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Coolant Flange (DIS Ignition Module Adapter),
Remove and Install
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Note: For clearer
representation, the graphics show a removed engine.
 Remove
Disconnect ground cable from battery.
Open coolant drain bolt on radiator – collect coolant.
For X 20 XEV: Detach vacuum hose (1) from exhaust gas
recirculation solenoid valve.
Detach wiring harness plug (2) from exhaust gas recirculation
solenoid valve.
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Detach wiring harness plug (1) from coolant temperature sender
and wiring harness plug (2) from coolant temperature sensor.
Unclip cable bundle from bracket.
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Remove
For X 20 XEV: Disconnect wiring harness plugs and ignition
cables from DIS ignition module.
Note: When detaching
the hoses, ensure that the valve connection is not damaged. Damaged
valves must be replaced.
Caution
Damaged valve supports can cause a vehicle fire as a result of
leaks.
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Remove
For X 20 XEV: Detach vacuum hoses and wiring harness plug from
tank vent valve.
Detach coolant hose from coolant flange (DIS ignition module
adapter).
Remove fastening bolts (1 – M10) and (2 – M8) from
cylinder head and remove coolant flange (DIS ignition module
adapter).
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Remove
When replacing the coolant flange (DIS ignition module adapter):
Transfer coolant temperature sender, coolant temperature sensor,
bracket and exhaust gas recirculation solenoid valve. For X 20 XEV:
Transfer DIS ignition module.
Torque
For X 20 XEV: DIS ignition module to coolant flange (DIS
ignition module adapter) – 8 Nm / 6 lbf. ft.
Bracket to coolant flange (DIS ignition module adapter) –
8 Nm / 6 lbf. ft.
Exhaust gas recirculation solenoid valve with new gasket to
coolant flange (DIS ignition module adapter) – 20 Nm / 15
lbf. ft.
Coolant temperature sensor to coolant flange (DIS ignition
module adapter) – 10 Nm / 7.5 lbf. ft.
Coolant temperature sender to coolant flange (DIS ignition
module adapter) – tightening torque 11 Nm / 8 lbf. ft.
Install
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Coolant flange (DIS ignition module adapter) to cylinder head
(M8) – tightening torque 20 Nm / 15 lbf. ft.
Coolant flange (DIS ignition module adapter) to cylinder head
(M10) – tightening torque 30 Nm / 22 lbf. ft.
Attach coolant hose to coolant flange (DIS ignition module
adapter).
For X 20 XEV: Attach vacuum hoses and wiring harness plug to
tank vent valve. Attach ignition cables (2) and wiring harness plug
(1) to DIS ignition module – note ignition sequence.
Clip cable bundle to bracket.
Connect wiring harness plugs to coolant temperature sensor and
coolant temperature sender.
Attach wiring harness plug to exhaust gas recirculation solenoid
valve.
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For X 20 XEV: Connect vacuum hose to exhaust gas recirculation
solenoid valve.
Close coolant drain bolt on radiator.
Connect ground cable to battery.
Inspect
Top up cooling system – see operations "Cooling System,
Top Up and Bleed" and "Cooling System, Check for Leaks".
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