Autopapyrus · SsangYong Kyron 2.0 XDi (2010)
https://autopapyrus.com/guides/ssangyong/kyron/glow-plug-replacement/

Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

SsangYong Kyron 2.0 XDi (2010): Glow Plug Replacement

The 2.0 XDi engine (D20DT) is a diesel and has no spark plugs. It uses 4 glow plugs instead. Replacement is recommended every 60-80 thousand km, or if you have hard cold starts or fault codes P0380-P0384. Access is tight because of the accessories, and on some trims you need to remove the air duct and move the fuel lines slightly out of the way.

Difficulty: Medium Time: 1-2 hours Steps: 25 Tools: 1/4" ratchet, 10 mm deep socket, 8 mm wrench, special glow plug socket (usually 10 mm, deep thin-wall), torque wrench, dielectric grease

Part

🔩 Glow plugs (OE 6650170341 or aftermarket equivalents Bosch 0 250 203 001, NGK CZ247, Beru GN091). Set of 4

There's a full repair manual for this car Every system, wiring diagrams and torque specs — not just this job. Haynes AutoFix (online). See manuals →

Step by step

25 steps · 4 phases

Phase 1 PREPARATION AND DIAGNOSTICS 4 steps

Make sure the engine has cooled down completely (at least 1 hour after running). Glow plugs can stay hot.
Disconnect the negative battery terminal with a 10 mm wrench and wait 2 minutes.
Open the hood and remove the engine cover (if equipped) by pulling it up or removing its fasteners.
Remove the air duct between the air filter housing and the turbocharger. Loosen the clamps with a screwdriver, disconnect the MAF sensor (if it is mounted on the duct), and set the duct aside.

Phase 2 REMOVING THE OLD GLOW PLUGS 8 steps

Locate the 4 glow plugs. They are on the left side of the cylinder head (in the direction of travel), one per cylinder. Each one is connected to a power bus bar or an individual wire with a connector.
Disconnect the power connectors from each plug. On the D20DT there is usually a common bus bar held by 8 mm nuts. Remove the 4 nuts with an 8 mm wrench, take off the bus bar, and set it aside.
Clean the area around the plugs with compressed air or a rag so that dirt does not fall into the combustion chamber.
Take the glow plug socket (deep thin-wall 10 mm) and attach it to an extension and the 1/4" ratchet.
Unscrew the first glow plug COUNTERCLOCKWISE. The effort should be 15-25 N·m (11-18 lb-ft). If the plug is seized, DO NOT USE FORCE. Warm the engine up to 50°C, then try again.
Pull the plug out of its bore. If it does not come out, gently rock the socket from side to side (without bending it).
Inspect the removed plug. If the tip is broken or burned away, DO NOT START the engine until you have inspected the bore with an endoscope (a broken piece in the combustion chamber will destroy the piston).
Repeat steps 9-11 for the remaining three plugs.

Phase 3 INSTALLING THE NEW GLOW PLUGS 5 steps

Check the threads in the cylinder head bores with your finger or a flashlight. There should be no carbon buildup or damaged threads.
Apply a thin layer of dielectric grease to the threads of the new plug (NOT on the heating tip).
Thread the first new plug into the bore by hand CLOCKWISE. It should turn easily, with no effort, for 3-4 turns.
Tighten the plug with a torque wrench to 15-20 N·m (11-15 lb-ft). Confirm the exact value in the SsangYong service manual; for the D20DT it is usually 15 N·m (11 lb-ft).
Repeat steps 14-16 for the remaining three plugs.

Phase 4 REASSEMBLY AND CHECK 8 steps

Apply dielectric grease to the threads of the bus bar nuts.
Place the bus bar onto the terminals of all four plugs and tighten the 8 mm nuts to 5-8 N·m (44-71 lb-in) (hand-tight plus 1/4 turn with the wrench).
Reinstall the air duct, tighten the clamps, and reconnect the MAF sensor.
Reinstall the engine cover (if you removed it).
Reconnect the negative battery terminal and tighten the 10 mm nut.
Turn the ignition on (WITHOUT starting the engine). The glow plug indicator on the instrument panel should light for 2-6 seconds, then go out.
Start the engine. It should start quickly (1-2 seconds), without long cranking.
Scan for codes P0380-P0384. There should be none. If a code remains, check the glow plug relay (under the hood in the fuse/relay box) and the bus bar wiring.

Common mistakes and warnings

Never exceed the tightening torque. These glow plugs have ceramic elements, and overtightening will crack them and break off the heater inside the bore. If a plug does not unscrew with moderate effort, DO NOT FORCE it. Take it to a repair shop to have it drilled out (fragments in the combustion chamber can lead to an engine overhaul). Do not use plugs without a manufacturer part number. Cheap knock-offs burn out after 5-10 thousand km.