how to replace the Starter Motor and Solenoid

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My Name: C3CAR

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Posts: 2661
Joined: Wed May 04, 2011 10:01 am
Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4 (16v)
Fuel Type: Diesel
Mileage: 140000
Trim Level: Exclusive
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)
Engine name: DV4 16-valve diesel (90 PS)
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Citroen C3 1.4 HDi starter motor location pictures included.



Thanks to Adam for his guide on removing the Starter on a Diesel C3, which will also be of benefit to Petrol C3 owners. I have expanded it and added some photos and links.

Euro Car Parts will do a good discount on a replacement C3 starter, or Diesels (click here) and and Petrols (click here)
The Starter is located on the rear of the engine at the transmission end.



Tools used;

8mm & 13mm combination spanners.
6mm, 8mm, 10mm & 13mm long reach sockets with t-bar and ratchets.
6mm ball ended allen key.
Various screw drivers.
Torch and mirror.
And an old rag :)

The job,
If like me you have a bad back, things can take time. Some bits of the work where done blind with a lot of feel.

I didn't need to jack up the car in any way also.

Disconnect the battery.

Removed;

Engine top cover
Inlet piping to and from air box,
Air box,
Battery tray,
Fuel filter,
vacuum line from vacuum pump to brake servo.

It's not to much of a bad job, I just took my time and actually enjoyed most of it.

Adam.
Citroen C3 Starter motor and solenoid loction
Citroen C3 Starter motor and solenoid loction

If you want to recondition the solenoid, this topic has plenty of pictures and a video for replacing the brushes.
My Name: Ploddit

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Posts: 10
Joined: Fri Aug 15, 2014 10:42 pm
Model: C3 2002-2005, Original shape model
Year: 2004 (54)
Engine Size: 1.4 (8v)
Fuel Type: Diesel
Mileage: 80000
Trim Level: VTR+
Gearbox: Manual 5 speed
DPF: No

Post

I had exactly the same issue as you, including my faulty diagnosis of a solenoid, where when I connected the 'big' power connection it engaged perfectly, it seems that the motor needs the 12V direct from the battery for the solenoid to work.

My car is a 8V 1.4Hdi the build date from decoding the pillar sticker is 4/04.

My starter wasn't the same as yours (Valeo DR6LA) but a Valeo D7G which has four brushes, I bought a whole brush holder from eBay to eliminate a bit of soldering. I am also obliged to change my ignition lock and notice that mine is the same as a later Pluriel upto 2009 and not the 2002-2004 C3's so it seems Citroen changed a few little things around my build date.


https://www.ebay.co.uk/itm/121310733377? ... EBIDX%3AIT

My car has 120000km but has had a lot of short journeys, also it had a fuel leak from the leak off pipes and after a mechanics intervention from the rigid pipes, this leaking diesel went onto the brushes and combined with the dust from the brushes made a horrible paste. The brushes although 80% worn worked gain after a good clean with WD40, but I will replace then anyway.

Thanks for the help and site, feel free to edit this post with pics or links if you want to.
My Name: Ploddit

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Posts: 10
Joined: Fri Aug 15, 2014 10:42 pm
Model: C3 2002-2005, Original shape model
Year: 2004 (54)
Engine Size: 1.4 (8v)
Fuel Type: Diesel
Mileage: 80000
Trim Level: VTR+
Gearbox: Manual 5 speed
DPF: No

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My Valeo D7G had only a Peugeot/Citroen sticker with the part number 5802EG
My Name: Addixxtion

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Posts: 9
Joined: Fri Nov 11, 2016 10:40 am
Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4
Fuel Type: Petrol
Mileage: 88000
Trim Level: Touch
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)

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Hi thanks put is there pictures for this? I've got two 13mm bolts off but I cannot get the Allen head bolt off that's facing the opposite way it's welded in! What size Allen head is it?

And to make sure it's the correct bolt it's the one under the loom that's accessible from removing the battery tray? It's a 2002 1.4 petrol C3.

The space is too small to put my impact driver in and I'm worried I'm going to strip the bolt the way I'm going.

Thanks.
My Name: Addixxtion

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Posts: 9
Joined: Fri Nov 11, 2016 10:40 am
Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4
Fuel Type: Petrol
Mileage: 88000
Trim Level: Touch
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)

Post

This is a photo of the bolt it's definitely larger than 6mm more like 12 or more?
Citroen C3 Starter Motor Bolt
Citroen C3 Starter Motor Bolt
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My Name: Arfur Dent

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Joined: Sat Jul 23, 2011 3:47 pm
Model: C3 2002-2005, Original shape model
Year: 2002 (52)
Engine Size: 1.4 (16v)
Fuel Type: Diesel
Mileage: 100000
Trim Level: Exclusive
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)
Engine name: DV4 16-valve diesel (90 PS)
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Addixxtion wrote: Wed May 16, 2018 12:33 pm This is a photo of the bolt it's definitely larger than 6mm more like 12 or more?
It looks like a rounded off mess to me. I don't think any hex spanner will fit it now :cry:
Addixxtion wrote: Wed May 16, 2018 12:33 pm What size Allen head is it?
You mean the socket cap screws?
6mm ball ended allen key.
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My Name: Addixxtion

Contributor
Posts: 9
Joined: Fri Nov 11, 2016 10:40 am
Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4
Fuel Type: Petrol
Mileage: 88000
Trim Level: Touch
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)

Post

Arfur Dent wrote: Wed May 16, 2018 12:45 pm
Addixxtion wrote: Wed May 16, 2018 12:33 pm This is a photo of the bolt it's definitely larger than 6mm more like 12 or more?
It looks like a rounded off mess to me. I don't think any hex spanner will fit it now :cry:
Addixxtion wrote: Wed May 16, 2018 12:33 pm What size Allen head is it?
You mean the socket cap screws?
6mm ball ended allen key.
Definitely not a 6mm for all the tea in China. I've removed two 13mm bolts and the picture is of a bolt that goes in the opposite direction to the others I can't find anything else that it might be can't find any photos specific to my car on the net mostly of HDi models.

Need help asap otherwise I guess I'll have to spend on a Haynes manual for one bolt lol!
My Name: Addixxtion

Contributor
Posts: 9
Joined: Fri Nov 11, 2016 10:40 am
Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4
Fuel Type: Petrol
Mileage: 88000
Trim Level: Touch
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)

Post

That's a picture of the motor I need it's the very top bolt I can't get off soaked it in wd40 overnight too. But I assure you it's not 6mm I put a 6mm Allen head in it and it was lost in it.

Guess I'll have to get a mechanic out it's really p-ing me off hate this car it's the misses nothing but problems since she had it.

Screenshot_20180516-143916.jpg
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My Name: Arfur Dent

Guru
Posts: 3423
Joined: Sat Jul 23, 2011 3:47 pm
Model: C3 2002-2005, Original shape model
Year: 2002 (52)
Engine Size: 1.4 (16v)
Fuel Type: Diesel
Mileage: 100000
Trim Level: Exclusive
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)
Engine name: DV4 16-valve diesel (90 PS)
Has thanked: 311 times
Been thanked: 119 times

Post

Addixxtion wrote: Wed May 16, 2018 1:32 pm Need help asap otherwise I guess I'll have to spend on a Haynes manual for one bolt lol!
Addixxtion wrote: the picture is of a bolt that goes in the opposite direction to the others
Haynes doesn't tell you what size it is.

Haynes does have a small picture with an arrow and it looks like a socket cap allen bolt and not a hex head as your picture shows for the one on the transmission housing side.

But,

The Citroen Diagram for a 2002 petrol starter shows a M8 bolt with a hex head for all 3 (same part number)
This part: 6922.89
Qty: 03
(MUL)SELF LOCK SELF-TAP SCREWS
DIAM 8X125-60

Starter Motor diagram on a Citroen C3
Starter Motor diagram on a Citroen C3
Use the diagram above to identify and check you are actually trying to remove the correct bolt ;)
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My Name: Addixxtion

Contributor
Posts: 9
Joined: Fri Nov 11, 2016 10:40 am
Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4
Fuel Type: Petrol
Mileage: 88000
Trim Level: Touch
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)

Post

Arfur Dent wrote: Wed May 16, 2018 1:43 pm
Addixxtion wrote: Wed May 16, 2018 1:32 pm Need help asap otherwise I guess I'll have to spend on a Haynes manual for one bolt lol!
Addixxtion wrote: the picture is of a bolt that goes in the opposite direction to the others
Haynes doesn't tell you what size it is.

Haynes does have a small picture with an arrow and it looks like a socket cap allen bolt and not a hex head as your picture shows for the one on the transmission housing side.

But,

The Citroen Diagram for a 2002 petrol starter shows a M8 bolt with a hex head for all 3 (same part number)
This part: 6922.89
Qty: 03
(MUL)SELF LOCK SELF-TAP SCREWS
DIAM 8X125-60


starter-motor-diagram-citroen-C3.jpg
You legend! Thanks! Looks like I've been trying to remove the wrong frigging bolt! There is a hex head bolt below it so I guess that's the one I need to remove! I'll give it a try! 👍
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