Oil Pressure Sensor

Replace the oil pressure sensor on the 5.9L Cummins diesel engine to restore accurate oil pressure readings to the instrument cluster and ECM.

Warnings

Tools required

Parts

• Oil pressure sensor × 1 — Use OEM Mopar specification for 5.9L Cummins

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely for at least 30 minutes
3. Open hood and secure with prop rod
4. Locate oil pressure sensor on driver side of engine block, below and forward of the fuel filter housing
5. Position oil drain pan below sensor location to catch oil spillage

Procedure

1. 1

   Access the oil pressure sensor
   The oil pressure sensor is located on the driver side of the engine block, below the fuel filter housing and above the oil filter. From above the engine bay, identify the sensor by its single wire connector and hex body. You may need to trace the wire harness to positively identify it.
2. 2

   Disconnect the electrical connector
   Press the tab on the electrical connector and pull straight away from the sensor to disconnect. Do not pull on the wires themselves. Move the connector out of the way to prevent oil contamination.
3. 3

   Remove the oil pressure sensor
   Using a 24mm deep socket or wrench, turn the sensor counterclockwise to remove it from the engine block. Be prepared for approximately 4-6 ounces of engine oil to drain from the port once the sensor is removed. Keep the drain pan positioned below and have shop towels ready to control spillage.
4. 4

   Clean the sensor port
   Once oil has stopped draining, use a shop towel to wipe the threads in the engine block port. If there is corrosion or debris present, carefully clean the threads with a wire brush. Inspect the port threads for damage. Do not allow debris to fall into the engine.
5. 5

   Prepare the new sensor
   Apply a thin coating of thread sealant with PTFE to the threads of the new oil pressure sensor. Apply sealant only to the threads, keeping it away from the tip of the sensor. Do not use excessive sealant as it can contaminate the oil or interfere with sensor operation.
6. 6

   Install the new sensor
   Thread the new oil pressure sensor into the engine block port by hand, turning clockwise. Once hand-tight, use the 24mm socket or wrench to snug the sensor firmly. Tighten to the factory-specified torque; verify the correct value in the Cummins service manual before final tightening. Do not overtighten as this can damage the sensor or strip threads in the cast iron block.
7. 7

   Reconnect the electrical connector
   Wipe any oil from the sensor terminal and push the electrical connector straight onto the sensor until it clicks into place. Ensure the connector is fully seated and the locking tab is engaged.
8. 8

   Check engine oil level
   Remove the engine oil dipstick, wipe clean, reinsert fully, and remove again to check the oil level. Add 15W-40 diesel oil or 5W-40 synthetic as needed to bring level to the full mark if oil loss was significant, though typically the small amount lost will not require topping off.

Reassembly

1. Ensure electrical connector is fully seated and locked
2. Wipe any spilled oil from engine block and surrounding components
3. Remove drain pan and properly dispose of or recycle collected oil

Verification

• Start the engine and verify the oil pressure gauge on the instrument cluster shows normal reading within 5 seconds
• Normal idle oil pressure should be approximately 10-20 PSI at warm idle and 30-60 PSI at operating temperature and speed
• Check for oil leaks around the sensor base while engine is running
• If check engine light was illuminated due to low oil pressure fault, verify it clears after running engine for 1-2 minutes
• Turn off engine and recheck oil level on dipstick after 2-3 minutes of settling time

Related trouble codes on this vehicle

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