Kia 3610025020 Starter Assembly

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If a malfunction occurs in the starting circuit, do not immediately assume that the starter is causing the problem. First, check the following items: Make sure the battery cable clamps, where they connect to the battery, are clean and tight. Check the condition of the battery cables. Replace any defective battery cables with new parts. Test the condition of the battery. If it does not pass all the tests, replace it with a new battery. Check the starter solenoid wiring and connections. Check the starter mounting bolts for tightness. Check the fusible link. If it's burned, determine the cause and repair the circuit. Check the operation of the Park/Neutral switch. Make sure the shift lever is in PARK or NEUTRAL. Check the operation of the starter relay. If the starter does not actuate when the ignition switch is turned to the start position, check for battery voltage to the solenoid. This will determine if the solenoid is receiving the correct voltage signal from the ignition switch. Connect a test light or voltmeter to the starter solenoid positive terminal and while an assistant turns the ignition switch to the start position. If voltage is not available, and check all the fuses and relays in series with the starting system. If voltage is available but the starter motor does not operate, remove the starter and bench test it. If the starter turns over slowly, check the starter cranking voltage and the current draw from the battery. This test must be performed with the starter assembly on the engine. Crank the engine over and observe the battery voltage. It should not drop below 8.0 volts on manual transaxle models or 8.5 volts on automatic transaxle models. Also, observe the current draw using an ammeter. It should not exceed 400 amps or drop below 250 amps. If the starter motor cranking amp values are not within the correct range, replace it with a new unit. If the starter receives voltage but does not activate, remove and check the starter/solenoid assembly on the bench. Most likely, the solenoid is defective. In some rare cases, the engine may be seized, so be sure to try and rotate the crankshaft pulley before proceeding. With the starter/solenoid assembly mounted in a vise on the bench, install one jumper cable from the negative battery terminal to the body of the starter. Install the other jumper cable from the positive battery terminal to the B+ terminal on the starter. Install a starter switch and apply battery voltage to the solenoid S terminal and see if the solenoid plunger, shift lever, and overrunning clutch extend and rotate the pinion drive. If the pinion drive extends but does not rotate, the solenoid is operating but the starter motor is defective. If there is no movement but the solenoid clicks, the solenoid and/or the starter motor is defective. If the solenoid plunger extends and rotates the pinion drive, the starter/solenoid assembly is working properly.

Disconnect the cable from the negative terminal of the battery. Remove the lower engine splash shield, if so equipped. Detach the electrical connectors from the starter/solenoid assembly. Remove the starter heat shield, if so equipped. On 2001 through 2006 models, disconnect the speedometer cable and the transaxle shifter cable. Remove the starter motor mounting fasteners and remove the starter. Installation is the reverse of removal.