P2609, after P2262 and P0401

[kathleenhellhole]

Advice please. While on vacation I got a P0401 and later P2262 codes. Took to dealer and they cleaned the EGR and took care of cooler and cleaned the turbo after first telling me I needed a new turbo. Truck ran fine with those codes and still ran fine today but got new code in morning (not a cold day either) P2609, "Intake Air Heater System Performance". Dealer ran check of all codes and this is the only "active" one, rest show "stored". They are giving me the run-around about getting the truck in and leaving it. Question: Is it possible or likely that when the work was done on the turbo and EGR (less than 200 miles ago) that a wire was broken to the Intake heater or not connected properly? Any and all other suggestions would be appreciated. Truck is 2009 2500 4x4 with 6 speed manual trans 6.7L . Thank you for any words of wisdom. Truck has also been a pain from the beginning with O2 sensors. Currently less than 60K for miles but out of warranty by a few months. :--)

 

[jjhall]

I haven't had p0401, but I've had the others. First p2262 last summer; truck was running like EB was on all the time, but cleaning the turbo fixed it. P2609 showed up at the beginning of the summer. I haven't rushed to deal with it because it's been warm, but I checked the relay and it seemed to be working properly. I measured resistance between the terminal on the grid heater and ground and found an open circuit. It's my understanding that it should have continuity, so I think the problem is in the grid heater itself.

I thought the two were unrelated, but your post has made me reconsider. From what I understand, p0401 and p2262 are both caused by excess soot. I suppose if there was enough carbon built up on the heater grid, it would act as an insulator and decrease heat transfer to the intake air. However, the intake air sensor would still be reading cold air, so the computer would command more current to the heater. It's possible this could cause the heater to burn up -- this is all just conjecture though.

A year and 20k miles after the cleaning, p2262 showed up again the other day, along with p2563 (turbo actuator sensor). The truck isn't running as badly as it did last time. I'm debating whether to spend another $250 on re-cleaning, or drop $2100 on a new turbo. I don't think cleaning is a permanent solution for me at this point -- though I think it's worked for some people -- but I'm a little worried that even replacing the turbo won't be the end of the problem.

 

[kathleenhellhole]

With a lot or research and determination I solved my problem. When the dealer did the work for P0401 and P2262 they disconnected the batteries and failed to tighten the negative posts on both batteries. This is what caused the P2609 code. I tightened the connections (they were finger tight...wonder it started at all) then took it to great (real mechanic) and he checked and cleared all the codes. Been running fine ever since and no more codes. Personally I believe the dealer does this on purpose in order to get in big ticket repair bills and thinking I am just a stupid woman willing to pay anything to get my truck fixed. I took it back to Jack Powell in Escondido, CA and let them run the diagnostic (free) and showed them I don't need a $3500 turbo. I think the service writer was a little surprised and disappointed. I have had several offers from them to buy my truck back for their used vehicle inventory, at **** poor price I am sure. Either I should get rid of this problem OR they create a situation in which I would want to get rid of it. Not sure what I will do at this point. The truck is a real beast when running good which is most of the time. Will see when I get moved out of California and some of this CA smog crap pulled off. Seems that it is the smog/emissions stuff that causes these problems. Thanks for your reply and good luck with your situation.

 

[sag2]

I doubt dealers are that smart to leave a connection lose so they can sell you something else. More likely lack of paying attention. And the P2262 will not usually fix itself, it is caused by soot build up.

 

[kathleenhellhole]

I DID have the turbo and EGR cleaned. It was after that I got the P2609 code. So when I took it back Jack Powell immediately went to "replace the turbo" again. Perhaps it was negligence or an oversight that they did not tighten up the negative posts BUT from the git-go their recommendations were replace the turbo. Also have to realize that the day I got this truck (2009 brand new) it had a check engine light...O2 sensor and this problem continued for 6 different occasions before being resolved. I no longer have any confidence in this dealership.

 

[sag2]

They actually are a really good store in the area. They get lots of work from other dealers around them. The reason they go to replace is the cleaning procedure is really a crap shoot that it will work. It is a few hours work and if it doesn't work the customers want it for free. So to avoid the hassle the technician is going to recommend the replacement.

 

[kathleenhellhole]

Sounds more like a "parts changer" than a mechanic if that is the case. Not the first time I have had problems with Jack Powell. Before the one in Poway closed (Wes Hinckle?) I drove down there because there was a service writer I could trust...now all they are interested in is $$$$.