Kia Forte: Starting System / Starter

Kia Forte 2019-2020 (BD) Service Manual / Engine Electrical System / Starting System / Starter

Specifications
Specification

Item
Specification
Rated voltage
12 V, 0.9 kW
The number of pinion teeth
10
Performance
[No-load, 11.5 V]
Ampere
Max. 60 A
Speed
Min. 5,500 rpm

Components and components location
Components
[NON - ISG type]

1. Screw
2. Front bracket assembly
3. Stop ring
4. Stopper
5. Overrunning clutch
6. Lever
7. Lever plate
8. Lever packing
9. Magnet switch assembly
10. Armature assembly
11. Yoke assembly
12. Brush (-)
13. Brush holder
14. Brush (+)
15. Rear bracket assembly
16. Through bolt
17. Screw
18. Brush holder assembly
19. Stopper set

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.

In conjunction with the ISG function, the starter motor must do a great deal more work. Therefore, the starter motor is configured for a significantly higher number of start cycles. The components of the starter motor have been adapted to the higher requirements.

1. Solenoid
2. Brush assembly
3. Armature
4. Over runing clutch

Schematic diagrams
Circuit Diagram

Repair procedures
Removal
1.

Turn the ignition switch OFF and disconnect the battery negative (-) terminal.

2.

Remove the air cleaner.

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

3.

Remove the starter mounting upper bolt (A).

Starter mounting upper bolt:

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.

Remove the vacumm pump.

(Refer to Brake System - "Vacumm Pump")

6.

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

Starter solenoid "B" terminal mounting nut :

9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)

7.

Remove the starter mounting lower bolt (A).

Starter mounting lower bolt:

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
[NON - ISG type]
1.

Disconnect the M-terminal (A) on the magnet switchassembly.

2.

After loosening the 2 screws (A), detach the magnet switch assembly (B).

3.

Loosen the brush holder mounting screws (A) and the trough bolts (B).

4.

Remove the rear bracket assembly (A) and brush holder assembly (B).

5.

Remove the yoke assembly (A).

6.

Remove the packing (A), lever plate (B), lever (C), armature assembly (D).

  

Beware the direction of lever (A).

7.

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

8.

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

9.

Remove the stop ring (B), stopper (A), overrunningclutch (C) and armature (D).

  

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

Reassembly
1.

Reassemble in the reverse order 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
5.

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

6.

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

7.

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

8.

Rotate carbon pile to the off position.

9.

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

10.

Adjust until battery voltage shown on the voltmeter reads 11.5 volts.

11.

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

Current (Max.)
Speed (Min.)
60 A
5,500 rpm

Armature
12.

Remove the starter.

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 there is wear or damage, replace the armature.

15.

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).

16.

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

Commutator diameter

Standard (New) : 29.4 mm (1.1575 in)

Service limit : 28.8 mm (1.1339 in)

17.

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) : 0.05mm (0.0020in.) max

Service limit : 0.10mm (0.0039in.) max

18.

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) : 0.5 mm (0.0197 in.)

Limit : 0.2mm (0.0079 in.)

19.

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

20.

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.

Starter Brush
1.

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

Bruch length

Standard : 12.3 mm (0.4843 in)

Service linit : 5.5 mm (0.2165 in)

  

To seat new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.

Starter Brush Holder
21.

Check that there is no continuity between the (+) brush holder (A) and (-) plate (B).

If there is continuity, replace the brush holder assembly.

Overrunning Clutch
22.

Slide the overrunning clutch along the shaft.

Replace it if does not slide smoothly.

23.

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 of it locks in both directions, replace it.

24.

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 sol-vent 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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