Fix P0522: Mechanic’s solutions that WORKED

The P0522: Engine Oil Pressure Sensor/Switch Low Voltage code identifies a problem in the engine oil pressure sensor circuit, specifically indicating a low voltage situation. This sensor plays a crucial role in monitoring the engine’s oil pressure, which is essential for proper lubrication and functioning of the engine components. A low voltage alert could mean the sensor is malfunctioning or there are other issues affecting the oil pressure system.

P0522 quick overview

Meaning	P0522: Engine Oil Pressure Sensor/Switch Low Voltage
Is it serious?	This code indicates a potential issue with the engine’s oil pressure system, which can be serious if not addressed promptly.
Possible causes	– Faulty engine oil pressure sensor – Wiring or connector issues related to the oil pressure sensor – Low engine oil level or poor oil quality – Engine mechanical problems affecting oil pressure – Faulty Engine Control Module (ECM)
How to diagnose?	Check Oil Level and Quality: Ensure the engine oil level is adequate and the oil is in good condition. Inspect Sensor and Wiring: Look for any damage or disconnections in the oil pressure sensor and its wiring. Test Sensor Operation: Verify the functionality of the oil pressure sensor using diagnostic tools. Monitor Voltage and Resistance: Measure the voltage and resistance to check if they are within specifications. Evaluate ECM: Consider potential issues with the Engine Control Module if other diagnostics are inconclusive. Perform Engine Checks: If necessary, inspect for mechanical issues that could affect oil pressure.

How to fix P0522 – learn from mechanics

I looked into P0522 service cases at iatn.com website where in the private forums the mechanics seek advice from other mechanics. I looked up a bunch of cases to help you decide how to fix your issue and see what would a real mechanic do to solve it.

Case #1: Dodge

Vehicle Information: 2003 Dodge Grand Caravan 2.4L (initially stated as 3.3L but corrected to 2.4L)

Issue + Repair History:

• Engine oil light coming on.
• Code P0522 encountered.
• Manual gauge oil pressure check showed 70 psi.
• Electrical circuits checked and found to be okay.
• Initial suspicion of a faulty computer due to the oil light going out only after clearing the P0522 code.
• The light reappeared after sitting overnight, and clearing the code was the only solution to turn it off.

Other OBD2 Codes + Test Results:

• P0522: Oil pressure sensor low.
• Voltage check: Okay.
• Pressure check: 70 psi.

Suggestions to Fix Issue:

• The possibility of it not being a PCM issue, but rather an issue with the oil pressure switch or its connector.
• Mention of updates for the oil light issue.
• A new PCM update from Chrysler that could clear the condition.
• Check for delay in oil pressure the next morning, possibly due to a cheap oil filter.
• Check if the oil pressure sensor was leaking internally.
• Replace the pressure switch as a preliminary step.

Final Fix:

• The solution was found in TSB18-026-03 Rev A, which addressed ghost codes.
• The vehicle required a reflash to solve the problem.
• The technician noted the rarity of this code appearing after many years and miles on the vehicle.
• The customer planned to bring the vehicle back to the dealer for the reflash.

Case #2: Chevrolet

Vehicle Information: 2006 Chevrolet Impala LT 3.9L

Issue + Repair History:

• Oil light sometimes comes on when it’s hot outside and driving at 68-70 mph.
• Code P0522 retrieved.
• Scan tool consistently showing 130 psi oil pressure.
• Oil sender replaced last month for a similar issue.
• No engine noise detected.
• Sensor unplugged during test, scan tool reading dropped to 0.

Computer Codes & Descriptions:

• P0522: Engine oil pressure sensor signal low.

Suggestions to Fix Issue:

• Speculation that it might be a faulty sensor.
• Check 5v reference, ground, and signal circuits.
• Manual check of engine oil pressure suggested due to vehicle’s high mileage (150k).
• Average hot idle oil pressure should be 15 to 25 psi; sensor stuck high indicated.
• Recommendation to replace with a GM oil pressure switch.
• Suggestion for oil pressure reading to be around 30 – 45 psi at 1850 RPM when hot.

Final Fix:

• Replacing the oil sender fixed the issue.
• New sender now shows 25 psi at idle and 45-47 psi at 70 mph on the scan tool.
• The problem was resolved through community suggestions of replacing the sender.

Case #3: Chrysler

Vehicle Information: 2005 Chrysler 300 C 5.7L

Issue + Repair History:

• MIL lamp on.
• Oil pressure reading 1 psi and .56 volts KOEO on two different scanners.
• Code cleared, but reappeared after key cycle.
• Replaced sensor with Standard brand, code did not return initially.
• After a short period, the MIL lit again with P0522 as active.
• Voltage reading changed to .54 volts, pressure still at 0.0 PSI KOEO.
• Original sensor replacement at another shop for P0520, then P0522 set.

Computer Codes & Descriptions:

• P0522: Engine oil pressure circuit low.

Suggestions to Fix Issue:

• Check for a “dummy plug” in the OPS connector on certain Chrysler models.
• Recommendation to use an OEM oil pressure sensor (OPS), as aftermarket sensors may not be compatible.
• Suggestion to check for a potential short in the circuit.
• Multiple instances where aftermarket sensors on Chrysler vehicles caused issues.
• General consensus on the need for an OEM sensor, particularly for Chrysler 5.7L engines.

Final Fix:

• The issue was resolved by installing an OEM sensor.
• The technician found that both scanners reported oil pressure and voltage accurately, but it was insufficient to identify the exact issue.
• Resistance measurements on the OEM sensor differed from aftermarket sensors.
• The OEM sensor read .49 volts initially, increasing to .58 volts and 1 PSI KOEO after warming up, the highest out of all sensors tested.
• The technician concluded that the specific resistance in one of the sensor’s pins was crucial for the 5.7L model, which might not be the case in other Chrysler products.

Case #4: Jeep

Vehicle Information: 2004 Jeep Liberty Sport 3.7L

Issue + Repair History:

• Upon starting, engine revs up to 4000rpm then stalls.
• Codes P0522, P2305, P2308 were present.
• Blocking throttle, IAC, and other intake air sources did not change the symptom.
• Suspected a large intake air source, possibly a crack in the plastic upper plenum.

Computer Codes & Descriptions:

• P2305: Coil 2 ionization.
• P2308: Coil 3 ionization.
• P0522: Oil pressure sensor.

Suggestions to Fix Issue:

• Use a smoke machine or soapy water to check for intake leaks.
• Check ignition timing and possible PCM issues.
• Inspect the IAC motor for debris and the intake for damage, especially at the rear for a popped-off plastic casting.
• Check and possibly replace spark plugs.

Final Fix:

• Found a hole in the plastic plenum at the rear, likely from backfiring.
• Spark plugs were completely worn out, and detonation sensors were not working due to a mouse-damaged wiring harness.
• Repaired by replacing the plenum, spark plugs, all coils, detonation sensors (with new harness), and the PCV valve and tubing.
• After repairs, the vehicle ran smoothly.
• Advised customer on the importance of regular maintenance.

Case #5: GMC

Vehicle Information: 2006 GMC Sierra 2500 HD SLT 6.6L

Issue + Repair History:

• Truck exhibited reduced engine power and several low voltage codes.
• No 5V reference from ECM, except on oil pressure sensor.
• Replaced ECM with OEM part, but the issue and codes remained.
• Suspected short in the wiring or a faulty sensor.

Computer Codes & Descriptions:

• P0652: 5-volt reference low voltage.
• P0522: Engine oil pressure low voltage.
• P0405: EGR low voltage.
• P0462: Fuel level sensor low voltage.
• P0672, P0673, P0674, P0677: Glow plug control circuit.

Other Test Results:

• No 5V reference coming out of ECM.

Suggestions to Fix Issue:

• Check for a shorted sensor pulling down the voltage.
• Inspect all 5V references and wiring, load test wires.
• Check vehicle voltage, battery, charging system, and ECM connections.
• Inspect for continuity to ground and chase down any shorts.
• Check VREF with new PCM before re-attaching sensors.
• Inspect connectors C108 and C107 for pushed out pins.

Final Fix:

• Found wires smashed behind the power steering bracket, likely from a previous water pump replacement.
• Repairing these wires resolved all issues.
• The problem was a wiring fault, not a faulty sensor or ECM.

Advice	Brief Description of Diagnostic Step
Check for Wiring Issues	Inspect and test wiring for shorts, grounding, or damage to sensor wiring.
Use OEM Parts	Replace sensors with Original Equipment Manufacturer (OEM) parts for compatibility and reliability.
Verify Sensor Operation	Check if the sensor is functioning properly, using a scanner or voltmeter.
Inspect Connectors	Examine electrical connectors for loose, corroded, or damaged pins.
Monitor Voltage and Resistance	Measure voltage and resistance to ensure they are within the specified range.
Consider ECM/PCM Issues	Evaluate the Engine Control Module (ECM) or Powertrain Control Module (PCM) for potential faults.
Perform Comprehensive Diagnostics	Conduct thorough diagnostics, considering all potential sources of the issue.