Kia Cadenza VG Owner's Manual Quiz
Engine Electrical System

Starter Repair Procedures

In this manual: Engine Electrical System
General Information — 15Engine Mechanical System — 95Engine Electrical System — 54Emission Control System — 24Engine Control System/Fuel System — 115Automatic Transmission — 91Drive Shaft and Axle — 13Suspension System — 35Steering — 19Restraints — 46Brake System — 43Body (Interior and Exterior) — 51Body Electrical System — 245Heating, Ventilation, and Air Conditioning — 56
45steps
~270min
4/5difficulty
02040608010063.747N·mlb·ft
Tightening torque found on this page
Done 0 of 45

Removal

  1. Turn the ignition switch OFF and disconnect the negative (-) battery cable.
  2. Remove the undercover (A) and (B).
  3. Remove the starter cover (A).
  4. Disconnect the starter cable (B) from the solenoid B terminal, then disconnect the connector (A) from the S terminal.
  5. Remove the 2 bolts securing the starter, then remove the starter (C).

Installation

  1. Install in the reverse order of removal. Starter mounting bolt: 49.0 ~ 64 N·m Starter cover mounting bolt: 8.8 ~ 13.7 N·m Starter cover mounting nut: 3.9 ~ 5.9 N·m

Disassembly

  1. Disconnect the M terminal (A) on the starter solenoid unit (B).
  2. Loosen the 3 screws (A), then disconnect the starter solenoid assembly (B).
  3. Loosen the through bolts (A).
  4. Remove the brush holder assembly (C), yoke (B), armature (C) and rear housing (D).
  5. Remove the lever seal (A) and lever plate (B).
  6. Remove the end frame (A) and packing (B).
  7. Remove the planetary gear (A).
  8. Remove the planetary shaft assembly (A) and lever (B).
  9. Press the stopper (A) using a socket (B).
  10. Remove the snap ring (A) using snap ring pliers (B).
  11. Remove the stopper (A), overrunning clutch (B), internal gear (C) and planetary shaft (D).
    Using a suitable puller (A), slide the overrunning clutch snap ring (B) onto the stopper (C).
  12. Assembly is the reverse of disassembly.

Inspection

Starter Solenoid Inspection
  1. Disconnect the lead wire from the M terminal of the magnetic switch.
  2. Connect the battery as shown in the illustration. If the starter pinion gear moves out, it is in good condition.
    • To prevent damage to the starter, do not keep the battery connected for more than 10 seconds.
  3. Disconnect the battery from the M terminal. If the pinion gear does not retract, the hold-in coil is operating correctly.
    • To prevent damage to the starter, do not keep the battery connected for more than 10 seconds.
  4. Also disconnect the battery from the housing. If the pinion gear retracts immediately, it is operating correctly.
    • To prevent damage to the starter, do not keep the battery connected for more than 10 seconds.
  5. Place the starter in a vise with soft jaws and connect a fully charged 12-volt battery to the starter as follows.
  6. Connect a test ammeter (150 A scale) and carbon pile rheostat as shown in the illustration.
  7. Connect a voltmeter (15-volt scale) to the starter.
  8. Turn the carbon pile to the OFF position.
  9. Connect the battery cable from the negative battery terminal to the starter housing.
  10. Adjust until the battery voltage shown on the voltmeter reads 11 volts.
  11. Make sure the maximum current is within specification and that the starter rotates smoothly and freely.
    Items Specification
    Current (Max.) 85
    Speed (Min.) 2550
  12. Remove the starter motor.
  13. Disassemble the starter as shown at the beginning of this procedure.
  14. Inspect the armature for wear or damage from contact with the permanent magnet. If wear or damage is found, replace the armature.
  15. Inspect the commutator surface (A). If the surface is dirty or burnt, grind it with sandpaper or on a lathe within specification, or polish with #500 or #600 sandpaper (B).
  16. Measure the commutator runout (A).
    • If the commutator runout is within the limit, check the commutator for carbon dust or brass chips between the segments.
    • If the commutator runout exceeds 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.)
  17. Check the undercut depth of the mica (A). If the mica is too high (B), undercut the mica with a hacksaw to the correct depth. Cut away all mica (C) between the commutator segments. The undercut must not be too shallow, too narrow, or V-shaped (D). Commutator mica undercut depth — Standard (new): 0.8 mm (0.314 in) — Limit: 0.2 mm (0.0079 in)
  18. Check the continuity between the commutator segments. If there is an open circuit between any segments, replace the armature.
  19. Using an ohmmeter, check that there is no continuity between the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature.
  20. Make sure there is no continuity between the (+) brush holder (A) and the (-) plate (B). If there is continuity, replace the brush holder assembly.
  21. Lift each brush spring (A) with a screwdriver, then install the brush (B) about halfway into the holder and release the spring to hold it in place.
  22. Install the armature into the housing and install the brush holder. Then lift the spring of each brush again and push the brush down until it seats on the commutator, then release the spring against the end of the brush.
    To seat new brushes, place a strip of #500 or #600 sandpaper, grit side up, between the commutator and each brush, and rotate the armature smoothly. The brush contact surface will be ground to the same contour as the commutator.
  23. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.
  24. Rotate the overrunning clutch in both directions. It should lock in one direction and rotate smoothly in the other. If it does not lock in either direction, or locks in both directions, replace it.
  25. If the starter pinion gear is worn or damaged, replace the overrunning clutch assembly (the pinion gear is not sold separately). Check the condition of the flywheel or drive plate ring gear if the starter pinion teeth are damaged.
Free Travel Inspection; Armature Inspection and Test; Inspect Starter Brushes. Brushes that are worn or oil-soaked must be replaced. Starter Brush Holder Test; Inspect Overrunning Clutch

Cleaning

  1. Do not immerse parts in cleaning solvent. Immersing the yoke and/or armature assembly may damage the insulation. Wipe these parts with a cloth only.
  2. Do not immerse the drive in cleaning solvent. The overrunning clutch is pre-lubricated at the factory, and solvent will wash the lubricant out of the clutch.
  3. The drive may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.

Test yourself

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