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xsvector, Auto Mechanic
Category: Dodge
Satisfied Customers: 15040
Experience:  asetech
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Tips on replacing the turbo on a 2008 2500 sprinter

Customer Question

tips on replacing the turbo on a 2008 2500 sprinter
Submitted: 2 months ago.
Category: Dodge
Expert:  xsvector replied 2 months ago.


WARNING: The normal operating temperature of the exhaust system is very high. Never work around or attempt to service any part of the exhaust system until it is cool. Care should be taken when working near the turbocharger. The temperature of the turbocharger rises to a high level after a short period of engine operation time.

NOTE: There is no procedure for repairing the turbocharger. If damage is found during inspection, the turbocharger must be replaced.

1.Disconnect negative battery cable.
2.Remove the engine trim cover.
3.Remove air intake tube (air cleaner to turbo) (1).
4.Remove engine cover front bracket (2).
5.Remove air tube (turbo to cooler) (3).
6.Remove the turbo heat shield (4).

7.Remove the elbow to converter exhaust clamp (1).

8.Remove the turbo front bracket retaining bolts (1).
9.Raise vehicle, remove front splash shield.
10.Drain cooling system See: Engine, Cooling and Exhaust\Cooling System\Service and Repair.
11.Disconnect the downstream catalytic converter at the extension pipe.
12.Disconnect the extension pipe to muffler.
13.Disconnect O2 sensor wire connector.
14.Reposition extension pipe and catalytic converter.
15.Lower vehicle and disconnect catalytic converter to downstream catalytic converter clamp.
16.Remove upstream catalytic converter.
17.Disconnect transmission fill tube and trim cover bracket and set aside.

18.Disconnect exhaust elbow at turbo (2).
19.Disconnect EGR tube at manifold to left cylinder head (3).
20.Remove left and right exhaust manifold retaining bolts and gaskets (4).

21.Remove front turbo retaining bolts (1).
22.Remove turbo mount retaining bolts.
23.Remove turbo.
24.Disconnect turbo boost pressure servo connector (2).

Expert:  xsvector replied 2 months ago.

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