Kia Optima: Starting System / Starter

Kia Optima DL3 2019-2020 Service and Repair Manual / Engine Electrical System / Starting System / Starter

Description and operation
Description

The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch (A/T), clutch pedal switch (M/T), ignition lock switch, connection wires and the battery cable.

When the ignition key is turned to the start position, current flows and energizes the starter motor's solenoid coil.

The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.The contacts close and the starter motor cranks.

In order to prevent damage caused by excessive rotation of the starter armature when the engine starts, the clutch pinion gear overruns.

Specifications
Specification

Item
Specification
Rated voltage
12V, 1.2 kW
The number of pinion teeth
13
Performance
[No-load, 11V]
Ampere
70A
Speed
Min. 2,400 rpm

Components and components location
Components

1. Front bracket assembly
2. Magnet switch assembly
3. Lever
4. Reducer assembly
5. Lever stop
6. Gasket sheet
7. Yoke assembly
8. Armature assembly
9. Brush holder assembly

Schematic diagrams
Circuit Diagram

Repair procedures
Removal
1.

Disconnect the negative battery (-) terminal.

2.

Remove the air cleaner assembly.

(Refer to Engine Mechanical System - "Air Cleaner")

3.

Remove the starter mounting upper bolt (A).

Tightening torque :

49.0 - 63.7 N·m (5.0 - 6.5 kgf·m, 36.2 - 47.0 lb·ft)

4.

Remove the engine room under cover.

(Refer to Engine Mechanical System - "Engine Room Under Cover")

5.

Disconnect the starter cable (A) from the B terminal on the solenoid, then disconnect the connector (B) from the S terminal.

Tightening torque :

11.8 - 16.7 N·m (1.2 - 1.7 kgf·m, 8.7 - 12.3 lb·ft)

6.

Remove the wiring bracket (A).

7.

Remove the starter mounting lower bolt (B).

Tightening torque

A : 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

B : 49.0 - 63.7 N·m (5.0 - 6.5 kgf·m, 36.2 - 47.0 lb·ft)

8.

Remove the starter (A).

Installation
1.

Install in the reverse order of removal.

Disassembly
1.

Disconnect the M-terminal (A) on the magnet switch assembly.

2.

After loosening the screws (A), detach the magnet switch ssembly (B).

3.

Loosen the through bolts (A).

4.

Remove the brush holder assembly (A), armature assembly (B) and yoke assembly (C).

5.

Remove the gasket sheet (A) and lever stop (B).

6.

Remove the reducer assembly (A) and lever (B).

7.

Press the stopper (A) using a socket (B).

8.

After removing the stop ring (A) using stop ring pliers (B).

9.

Disconnect the stopper (A), overrunning clutch (B) and internal gear (C).

  

Using a suitable pulling tool (A), pull the overrunning clutch stopper (C) over the stop ring (B).

10.

Reassembly is the reverse of disassembly.

Inspection

Starter Solenoid Inspection

1.

Disconnect the lead wire from the M-terminal of solenoid switch.

2.

Connect the battery as shown. If the starter pinion pops out, it is working properly.

  

To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.

3.

Disconnect the battery from the M terminal.

If the pinion does not retract, the hold-in coil is working properly.

  

To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.

4.

Disconnect the battery also from the body. If the pinion retracts immediately, it is working properly.

  

To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.

Free Running Inspection

1.

Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter motor as follows.

2.

Connect a test ammeter (150-ampere scale) and carbon pile rheostats shown is the illustration.

3.

Connect a voltmeter (15-volt scale) across starter motor.

4.

Rotate carbon pile to the off position.

5.

Connect the battery cable from battery's negative post to the starter motor body.

6.

Adjust until battery voltage shown on the voltmeter reads 11 volts.

7.

Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely.

Items
Specification
Current (Max.)
70
Speed (Min.)
2,400

Armature Inspection And Test

1.

Remove the starter.

2.

Disassemble the starter as shown at the beginning of this procedure.

3.

Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.

4.

Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with #500 or #600 sandpaper (B).

5.

Check the commutator diameter. If the diameter is below the service limit, replace the armature.

Commutator diameter

Standard (New): 27.0 mm (1.06 in.)

Service limit: 26.0 mm (1.02 in.)

6.

Measure the commutator (A) runout.

If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments.

If the commutator run out is not within the service limit, replace the armature.

Commutator runout

Standard (New): 0.05 mm (0.0019 in.) max

Service limit: 0.08 mm (0.0031 in.)

7.

Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or v-shaped (D).

Commutator mica depth

Standard (New): 0.8 mm (0.0314 in.)

Limit: 0.2 mm (0.0079 in.)

8.

Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.

9.

Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If continuity exists, replace the armature.

Inspect Starter Brush

Brushes that are worm out, or oil-soaked, should be replaced.

Starter Brush Holder Test

Make sure there is no continuity between the (+) brush holder (A) and (-) plate (B). If there is continuity, replace the brush holder assembly.

Overrunning Clutch

1.

Slide the overrunning clutch along the shaft.

Replace it if does not slide smoothly.

2.

Rotate the overrunning clutch both ways.

Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it locks in both directions, replace it.

3.

If the starter drive gear is worn or damaged, replace the overrunning clutch assembly. (the gear is not available separately).

Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.

Cleaning
1.

Do not immerse parts in cleaning solvent. Immersing the yoke assembly and/or armature will damage the insulation. Wipe these parts with a cloth only.

2.

Do not immerse the drive unit in cleaning solvent. The overrun clutch is pre-lubricated at the factory and solvent will wash lubrication from the clutch.

3.

The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.

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