Oil Level Sensor

Replace the engine oil level sensor on the 5.9L Cummins diesel engine to restore accurate oil level monitoring.

Warnings

Tools required

Parts

• Engine oil level sensor × 1 — Use OEM Mopar or quality aftermarket
• Engine oil (for top-off) × 1 — 15W-40 diesel or 5W-40 synthetic

Fluids

• 15W-40 diesel oil or 5W-40 synthetic — 1 qt

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks behind rear wheels
3. Allow engine to cool completely if recently operated
4. Raise front of vehicle and support securely on jack stands
5. Position oil drain pan under the oil pan on driver side
6. Disconnect negative battery cable to prevent fault codes during sensor replacement

Procedure

1. 1

   Locate the oil level sensor
   From underneath the vehicle, locate the oil level sensor on the driver side of the oil pan, approximately 6-8 inches back from the front of the pan. The sensor has a single electrical connector and threads into the oil pan.
2. 2

   Disconnect electrical connector
   Press the release tab on the electrical connector and pull straight out to disconnect from the oil level sensor. Move the wiring harness out of the work area to prevent damage.
3. 3

   Clean around sensor
   Use a wire brush to clean dirt and debris from around the sensor body and the oil pan surface. This prevents contamination from entering the oil pan when the sensor is removed.
4. 4

   Remove old oil level sensor
   Using a 24mm wrench or deep socket, turn the oil level sensor counterclockwise to remove it from the oil pan. Have the drain pan positioned directly below as approximately 0.5-1 quart of oil will drain out. Remove sensor completely and allow oil to drain.
5. 5

   Inspect oil pan threads
   Once oil drainage has slowed, inspect the threaded hole in the oil pan for damage or debris. Clean the threads with a shop towel if needed. Check the old sensor for metal shavings or debris that might indicate internal engine problems.
6. 6

   Prepare new sensor
   Apply a thin coat of thread sealant (Loctite 567 or equivalent) to the threads of the new oil level sensor. Do not use Teflon tape as it can contaminate the oil system. Apply sealant only to the threads, keeping it away from the sensor tip.
7. 7

   Install new sensor
   Thread the new oil level sensor into the oil pan by hand, turning clockwise until hand-tight. Using the 24mm wrench, tighten the sensor snugly. Tighten firmly but do not overtighten as the pan threads can be damaged. Typical installation is hand-tight plus 1/4 to 1/2 turn.
8. 8

   Reconnect electrical connector
   Push the electrical connector onto the new oil level sensor until it clicks into place. Ensure the connector is fully seated and the locking tab engages properly.
9. 9

   Check and top off oil level
   Lower the vehicle from jack stands. Reconnect the negative battery cable. Check the engine oil level using the dipstick. Add oil as needed to bring level to the full mark, accounting for the oil lost during sensor replacement (typically 0.5-1 quart).

Reassembly

1. Ensure electrical connector is fully seated and locked
2. Verify no tools or shop towels were left under vehicle
3. Double-check oil level on dipstick after top-off

Verification

• Start the engine and verify the oil pressure warning light functions normally
• Check for oil leaks around the new sensor while engine is running
• Use a scan tool or observe the instrument cluster to verify the oil level warning system is functioning properly
• Allow engine to idle for 2-3 minutes, then shut off and recheck for leaks
• Check oil level again after test to ensure proper fill level

Related trouble codes on this vehicle

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