Kia Optima DL3 Quiz
Engine Electrical System

Starter Motor

In this manual: Engine Electrical System
General Information — 8Advanced Driver Assistance System (ADAS) — 21Maintenance — 27Engine Mechanical System — 45Engine Electrical System — 11Emission Control System — 11Engine Control System/Fuel System — 25Automatic Transmission — 20Drive Shaft and Axle — 7Suspension System — 22Steering — 7Restraints — 11Brake System — 22Body (Interior and Exterior) — 116Body Electrical System — 90Heating, Ventilation, and Air Conditioning — 32
44steps
~264min
4/5difficulty
02040608010063.747N·mlb·ft
Tightening torque found on this page
Done 0 of 44

Description and Operation

Description

The starting system includes the battery, starter motor, magnetic switch, ignition switch, neutral safety switch (A/T), clutch pedal position switch (M/T), ignition lock switch, connecting wires, and battery cable.

When the ignition key is turned to the START position, current flows and energizes the starter solenoid coil.

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

To prevent damage caused by excessive rotation of the starter armature, the pinion gear overrunning clutch disengages when the engine starts.

Specifications

Specification

Item Specification
Rated Voltage 12 V, 1.2 kW
Number of Gear Teeth 13
Output
[No load, 11 V]		 Amperes 70A
Speed Min. 2400 rpm

Components and Component Location

Components

1. Front bracket assembly
2. Magnetic switch assembly
3. Lever
4. Gear reduction assembly
5. Stop lever		 6. Plate packing
7. Band assembly
8. Armature assembly
9. Brush holder assembly

Circuit Diagrams

Wiring 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 upper starter mounting bolt (A).

    Tightening Torque: 49.0–64 N·m

  4. Remove the engine room cover.

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

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

    Tightening torque: 11.8–16.7 N·m

  6. Remove the wiring bracket (A).

  7. Remove the lower starter mounting bolt (B).

    Tightening Torque

    A: 9,8–11.8 N·m

    B: 49,0–64 N·m

  8. Remove the starter (A).

Installation

  1. Install in the reverse order of removal.

Disassembly

  1. Disconnect the M terminal (A) on the magnetic switch unit.

  2. Loosen the screws (A), then disconnect the magnetic switch assembly (B).

  3. Loosen the through bolts (A).

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

  5. Remove the packing plate (A) and the lever stopper (B).

  6. Remove the gear reduction assembly (A) and the lever (B).

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

  8. After removing the snap ring (A) using pliers (B).

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

  10. 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 pops out, the starter is operating normally.

  3. Disconnect the battery from terminal M.

    If the pinion gear does not retract, the hold-in coil is operating normally.

  4. Disconnect the battery from the housing as well. If the pinion gear retracts immediately, the starter is operating normally.

No-Load Test

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

  2. Connect a test ammeter (150 A scale) and the carbon pile rheostat as shown. Illustration.

  3. Connect a voltmeter (15-volt scale) to the starter.

  4. Turn the carbon pile to the OFF position.

  5. Connect the battery cable from the negative battery terminal to the starter motor housing.

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

  7. Make sure the maximum current is within specification and that the starter rotates smoothly and freely.

    Items Specification
    Current (Max.) 70
    Speed (Min.) 2400

Armature Inspection and Test

  1. Remove the starter motor.

  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. Inspect the commutator surface (A). If the surface is dirty or burnt, correct it with a lathe according to the following specifications, or repair it with #500 or #600 sandpaper (B).

  5. Measure the commutator diameter. If the diameter is less than the service limit, replace the armature.

    Commutator diameter

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

    Maximum Service Limit: 26.0 mm (1.02 in.)

  6. Measure the commutator runout (A).

    • If the commutator runout is within the service 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.

    Maximum 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 to the correct depth. Remove all mica (C) between the commutator segments. The undercut must 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 commutator segments. If there is an open circuit between any segments, replace the armature.

  9. 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.

Inspect the Starter Brush

Brushes that are worn or contaminated with oil must be replaced.

Brush Holder Test

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

Overrunning Clutch

  1. Slide the overrunning clutch along the shaft.

    Replace it if it does not slide smoothly.

  2. Turn the overrunning clutch in both directions.

    Does it 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.

  3. If the starter pinion gear is worn or damaged, replace the overrunning clutch assembly (the gear is not sold separately).

    Inspect the flywheel ring gear or drive plate if the starter pinion 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 in cleaning solvent. The overrunning clutch is pre-lubricated at the factory, and solvent will wash the lubricant off the clutch.

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

Test yourself

A quick Kia Optima DL3 quiz: every answer comes with an explanation and a link to the manual page.