This procedure covers the removal and replacement of the Manifold Absolute Pressure (MAP) sensor on the 6.7L Cummins diesel engine intake manifold.

Warnings

Tools required

Parts

• Manifold Absolute Pressure (MAP) Sensor × 1 — Mopar 68105033AB or equivalent

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition off and remove key
3. Allow engine to cool completely for at least 30 minutes
4. Open hood and secure with prop rod
5. Disconnect negative battery cable to prevent electrical faults during sensor replacement

Procedure

1. 1

   Locate MAP sensor
   The MAP sensor is located on the driver's side of the intake manifold near the front of the engine. It is a small cylindrical sensor with a 3-wire electrical connector. Visually inspect the area for any debris or damage to surrounding components.
2. 2

   Disconnect electrical connector
   Press the red locking tab on the MAP sensor electrical connector and pull the connector straight off the sensor. Do not pull on the wires. Inspect the connector terminals for corrosion or damage. If connector shows signs of corrosion, clean with electrical contact cleaner and allow to dry completely.
3. 3

   Remove MAP sensor mounting screws
   Using the appropriate screwdriver or socket, remove the two mounting screws securing the MAP sensor to the intake manifold. Keep these screws in a clean location as they will be reused if in good condition. Note the orientation of the sensor before removal.
   Torque spec

   MAP Sensor Screws3 Nm (2 lb-ft)
4. 4

   Remove old MAP sensor
   Carefully pull the MAP sensor straight out from the intake manifold. There may be a small O-ring seal on the sensor body. Inspect the mounting bore in the intake manifold for any debris, oil contamination, or damage. Clean the mounting surface with a clean shop towel if needed.
5. 5

   Prepare new MAP sensor
   Remove the new MAP sensor from packaging and inspect for any shipping damage. Verify that the new sensor has an O-ring seal installed on the body. If the O-ring is not pre-installed, install it ensuring it seats properly in the groove. Do not use oil or grease on the O-ring unless specified by manufacturer.
6. 6

   Install new MAP sensor
   Align the new MAP sensor with the mounting holes in the intake manifold, ensuring the sensor body is oriented correctly to allow electrical connector access. Insert the sensor straight into the bore until it seats fully against the mounting surface. Do not force or rock the sensor during installation.
7. 7

   Install and torque mounting screws
   Thread both MAP sensor mounting screws by hand to ensure proper thread engagement. Once both screws are started, use a torque wrench to tighten the screws to specification in a cross-pattern. The low torque specification requires careful attention to avoid over-tightening.
   Torque spec

   MAP Sensor Screws3 Nm (2 lb-ft)
8. 8

   Reconnect electrical connector
   Apply a small amount of dielectric grease to the sensor terminals if desired for corrosion protection. Align the electrical connector with the sensor and push firmly until the red locking tab clicks into place. Gently tug on the connector to verify it is fully locked.
9. 9

   Reconnect battery and clear codes
   Reconnect the negative battery cable. If a check engine light was present prior to sensor replacement, it may be necessary to clear diagnostic trouble codes using a scan tool, or allow the vehicle's onboard diagnostics to clear the codes after several drive cycles.

Reassembly

1. Ensure all electrical connections are fully seated and locked
2. Verify no tools or parts have been left in the engine compartment
3. Close hood securely

Verification

• Start engine and verify it runs smoothly without rough idle or stalling
• Check for any check engine lights on the instrument cluster
• Use a scan tool to verify MAP sensor is reading atmospheric pressure with key on engine off (approximately 14.7 psi at sea level)
• With engine running, verify MAP sensor reading changes appropriately with throttle input
• Test drive vehicle to ensure normal performance and boost pressure response
• Re-check for diagnostic trouble codes after test drive

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