Replace the boost pressure sensor on the 6.7L Cummins diesel engine to restore proper turbocharger boost monitoring and engine performance.

Warnings

Tools required

Parts

• Boost pressure sensor × 1 — Mopar 68249003AA or equivalent

Preparation

1. Park vehicle on level surface and apply parking brake
2. Turn ignition off and remove key
3. Open hood and secure with prop rod
4. Disconnect negative battery cable to prevent fault codes during sensor replacement
5. Allow engine to cool to ambient temperature if recently operated

Procedure

1. 1

   Locate boost pressure sensor
   The boost pressure sensor is mounted on the passenger side of the intake horn between the turbocharger outlet and the charge air cooler inlet. It is a small cylindrical sensor with a single electrical connector and threaded body. Identify the sensor location before proceeding.
2. 2

   Disconnect electrical connector
   Press the red locking tab on the electrical connector and pull the connector straight away from the boost pressure sensor. Do not pull on the wiring harness itself. If connector is difficult to release, use a small pick or electrical connector release tool to depress the locking tab fully.
3. 3

   Remove boost pressure sensor
   Using a 10mm socket, carefully unscrew the boost pressure sensor from the intake horn in a counterclockwise direction. Support the intake horn with your other hand to prevent stress on connecting boots. Remove the sensor completely and inspect the threads on both the sensor and intake horn for damage or debris.
4. 4

   Clean mounting area
   Use a shop towel to clean the sensor mounting hole in the intake horn. Remove any dirt, oil residue, or debris from the threads and sealing surface. If corrosion is present, carefully clean threads with a wire brush. Inspect the O-ring sealing surface inside the intake horn for damage or gouging.
5. 5

   Prepare new sensor
   Inspect the new boost pressure sensor for damage during shipping. Verify the O-ring is properly seated in the sensor body groove. Optional: Apply a small amount of anti-seize compound to the sensor threads, avoiding the O-ring area and sensor port. Do not use thread sealant or excessive anti-seize as this can contaminate the intake system.
6. 6

   Install new boost pressure sensor
   Thread the new boost pressure sensor into the intake horn by hand in a clockwise direction until it seats against the O-ring. Ensure the sensor threads in smoothly without resistance. If binding occurs, remove and check for cross-threading. Hand-tighten the sensor until snug, then use a torque wrench and 10mm socket to tighten to specification.
   Torque spec

   Boost Sensor15 Nm (11 lb-ft)
7. 7

   Reconnect electrical connector
   Push the electrical connector onto the boost pressure sensor until you hear and feel a positive click. The red locking tab should snap into the locked position. Gently tug on the connector to verify it is securely latched. Ensure the wiring harness has adequate slack and is not stretched or kinked.
8. 8

   Reconnect battery and clear codes
   Reconnect the negative battery cable. Turn the ignition to the ON position without starting the engine. Wait 10 seconds, then turn ignition OFF. This allows the ECM to detect the new sensor. If a scan tool is available, clear any diagnostic trouble codes related to boost pressure that may have been set during the repair.

Reassembly

1. Ensure all electrical connections are secure and locked in place
2. Verify boost pressure sensor is torqued to specification and not over-tightened
3. Check that wiring harness has proper routing and is not contacting hot surfaces

Verification

• Start engine and allow to idle for 2 minutes, listening for unusual air leaks around the sensor
• Rev engine to approximately 2000 RPM and verify no air leaks or whistling sounds from sensor area
• Use a scan tool to verify boost pressure sensor is reading atmospheric pressure at idle (approximately 14.7 PSI at sea level)
• Perform a test drive with moderate acceleration to verify proper boost pressure readings and no check engine light
• If scan tool is available, monitor boost pressure under load to confirm readings are within normal range (typically 25-35 PSI under acceleration)

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