Starting System (Engine Electrical System (G6EA - Gsl 2.7L)): Other Kia Optima II

STARTER CIRCUIT

Note. The battery must be in good condition and fully charged.

1. Remove the fuel pump relay (A) from the fuse box.
2. With the shift lever in N or P (A/T) or clutch pedal pressed (M/T), turn the ignition switch to "START" If the starter normally cranks the engine, starting system is OK. If the starter will not crank the engine at all, go to next step. If it won't disengage from the ring gear when you release key, check for the following until you find the cause. Solenoid plunger and switch malfunction. Dirty pinion gear or damaged overrunning clutch.
3. Check the battery condition. Check electrical connections at the battery, battery negative cable connected to the body, engine ground cables, and the starter for looseness and corrosion. Then try starting the engine again. If the starter cranks normally the engine, repairing the loose connection repaired the problem. The starting system is now OK. If the starter still does not crank the engine, go to next step.
4. Disconnect the connector from the S-terminal of solenoid. Connect a jumper wire from the B-terminal of solenoid to the S-terminal of solenoid. If the starter cranks the engine, go to next step. If the starter still does not crank the engine, remove the starter, and repair or replace as necessary.
5. Check the following items in the order listed until you find the open circuit. Check the wire and connectors between the driver's under-dash fuse/relay box and the ignition switch, and between the driver's under-dash fuse/relay box and the starter. Check the ignition switch (Refer to appropriate IGNITION SYSTEM article ). Check the transaxle range switch connector or ignition lock switch connector. Inspect the starter relay.

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1. Disconnect the field coil wire from the M-terminal of solenoid switch.
2. Connect the battery as shown in illustration. 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.

Scheme 37

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 (100-ampere scale) and carbon pile rheostats as shown in 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.

Current: 90A max

speed: 2,800 RPM

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1. Disconnect the battery negative cable.
2. Disconnect the starter cable (A) from the B terminal (B) on the solenoid (C), then disconnect the connector (D) from the S terminal (E).
3. Remove the 2 bolts holding the starter, then remove the starter.
4. Installation is the reverse of removal.
5. Connect the battery negative cable to the battery.

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1. Disconnect the M-terminal (A) on the magnet switch assembly (B).
2. After loosening the 3 screws (A), detach the magnet switch assembly (B).
3. Loosen the through bolts (A).
4. Remove the brush holder assembly (A), yoke (B) and armature (C).
5. Remove the packing (B).
6. Disconnect the planet gear (A).
7. Disconnect the planet shaft assembly (A) and lever (B).
8. Press the stop ring (A) using a socket (B).
9. After removing the stopper (A) using stopper pliers (B).
10. Disconnect the stop ring (A), overrunning clutch (B), internal gear (C) and planet shaft (D).
11. Reassembly is the reverse of disassembly. NOTE: Using a suitable pulling tool (A), pull the overrunning clutch stop ring (B) over the stopper (C).

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1. Remove the starter.
2. Disassemble the starter as shown in «DISASSEMBLY»(ref-266001-S07282277402007092700000) .
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. 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): 0.02mm (0.0008in.) max Service limit: 0.05mm (0.0020in.)
6. 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.)
7. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.
8. 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

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

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1. Check that there is no continuity between the (+) brush holder (A) and (-) brush holder (B). If there is no continuity, replace the brush holder assembly.
2. Pry back each brush spring (A) with a screwdriver, then position the brush (B) about halfway out of its holder, and release the spring to hold it there.
3. Install the armature in the housing, and install the brush holder. Next, pry back each brush spring again, and push the brush down until it seats against the commutator, then release the spring against the end of the brush. NOTE: 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.

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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 of 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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1. Remove the fuse box cover.
2. Remove the starter relay.
3. Using an ohmmeter, check that there is continuity between each terminal. TERMINALS CONTINUITY CHART Terminal Continuity 30 - 87 NO 85 - 86 YES
4. Apply 12V to terminal 85 and ground to terminal 86. Check for continuity between terminals 30 and 87.
5. If there is no continuity, replace the starter relay.
6. Install the starter relay.
7. Install the fuse box cover.