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Check the Intake Grid Heater stud connection to see if it is loose. If it is loose and/or melted then I'd suspect the nut on the inside of the intake probably melted off and got inhaled into the combustion chamber. Not good.
Sorry to hear you are experiencing this, we certainly understand why this would be concerning. If you end up addressing this with your local dealer, please let us know via PM. We'd be more than happy to provide you with an additional layer of assistance for that process.
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