! The best I've seen so far!!!

  13. Avataaar/Circle Created with python_avatars Robert Kohut says:

    Nice!! Tricky… 馃檪

  14. Avataaar/Circle Created with python_avatars bookerol says:

    Both of the relays were bad… 40 ohms on the glow plug coil and 1 ohm on the intake heater coil. Obviously, diesel vibration takes it's toll on those relays, eventually. Good catch Eric!

  15. Avataaar/Circle Created with python_avatars Howard Iko says:

    What is the model of Autel are you using? Like to have the same documents.

  16. Avataaar/Circle Created with python_avatars Garth Clark says:

    Nice demo Eric, was that serpentine belt manufactured on St Patrick's Day ? Nice to see how the circuits function with the control modules. Seems to me like many "computer" vehicles come in for problems that a non-computer vehicle would never come in for meaning, seems like the newer vintage has problems of their own which generate more maintenance vs. the old. Computer run vehicles are a dream if they work correctly however, if there's a failure while on the road, there's likely no roadside fix going to take place so it's flatbed time to a garage that is local to the breakdown location which is totally risky from my experience. Sounded like the lunch siren went off and Eric continued working as usual. Reminds me of the film, My Cousin Vinny, the local factory steam whistle at 5 AM, "to tell everyone its time to get up".

  17. Avataaar/Circle Created with python_avatars Moetic says:

    Hey that intake heater controller module near the fire wall on the gmc I'm trying to figure out where the ground white goes too i hooked all three wires right but I out have a black wire left which is the 4th black wire I forgot where it bolts too it's an 2003 gmc 6.6 diesel 2500 I did the injectors

  18. Avataaar/Circle Created with python_avatars Gabriel Malcolm says:

    My glow plugs arent seeing voltage on ignition either

  19. Avataaar/Circle Created with python_avatars Jake K says:

    My module only has one relay….. help

  20. Avataaar/Circle Created with python_avatars Ion Racer says:

    Had to watch on mute with the constant lip smacking….STOP IT!!!!!!!!!!

  21. Avataaar/Circle Created with python_avatars Sierra Vortec says:

    Man I wish I understood electrical half as much as you do

  22. Avataaar/Circle Created with python_avatars Mike Chiodetti says:

    Great Video. I've never seen a small relay do that, perhaps moisture or something got in there and did something to the insulation on the relay coil? Just thinking.
    Thanks Eric.

  23. Avataaar/Circle Created with python_avatars Wyo Kaiju says:

    Love the afternoon blast!

  24. Avataaar/Circle Created with python_avatars Duncan Mac says:

    The Nova was super nice. A labor of love considering the money involved. Great body work. Fun day in the shop. Thanks for the video.

  25. Avataaar/Circle Created with python_avatars Willie Gillie says:

    Shorted coil in one of the relays, nice catch

  26. Avataaar/Circle Created with python_avatars Jordan Wright says:

    Im just wondering I have asked all over and no one can give me a answer ive got a 2002 duramax with the 5 speed Allison and when I got to allerate it seems like it hesitates and blows a haze of black smoke I don't know if its the motor or the transmission. The transmission doesn't smell burn really there is a little but the color is still red. I would almost drescribe it as a 聽sluggish take off. It does not smoke anytime else other than alleration.

  27. Avataaar/Circle Created with python_avatars 906 PowerSports says:

    So what was the actual fix? Get 2 new relays inside the block?

  28. Avataaar/Circle Created with python_avatars Kayak USA says:

    New subscriber here, great video. My 02 Duramax is now throwing the same exact code. What's the OEM part number for that relay box? Thanks!

  29. Avataaar/Circle Created with python_avatars Tenright77 says:

    Excellent, oh that resistance. Thanks Eric…

  30. Avataaar/Circle Created with python_avatars Blake Ferrell says:

    Good catch

  31. Avataaar/Circle Created with python_avatars Daniel C. says:

    my goodness gracious can somebody have a little consideration because I tried to make my Youtube video!! Noise, noise, noise!!!
    LOL 馃槀!!!

  32. Avataaar/Circle Created with python_avatars California Cruisin鈥 says:

    My 2005 Chevy Silverado LT won't start unless the driver's door is opened and closed. I have a video on my channel, please help!

  33. Avataaar/Circle Created with python_avatars WMichael S says:

    Great video and explanation, demonstration. As usual.
    I think the big lesson is verifying the fix, using the ECM's output controls.
    Having written GM Powertrain diagnostics for 25 years, that is the last step we put in.
    OEM diagnostics are written for a tech/mechanic that does not have Eric's experience & skills. Therefore, they can be lengthy; however they are developed, tested, and verified on production vehicles – for all known faults that will set a DTC or cause a symptom.

  34. Avataaar/Circle Created with python_avatars Ozzstar's Cars says:

    That relay was kind of like a sci-fi situation. Did you get a chance to autopsy the old relay and find the contacts worn or dirty? What was causing the resistance issue?

  35. Avataaar/Circle Created with python_avatars Kyle Donovan says:

    Amazing

  36. Avataaar/Circle Created with python_avatars Brandon Hildebrand says:

    Hey man just wandering what do you use for all of your electrical diagrams and competent diagrams?

  37. Avataaar/Circle Created with python_avatars bodgit and leggit garage says:

    OEM parts only way to go great vid mate

  38. Avataaar/Circle Created with python_avatars mobilemechman says:

    That one would have thrown me for a loop for sure. Good call E.O.!

  39. Avataaar/Circle Created with python_avatars Jonathan Dean says:

    Hi Eric, just a quick question if you don't mind, on a Diesel engine do they have EGR flow at idle? Thanks Jonathan

  40. Avataaar/Circle Created with python_avatars Alex Andrea says:

    Do you think th autel scanner is good? What do you think

  41. Avataaar/Circle Created with python_avatars halleffect1 says:

    $200 relay holder.. what a racket.

  42. Avataaar/Circle Created with python_avatars cortes 433 says:

    what type of scaner are you using on this video

  43. Avataaar/Circle Created with python_avatars daveyio87 says:

    Great video! Something that could have been easily misdiagnosed!

  44. Avataaar/Circle Created with python_avatars Gerald Hinson says:

    Btw, why did you use the Vantage instead of the Verus? Just curious.

  45. Avataaar/Circle Created with python_avatars Ifeco Jahs says:

    I always look forward to seeing your videos. Thank you so much.

  46. Avataaar/Circle Created with python_avatars M. X. says:

    Eric O. what do you mean or what does it mean when you say CONTROL SIDE and why is it the CONTROL SIDE.

  47. Avataaar/Circle Created with python_avatars Matt W says:

    Man that was some trying conditions with the interruptions!!

  48. Avataaar/Circle Created with python_avatars Richard Gill says:

    Great informative video Dr.O