GRID HEATER PLATE UPGRADE KIT Installation Instructions

Applications / Fitment:

2007–2026 6.7L Cummins Turbo Diesel
Dodge/Ram 2500 / 3500 Pickup
Dodge/Ram 3500 / 4500 / 5500 Cab & Chassis

Download SPELAB Grid Heater Plate for 2007-2026 Dodge Ram 6.7L Installation Guide

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Introduction

This kit includes everything required to upgrade the electrical components found on the intake grid heater—eliminating the terminal stud and nut that is a well-known failure point and also addresses the fastener located between the heating elements. The kit provides worry-free stock performance while being easy to install and maintaining emissions compliance.

This kit is designed to upgrade the electrical circuit for the components found on the Cummins intake grid heater. It directly addresses the known weakness of the grid heater where the stud and nut on the underside of the heater regularly sees 200A causing it to work itself loose, arc, melt, and eventually fall into the engine leading to expensive repairs or even replacement. By eliminating the stud and nut and replacing it with an upsized bolt fastened through the top of the grid heater, this kit offers reliable performance and peace-of-mind. The updated kit now also addresses the melting fastener found in between the heating elements by directly connecting the busbar to the heating element. Additional features include self-locking threads in the lower busbar to maintain clamping force, included specialty tools for heater disassembly, and replacement of all the stock fasteners and gaskets.

Removal of Grid Heater

Record radio settings before disconnecting the negative terminals and then the positive terminals on both of the vehicle's batteries.

Pull out the oil dipstick then remove the four bolts that secure the plastic cover to the engine (8mm).
Disconnect the EGR valve connector from the EGR valve.
Note: For 2011+ models, the temperature sensor connector will need to be disconnected as well.
Loosen the EGR cross over pipe clamps (11 mm) and slide them down the pipe. Remove the bolt located at the center of the pipe, and remove the pipe from the vehicle (8mm).
Note: When releasing the pipe from the engine there will be a loose washer on both sides. Be sure not to lose these as they will be reused.
Remove the bolt holding the dipstick tube to the intake horn (10mm).
For 2013+ models: Remove the heatshield covering the intake control valve.
Loosen the clamp between the rubber coupler and the intake horn. Use a blade screwdriver to gently break the seal.
Pull off the harness clip from the intake horn.
Disconnect the thermocouple from the backside of the intake horn, along with the bracket securing the wiring harness to the horn (10mm).
Unplug the map sensor plug.
Remove the 6 bolts (10mm) that secure the horn to the engine.
Gently twist the intake horn to expose the throttle valve sensor on the bottom of the horn. Disconnect the throttle valve connector then remove the horn from the vehicle.
Note: The connector will need to be disconnected before you remove the horn from the vehicle.
Photo shown on bench for clarity.
Disconnect the breather hose to the motor. Disconnect the two fuel line harness connectors on the side of the motor.
Using a puller tool pull out the harness clips that secure the harness to the grid heater and the other clip on the backside of the valve cover.
For 2013+ Models: Remove the sound deadening foam rubber from around the fuel injection lines to allow access to the fuel lines.
Disconnect the high pressure lines from the rail. 2019-2020 models with the CP4 injection pump will have two high pressure lines. The remaining models, including 2021+, will have one high pressure line.
Refer to the end of the manual for a detailed view of the fuel rails and lines.
Loosen the fittings on the line that goes from the fuel rail to the fuel pump. Once both fittings are loose the line can be removed from the vehicle.
For 2019-2020 Models: The models with the CP4 pump have 2 lines to be removed from the side.
For 2007-2018 Models: Remove the banjo bolt with washer from the front side of the fuel rail (17mm).
For 2019+ Models: Remove the fuel return line (1) by removing the fuel return line banjo bolts (2, 3, 4).
Note: It is possible to remove the fuel rail with just the removal of bolt (2) by slipping it out from under the return line. Be careful not to excessively bend the line.
Remove the six injector lines starting with loosening of the fittings at the front of the fuel rail and the #1 injector (19mm). As you remove the fuel lines identify them in some way (eg. masking tape and felt pen) so they can be easily reinstalled in the same location.
Note: Fittings on both sides of the line will need to be backed off before the line can be removed.
Disconnect the intake air temperature sensor connector from the grid heater.
Note: 2013+ models have this sensor located closer to the driver side of the intake plate.
Disconnect CCV pressure sensor harness connector that is located at rear of the valve cover. This needs to be disconnected to allow you to coil the harness aside to access the grid heater.
Disconnect the EGR servo motor connector.
Remove the power wire from the grid heater (10 mm).
Remove the four bolts holding the fuel rail to the grid heater (10mm).
Disconnect the fuel rail connector from the back of the rail.
Note: For 2019+ models the harness connector is facing down.
Remove the four remaining bolts that hold the grid heater to the engine.
With the four bolts removed you may need to gently pry the grid heater from the gasket before it can be removed from the vehicle.
Note: Clean off the old gasket if any is left on the engine and wipe clean so the new gasket will have a good seal.

Installation of Grid Heater

Apply some pipe dope to the four OEM intake bolts then install the grid heater plate with the supplied gasket. Tighten to 18 ft-lbs (24.4 Nm).
Note: Threading in the intake horn bolts finger tight will help with the alignment of the holes so the horn will be easier to install later. Unthread intake horn bolts once the plate is in place.
Check the torque of the six (6) fuel injector connector tube nuts. Torque to 41 ft-lbs (55 Nm).
Reconnect the fuel rail connector. Then apply some pipe dope to the four OEM fuel rail bolts and install the fuel rail to the intake plate. Torque to 18 ft-lbs (24.4 Nm).
Reinstall the six injector lines (19mm). Torque to 30 ft-lbs (40.7 Nm).
For 2019+ Models: Reinstall the fuel return line as shown.
For 2007-2018 Models: Reinstall the banjo bolt with washers back into the side of the fuel rail (17mm).
Reinstall the line that goes from the fuel rail to the pump. 2019-2020 models will have 2 lines to reinstall.
Install the heater cable to grid heater stud using the supplied Nyloc nut. Tighten to 9 ft-lbs (12.2 Nm).
IMPORTANT! Ensure the cable connector is clocked so that it is butted up on the stop between the bolt head and grid heater stud when tightening to prevent contact with the bolt head.
Use the included zip ties to secure the heater cable to a nearby wire or component.
Reconnect the air breather hose to the motor and the fuel line harness connectors on the side of the motor (x2).
Reconnect the servo motor connector and CCV pressure sensor connector located behind the valve cover.
Reconnect the IAT sensor connector to the sensor in the intake plate.
Reconnect the harness clips onto the fuel rail in the same location as they were removed from.
Reconnect the throttle valve sensor to the bottom of the intake horn.
Reinstall the OEM horn into rubber coupler and fasten intake horn into place with the six bolts (10mm) along with the supplied gasket. Torque to 18 ft-lbs (24.4 Nm). Then tighten clamp at the rubber coupler connection.
Reconnect the thermocouple on the backside of the horn and reattach the bracket securing the wiring harness (10 mm). Reconnect the MAP sensor.
Reinstall dipstick bracket.
For 2013+ models: Reinstall the heatshield covering the intake control valve.
Reinstall the harness clip back onto the horn.
Reinstall the cross over pipe clamps (11 mm) and slide them down the pipe. Install the bolt (8mm) located at the center of the pipe, and tighten the clamps.
Reconnect the EGR valve connector to the EGR valve.
Note: For 2011+ models, reconnect the temperature sensor.
Reinstall the four bolts that secure the plastic cover to the engine (8mm). Reinsert the oil dipstick.
Once complete test the vehicle for proper function and check for leaks.

Troubleshooting and Diagnostics

DTC P2609 or P0542 Code Set: These codes indicate an issue with the Intake Air Heater System Performance. During the grid heater preheat cycle, the intake air heater monitor looks for a calibrated voltage drop to detect proper heater operation.

Diagnosis: The common cause of this DTC is an incorrectly installed grid heater upgrade kit, usually due to errors when installing insulating washers. Start by referring to the images on Page 4 and Page 24 to check for correct washer order installation.

With the kit installed in the truck, check for functionality of the heater by using a clamp ammeter on the power wire going to the grid heater. If it's working properly, you should get a reading of approximately 200A while the heater is on. Check that the grid heater circuit is properly grounded by testing resistance between the grid heater power connection point and battery negative using a multimeter. This should read zero or close to zero ohms. Further diagnosis will require removal of the grid heater in order to inspect.

Detailed View of 2019+ Fuel Rails

For model years 2019 and 2020, the Cummins 6.7L engine came with a CP4.2 injection pump before reverting back to a CP3 for 2021+.

Below is a detailed view of the 2019-2020 fuel rail. Note that there are two high pressure lines (16 and 17).

Below is a detailed view of the 2021+ fuel rail. Note that there is only high pressure line (15).

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