Boost Pressure Sensor

This procedure covers the replacement of the boost pressure sensor on a 2007 Ram 3500 with the 5.9L Cummins diesel engine, located on the intake manifold.

Warnings

Tools required

Parts

• Boost pressure sensor × 1 — Mopar 5033310AA or equivalent

Preparation

1. Ensure engine is completely cool to the touch
2. Park vehicle on level ground and engage parking brake
3. Open hood and secure in upright position
4. Disconnect negative battery terminal to prevent electrical issues
5. Locate boost pressure sensor on driver side of intake manifold near turbocharger outlet

Procedure

1. 1

   Access boost pressure sensor
   Remove engine cover if equipped by lifting upward from the rear clips. The boost pressure sensor is located on the intake manifold air horn on the 5.9L Cummins. It is a small sensor with a single electrical connector; verify the exact mounting location and whether it is retained by a single bolt or threaded into the port before proceeding.
2. 2

   Disconnect electrical connector
   Press down on the red connector lock tab and carefully pull the electrical connector straight away from the boost pressure sensor. Inspect the connector for corrosion, bent pins, or damage. If connector appears corroded, spray with electrical contact cleaner and allow to dry.
3. 3

   Remove sensor mounting hardware
   Remove the mounting fastener(s) securing the boost pressure sensor to the intake manifold using the appropriate socket. Verify the exact fastener count and size for this sensor. Keep any bolts as they will be reused with the new sensor. Note the orientation of the sensor for proper installation of the replacement. Socket set (verify required sizes for sensor mounting fastener and battery terminal)
4. 4

   Remove old sensor
   Carefully pull the boost pressure sensor straight out from the intake manifold. The sensor has an O-ring seal that may stick slightly. Wiggle gently if needed but do not pry against the intake manifold to avoid damage.
5. 5

   Inspect mounting location
   Examine the sensor port in the intake manifold for debris, carbon buildup, or damage. Use a clean shop rag to wipe away any dirt around the opening. Do not allow debris to enter the intake manifold. Check that the old O-ring has been fully removed and no pieces remain in the port.
6. 6

   Install new boost pressure sensor
   Verify the new sensor has a fresh O-ring installed on the mounting surface. Align the new boost pressure sensor with the mounting holes in the intake manifold, ensuring proper orientation matches the original sensor position. Insert the sensor fully into the port until it seats against the manifold surface.
7. 7

   Secure sensor with mounting bolts
   Thread the mounting fastener(s) by hand to prevent cross-threading, then tighten to secure the sensor. Tighten snug but do not overtighten as this can crack the sensor body or strip the mounting threads. Approximately 6-8 ft-lbs is sufficient, though no official torque specification is available.
8. 8

   Reconnect electrical connector
   Push the electrical connector firmly onto the new boost pressure sensor until it clicks into place. Ensure the red locking tab fully engages. Gently tug on the connector to verify it is securely locked to the sensor.
9. 9

   Reconnect battery and reinstall covers
   Reconnect the negative battery terminal and tighten securely. If engine cover was removed, reinstall by aligning the front tabs and pressing down on the rear until clips engage.

Reassembly

1. Ensure all electrical connections are secure and properly locked
2. Verify no tools or rags have been left in the engine compartment
3. Double-check mounting bolts are tight and sensor is properly seated

Verification

• Start the engine and allow it to idle - check for smooth operation with no unusual noises or boost leaks
• Verify the check engine light does not illuminate and no diagnostic trouble codes are present
• If available, use a scan tool to monitor boost pressure sensor readings - should show ambient pressure at idle (approximately 14.7 psi at sea level)
• Perform a brief test drive and confirm normal turbocharger boost operation under acceleration
• Recheck sensor mounting bolts and electrical connector for security after test drive

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle