1.6HDi full annual service (Peugeot Partner 2007)

How to to change oil, oil/air/fuel/diesel filters, remove air from fuel system and reset service counter indicator or service spanner.

The car is a 1.6HDi Peugeot Partner (2007; ~103,000 miles; M59; 9HXC engine; 90bhp). The car is the same as a Citroen Berlingo. This procedures should be fairly the same in 1.6TDCi (Ford) and various other diesels, e.g. Volvo, Suzuki, Mini, Mazda, etc.

Bolt dimensions and torque settings:
Original 1.6HDi sump bolt is 21mm socket (M10x1.25, 13mm length). Torque settings 25Nm. If it is leaking slightly, one can torque it a bit more, say up to 30Nm.
The original sump washer is a copper crusher washer with the following diameters:
Outside diameter 21mm, Inside diameter 10mm, thickness 2mm.
The oil filter is 27mm socket and the torque setting is 25Nm.

The tools and replacement parts I am using:
Original Febi Bilstein bolt + copper washer (amazon UK): https://amzn.to/3jvSTw6 or ebay: https://ebay.us/VLh1Zo
Just the oil sump copper washer Febi Bilstein ebay: https://ebay.us/dGBVna
27mm socket for the oil filter cover (amazon UK): https://amzn.to/42uGHTl or ebay: https://ebay.us/k5fR4C
Oil pan for collecting the old oil (amazon UK): https://amzn.to/2Hv2shr or ebay: https://ebay.us/vdgem8
Total Quartz Ineo ECS 5W-30 (5L) (amazon UK): https://amzn.to/2HDFmVL or ebay: https://ebay.us/a0msAJ
Oil filter: (amazon UK): https://amzn.to/3omtlVT or ebay: https://ebay.us/SMZqka
Delphi HDF939 diesel or fuel filter (amazon UK): https://amzn.to/2ORSsR1 or ebay: https://ebay.us/fYgIs8
The rubber o-rings for the fuel filter have Peugeot/Citroen part number: 190437 from ebay: https://ebay.us/zf3Aus
Air filter (Bosch 1457433160) (amazon UK): https://amzn.to/34yIZWp or ebay: https://ebay.us/g2OpPz
Rubber grommets (1422A3) if old ones have perished (amazon UK): https://amzn.to/3kBd4du or ebay: https://ebay.us/EfJfs1
To seal the crankcase breather I am using these nitrile rubber o-rings (19mmx27mmx4mm) (amazon UK): https://amzn.to/31KH3br or ebay: https://ebay.us/nnHLwX
If you want a water in diesel sensor the Peugeot/Citron part number is: 191311 from ebay: https://ebay.us/6bQf6w
Sealey 3/8" 2-24Nm torque wrench (amazon UK): https://amzn.to/3LJx2Ti or ebay: https://ebay.us/BgMfWN
Silverline 1/2" 28-210Nm torque wrench (amazon UK): https://amzn.to/3rO53q6 or ebay: https://ebay.us/FUqWsI
Sealey AK54 550ml oil suction syringe (amazon UK): https://amzn.to/31E8F1R or ebay: https://ebay.us/mXZSlw
The tubing is 7mm outside diameter and fits in the syringe. 8mm OD should also work.
Trim tools (amazon UK): https://amzn.to/48QCahd or ebay: https://ebay.us/WNuyRn


A few 1.6HDi engine videos that might be interesting and related to the annual service.
A video how to make the airbox not rattle that much:    • How to fix rattling air filter box in 1.6H...  
A video of how to replace the rubber o-ring on the crankcase breather:    • How to fix oil dripping from the crankcase...  
A video how to fit water in diesel sensor:    • How to fit a water in diesel/fuel sensor 1...  
A video showing how much oil is there left in the oil sump once you drain the oil:    • How much oil is left in the sump, 1.6HDi a...  
A video of how to properly clean the EGR valve:    • The complete guide to EGR cleaning (1.6HDi...  

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00:00 - 00:35 Introduction
00:36 - 02:10 Draining oil
02:10 - 04:58 Remove oil filter
04:58 - 08:27 Suck remaining oil
08:27 - 13:16 New oil filter
13:16 - 14:39 Oil sump bolt
14:39 - 17:02 Fill with oil
17:02 - 23:38 New air filter
23:38 - 31:48 Fuel/Diesel filter
31:48 - 32:41 Fit back Air box
32:41 - 35:52 Fit back everything
35:52 - 38:14 Bleed fuel system
38:14 - 40:28 Reset service counter
40:28 - 40:59 Final words

#HDi #AnnualService #PeugeotService

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