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Introduction

This tutorial shows how to change the starter on Citroen ZX 1.6 (XU engine).

  1. 
the starter is located in front of the engine

under the oil filler cap
    • the starter is located in front of the engine

    • under the oil filler cap

  2. 
unscrew the terminal retaining nut - , 10mm wrench

remove the pod

and put it on hold
    • unscrew the terminal retaining nut - , 10mm wrench

    • remove the pod

    • and put it on hold

  3. 
there are 2 wires connected to the starter
    • there are 2 wires connected to the starter

    • the + battery

    • the solenoid excitation wire

  4. 
unscrew the nut of the wire + battery, 13mm key

take out the nut

take out the wire
    • unscrew the nut of the wire + battery, 13mm key

    • take out the nut

    • take out the wire

  5. 
do the same for the excitation wire, 8mm key
    • do the same for the excitation wire, 8mm key

  6. 
grab the water hose

then move it slightly aside: the 3 starter screws are accessible

unscrew the 3 screws, 8 mm Allen key
    • grab the water hose

    • then move it slightly aside: the 3 starter screws are accessible

    • unscrew the 3 screws, 8 mm Allen key

    • Be careful not to damage the radiator with the key.

  7. 
release the starter, the rearmost screw can remain

do not mix the other 2 screws: the shortest one goes at the bottom

take out the starter
    • release the starter, the rearmost screw can remain

    • do not mix the other 2 screws: the shortest one goes at the bottom

    • take out the starter

  8. 
compare starters
    • compare starters

    • Sizes and shapes may vary depending on the equipment manufacturer: only the references will really inform us about compatibility (Citroën references: 5802S3, 5802EQ, 5802H8, 91536044, 91514125, 96054384).

    • The XU and XUD blocks having the same base, we find these starters on many petrol and diesel models: 205, 309, 405, bx, zx, c15...

    • Don't hesitate to get help from a professional, whether you are buying new or, as here, second-hand.

  9. 
there is a centering pin on the gearbox

in which the starter is wedged
    • there is a centering pin on the gearbox

    • in which the starter is wedged

  10. 
introduce the starter correctly

put in place the 3 screws and advance them by hand

finish tightening using the 8 mm Allen key
    • introduce the starter correctly

    • put in place the 3 screws and advance them by hand

    • finish tightening using the 8 mm Allen key

  11. 
recover the wire + battery

put it in place on the starter

tighten the nut, 13mm wrench
    • recover the wire + battery

    • put it in place on the starter

    • tighten the nut, 13mm wrench

  12. 
do the same for the excitation wire, 8mm key
    • do the same for the excitation wire, 8mm key

  13. 
put the pod - in place

tighten the nut, 10mm wrench

test the starter
    • put the pod - in place

    • tighten the nut, 10mm wrench

    • test the starter

Finish Line

a_bosc2000

Member since: 11/03/2019

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