This procedure covers the removal and replacement of the oil level sensor on the 6.7L Cummins diesel engine, which monitors engine oil level and alerts the driver to low oil conditions.

Warnings

Tools required

Parts

• Oil level sensor × 1 — Use OEM Mopar specification for 6.7L Cummins
• Oil level sensor O-ring seal × 1 — Usually included with sensor

Fluids

• Mopar 5W-40 Synthetic Diesel Engine Oil — 1 qt

Preparation

1. Ensure engine is cool and vehicle has been sitting for at least 15 minutes to allow oil to drain to pan
2. Disconnect negative battery terminal to prevent electrical faults during sensor removal
3. Raise and support vehicle on jack stands if additional clearance is needed for access
4. Locate the oil level sensor on the driver side of the oil pan, approximately mid-length of the pan
5. Clean the area around the sensor with parts cleaner to prevent contamination

Procedure

1. 1

   Position drain pan
   Place oil drain pan directly beneath the oil level sensor location on the driver side of the oil pan. Expect approximately 0.5-1 quart of oil to drain when the sensor is removed.
2. 2

   Disconnect sensor electrical connector
   Locate the electrical connector attached to the oil level sensor. Press the release tab and carefully pull the connector straight off the sensor. Inspect connector terminals for corrosion or damage.
3. 3

   Remove oil level sensor
   Using the appropriate socket, carefully unscrew the oil level sensor from the oil pan in a counterclockwise direction. Allow oil to drain into the pan as the sensor is removed. Remove the sensor completely and set aside.
   Torque spec

   Oil Level Sensor15 Nm (11 lb-ft)
4. 4

   Inspect sensor mounting hole
   Examine the threaded hole in the oil pan for debris, metal shavings, or damage to the threads. Use a wire brush to clean threads if necessary. Wipe clean with a shop towel. Check the old sensor O-ring for damage or deterioration.
5. 5

   Prepare new sensor
   Remove the new oil level sensor from packaging. Verify it matches the old sensor design. Check that the new O-ring seal is properly seated in the sensor groove. Apply a light coating of clean engine oil to the O-ring to aid installation.
6. 6

   Install new oil level sensor
   Thread the new oil level sensor into the oil pan by hand, turning clockwise. Ensure it threads smoothly without cross-threading. Once hand-tight, use a torque wrench to tighten the sensor to specification.
   Torque spec

   Oil Level Sensor15 Nm (11 lb-ft)
7. 7

   Reconnect electrical connector
   Spray electrical contact cleaner on the sensor terminal if needed. Align the electrical connector with the sensor terminal and push firmly until the locking tab clicks into place. Gently tug on the connector to verify it is secure.
8. 8

   Check oil level and add if necessary
   Lower vehicle if raised. Reconnect negative battery terminal. Check engine oil level with dipstick. Add Mopar 5W-40 synthetic diesel engine oil as needed to bring level to the full mark. Account for oil lost during sensor removal.

Reassembly

1. Ensure electrical connector is fully engaged with audible click
2. Verify no oil leaks are present around sensor installation area
3. Double-check that torque specifications were met on sensor installation

Verification

• Start the engine and allow it to idle for 2-3 minutes while monitoring for oil leaks at the sensor
• Check instrument cluster to verify the oil level warning light functions properly (may illuminate briefly during startup then extinguish)
• Shut off engine, wait 5 minutes, and recheck oil level with dipstick to ensure proper fill level
• Inspect under vehicle one final time for any signs of oil seepage from the sensor location

More procedures for this vehicle