ModerateAffected: 2006-201260,000–110,000 miles

Peugeot 207 1.6 HDi 90bhp — Glow Plug Failure / Snapping in Head

Diesel glow plugs burn out over time causing cold starting issues. The major problem is they often snap in the cylinder head when mechanics try to remove them.

Severity

Moderate

DIY Difficulty

Moderate

Est. Cost

£100–£300

OBD Codes

P0380

Component Diagram

Injectors

Typical layout and location for the Injectors assembly.

Reference Illustration

Symptoms

Hard starting in cold weather (below 5°C)
White smoke on cold start for 30 seconds
Flashing coil light or EML on dash

Root Cause

Carbon buildup around the tip of the glow plug effectively welds it into the cylinder head. Applying too much torque to remove it shears the threaded top off.

How To Fix

Soak the glow plugs in penetrating oil for several days before attempting removal.
Only attempt removal with the engine piping hot.
If a plug snaps, specialist removal tools are required (£150-300 call-out fee).
Standard replacement cost: £100-200

Estimated Repair Costs

Repair Option	Est. Cost (GBP)
DIY (parts only)	£40–£120
Independent Garage	£100–£300
Main Dealership	£160–£480

Other Faults on This Variant

Timing Belt Failure (60,000 Mile Interval)

Critical

2006-20121–60,000 miles£300–£600

The PSA 1.6 HDi engine has a 60,000-mile or 4-year timing belt interval — much shorter than most competitors. Belt failure destroys the engine. Many 207 owners are unaware of this critical maintenance item.

Injector Seal Leak (Chuffing / Black Death)

Severe

2006-201250,000–100,000 miles£150–£600

Copper injector seals fail, allowing exhaust gases and unburnt diesel to escape and coat the top of the engine in a hard black tar affectionately known as 'Black Death'.

Turbo Oil Starvation and Destruction

Critical

2006-201260,000–120,000 miles£700–£1200

The 1.6 HDi (DV6) engine is infamous for destroying turbos. The cause is almost always oil sludge blocking the tiny gauze filter in the turbo oil feed pipe.

Disclaimer: Repair cost estimates are indicative and based on community data. Always get a quote from a qualified mechanic before proceeding with any repair.