Engine [2016-2019, B4204T28, TG-81SC | 2020, B4204T28; B4204T39, TG-81SD]: Removal

NOTE:

Removal steps in this procedure may contain installation details.

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See information about safety information fuel system, refer to: SAFETY INFORMATION FUEL SYSTEM

Perform cooling system high voltage battery, draining, charging and bleeding, refer to: HIGH VOLTAGE BATTERY COOLING SYSTEM, DRAINING, FILLING, AND BLEEDING

Remove the following items:

Inverter Generator Module (IGM), refer to: INVERTER GENERATOR MODULE
engine cooling fan, refer to: ENGINE COOLING FAN

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CAUTION:

Make sure that the component is protected.

Refer to: Special Tool: 999 5474

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Release the catches.

Remove the marked part.

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Remove the nut.

Torque: M6, 10Nm

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Release the locks.

Loosen the marked detail/details.

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Release the connector's catch.

Disconnect the connector.

Fold marked part aside.

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Fold marked part aside.

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Release the catches.

Remove the marked part.

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Remove the nut.

Torque: M8, 24Nm

Fold marked part aside.

Remove the engine control module (ECM), refer to: ENGINE CONTROL MODULE

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Remove the screws.

Torque: M6, 10Nm

Loosen the wiring harness or move it to the side.

Remove the marked part.

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Remove the screw.

Torque: M6, 10Nm

Fold marked part aside.

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Remove the screw.

Torque: M6, 10Nm

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Remove the nut.

Torque: M6, 10Nm

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Remove the marked part.

HINT: It may be necessary to twist or turn the component.

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Fold marked part aside.

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Remove the screw.

Torque: M8, 24Nm

Fold marked part aside.

Remove the following items:

Secondary Bulkhead Panel RH, refer to: SECONDARY BULKHEAD PANEL RH (2016 - 20)
lambda probe, front, refer to: LAMBDA PROBE, FRONT

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Disconnect the connector.

Loosen the clip.

Remove the marked part.

Refer to: Special Tool: 999 5543

Torque: Lambda probe, tightening, 45Nm

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Release the locks.

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Undo the hose from the connection.

Fold marked part aside.

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WARNING:

Be prepared to collect escaping fluid.

Refer to: Special Tool: 981 4123

Release the lock.

Undo the hose from the connection.

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Loosen the hose clamp.

Remove the marked part.

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Depress the locking device.

Undo the hose from the connection.

Fold marked part aside.

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Depress the locking device.

Undo the hose from the connection.

Fold marked part aside.

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Loosen the hose clamp.

Remove the screw.

Torque: M6, 10Nm

Undo the hose from the connection.

Fold marked part aside.

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WARNING:

Be prepared to collect escaping fluid.

Release the lock.
Undo the hose from the connection.

Fold marked part aside.

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NOTE:

Make sure that the component is suspended in a proper way.

Remove the screws.

Torque: M6, 10Nm

Fold marked part aside.

Remove the following items:

Driveshaft left, refer to: DRIVESHAFT LEFT
Drive shaft right, refer to: DRIVE SHAFT RIGHT
Engine Rear Lower Support Insulator RH, refer to: ENGINE REAR LOWER SUPPORT INSULATOR RH
Engine Rear Lower Support Insulator LH, refer to: ENGINE REAR LOWER SUPPORT INSULATOR LH

VEHICLES WITH BYPASS VALVE

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Remove the screws.

Torque: M5, 5Nm

Fold marked part aside.

ALL VEHICLES

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Remove the screws.

Torque: M8, 24Nm

Fold marked part aside.

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Remove the nuts.

Torque: M8, 24Nm

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Remove the screw.

Torque: M6, 10Nm

Remove the marked part.

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NOTE:

Make sure that a new component is installed.

Loosen the screws.

Torque: Clamp catalytic converter, 20Nm

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HINT: It may be necessary to twist or turn the component.

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Loosen the marked detail/details.

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Remove the screws.

Torque: M8, 24Nm
Torque: M10, 50Nm

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Loosen the hose clamp.

Undo the hose from the connection.

Fold marked part aside.

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Release the lock.
Undo the hose from the connection.

Remove the marked part.

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NOTE:

Make sure that the mating faces are clean and free of foreign material.

NOTE:

Make sure that the seal is correctly located.

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WARNING:

Be prepared to collect escaping fluid.

Loosen the hose clamp.

Undo the hose from the connection.

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WARNING:

Be prepared to collect escaping fluid.

Release the locks.

Undo the hoses from the connections.

On both sides.

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Loosen the hose clamps.

Undo the hoses from the connections.

Fold marked part aside.

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Loosen the hose clamp.

Loosen the clip.

Undo the hose from the connection.

Fold marked part aside.

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Loosen the hose clamp.

Undo the hose from the connection.

Fold marked part aside.

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Loosen the hose clamp.

Undo the hose from the connection.

Fold marked part aside.

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Remove the screws.

Torque: M6, 10Nm

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Remove the marked part.

HINT: It may be necessary to twist or turn the component.

Remove the upper torque rod, refer to: UPPER TORQUE ROD

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NOTE:

Orientation view

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Disconnect the connector.

Loosen the clip.

Fold marked part aside.

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CAUTION:

Be extra careful when removing or installing this component.

Disconnect the connector.

Fold marked part aside.

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Loosen the clips.

Fold marked part aside.

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Remove the nuts.

Torque: M6, 10Nm

Remove the marked part.

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NOTE:

Make sure that the component is suspended in a proper way.

Remove the screws.

Torque: M8, 24Nm

Remove the part carefully

Fold marked part aside.

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Remove the screw.

Torque: M6, 10Nm

Fold marked part aside.

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Refer to: Special Tool: 999 7503

Install the screw.

Torque: M10, 50Nm

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Refer to: Special Tool: 999 2810 and Special Tool: 999 5185

Use: Engine lift

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Remove the screws.

Torque: Engine mount bracket, to Engine pad, 110Nm
Torque: Engine mount bracket, to Cylinder head, M12
- Stage 1: 90 Nm
- Stage 2: 130 °
Torque: Engine mount bracket, to Cylinder head, M10, 60Nm

Remove the marked part.

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Remove the screws.

Torque: Engine pad bracket, to Transmission, 110Nm

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Lower the engine.

Use: Engine lift

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Remove the screws.

Torque: Engine pad to frame member, 60Nm

Remove the marked part.

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Lift the marked component up

Use: Engine lift

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NOTE:

Make sure that no components catch.

NOTE:

This step requires the aid of another technician.

Lift the marked component up

Use: Engine lift