If your Peugeot Expert van is clicking when you try to start it — or sometimes cranks and sometimes doesn't — chances are the starter motor solenoid is failing. On the 2016 onwards Expert, the starter motor is located on the side of the gearbox and is held in by three 6mm Allen key bolts: two accessed from underneath the vehicle and one from the engine bay.
The job requires putting the van on a ramp or jacking it up safely so you can work underneath. The key trick is to start all three bolts by hand before tightening any of them, so the motor sits correctly on its locating dowel and lines up properly before you torque everything down.
Step-by-Step Guide
🛒 Parts & Tools for This Job
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Disconnect the Battery
Open the driver's door and remove the plastic trim cover at the base of the door aperture to access the battery. Disconnect the negative (power) lead and tuck it safely out of the way so the vehicle is not live while you work.
Locate the Starter Motor & Remove the Top Bolt
Open the bonnet. The starter motor sits against the side of the gearbox and is secured by three 6mm Allen key bolts — two from underneath and one from the top. For the top bolt, look down the engine bay on the gearbox side, just below the pipes and hoses. Reach your fingers in and feel for the 6mm Allen head. Undo that bolt and carefully remove it, or leave it in position so you don't lose it.
Raise the Vehicle & Remove the Electrical Connections
Put the van up on a ramp or jack it up safely so you can work underneath. Come underneath and look up the side of the gearbox — you will see the starter motor. There are two electrical cables attached: a small cable with an 8mm nut and a large cable with a 13mm nut. Undo both nuts and tuck the cables safely out of the way.
Remove the Two Underneath Bolts & Extract the Starter
With the cables disconnected, you will see the two remaining Allen key bolts — one at the base of the starter and one just above it going into the gearbox. Remove both 6mm Allen key bolts completely. Once all three bolts are out, wiggle the starter motor as it will be sitting on a couple of locating dowels. Pull it free and lower it to the floor.
Prepare the New Starter Motor
Hold the old and new starter motors side by side to confirm they are identical. There is a locating dowel on the old motor — transfer this dowel to the same position on the new unit. Remove any plastic cable ties that the new part ships with. The new motor will come with its own nuts which you can spin off and set aside for use.
Refit the New Starter Motor
Push the new starter motor up into position against the gearbox, locating the dowel in its hole at the top. Start the two bottom Allen key bolts by hand from underneath — do not tighten yet, just get them started. Lower the van back to the floor and start the top bolt from the engine bay by feel, twisting it in finger-tight. Once all three bolts are started and the motor is aligned, raise the van again and tighten all three bolts fully.
Reconnect the Electrical Cables & Battery
With the van still raised, reconnect the electrical cables. First fit the small washer onto the small cable terminal, then thread on the 8mm nut and tighten with your 8mm socket. Fit the large cable and tighten with the 13mm socket. Both should be done up nice and tight. Lower the van, then come around to the battery and reconnect the power lead.
Test the Van
With the battery reconnected, try starting the van. It should crank immediately and start cleanly without any clicking or hesitation. Job done.
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