Engines 2.0 l TDI-CR (CFFB, CFGB, CLJA)
1. Remove the key from the ignition switch.
2. Remove the top engine cover.
3. If present, remove the sound insulation from the injectors.
4. Disconnect the connector (1 on the accompanying illustration) fuel pressure sensor "G247", unscrew the bolts (arrows) of the upper coolant pipe and the fuel return pipe. Disconnect the hose (2) from the fuel return line.
8.4 Connections above glow plugs
5. Open the fasteners (see accompanying illustration) cable channel and release the electrical wiring.
8.5 Glow Plug Wiring Channel Clamps
6. Carefully disconnect the glow plug connectors using a 12 mm open-end wrench (see accompanying illustration), without allowing them to be damaged.
8.6 Glow Plug Connector
Caution: If the connector is damaged, the entire wiring harness will need to be replaced.
5. Clean the glow plug well in the cylinder head to prevent dirt from getting into the cylinder. Use a grease remover to do this, then blow the dirt out with compressed air.
6. Remove the glow plugs using a long 10mm socket.
7. Installation is performed in the reverse order. Tighten the glow plugs with a force of 16-18 Nm. Make sure that the connectors are in good contact. Finally, clear the ECM fault memory.
1.9 L TDI-PD engines (HXE, BLS)
8. Remove the key from the ignition switch.
9. Remove the top engine cover.
10. Disconnect the glow plug connectors (see accompanying illustration) and unscrew them using a long swivel head (e.g. No.3220). If ceramic glow plugs are installed, do not apply more than 20 Nm of force to loosen them. If this force is not sufficient when using the wrench, use alternative devices to loosen the fasteners, also not exceeding 20 Nm. If the spark plug cannot be loosened using alternative devices, it should be unscrewed with the cylinder head removed. After loosening the ceramic spark plug, put a long hose on it (approximately 25 cm) and unscrew it without distortion and without hitting adjacent parts.
8.10 Glow plug connectors for 1.9 l TDI-PD engines
11. Check the electrical resistance of the spark plugs - it should not exceed 1 Ohm.
12. Installation is carried out in the reverse order. Tighten metal glow plugs with a force of 15 Nm, and ceramic ones with a force of 12 Nm.
