DIY kia rio starter repair

In detail: do-it-yourself repair of a kia rio starter from a real master for the site my.housecope.com.

Kia Rio 3. STARTER REPAIR

Before disassembling the starter motor, verify that it is defective by the following simple checks.

1.Use a screwdriver to check that the drive coupling can move easily along the shaft.
2. Rotate the drive gear. It should turn easily relative to the coupling hub in the direction of rotation of the armature and should not turn in the opposite direction.

3. Connect the wires for "lighting" the "minus" terminal of the battery removed from the car with the starter housing. Connect the second wire with one end to the "plus" terminal of the storage battery, and the other - to the output of the control wire of the traction relay. If the traction relay is working properly, then a click will be heard and the drive clutch will extend. Otherwise, the traction relay must be replaced.

... and install on the rotor by sliding from the mandrel onto the rotor manifold;

- before installing the traction relay, apply a thin layer of silicone sealant to the surface of the relay in contact with the starter cover.

Symptoms: the engine does not start well, the starter motor is idling, the starter motor rotates, but the engine does not start, the starter motor does not rotate.

Possible cause: defective starter.

Tools: a set of heads, a set of wrenches, a set of screwdrivers, an auto-tester.

1. Place the vehicle on a viewing ditch or on a lift.

2. Dismantle the protective element of the crankcase and the side mudguards of the engine from the car (see Removing and installing the protective element of the crankcase and the mudguards of the engine).

3. Disconnect the terminal of the negative wire from the corresponding terminal of the storage battery.

Video (click to play).

4. Press out the retaining element of the block of the control wire, and then disconnect the block from the traction relay.

5. Remove the protective cap and then remove the starter power cord lug retaining nut.

6. Disconnect the wire lug from the contact bolt.

7. Loosen and remove the harness retainer retaining bolt, then slide the retainer to the side.

8. Unscrew and remove the two starter mounting bolts from the clutch housing side.

9. Remove the starter from the vehicle.

10. Before disassembling the starter, perform a series of simple checks as described below:

- Using a screwdriver, check the ease of movement of the coupling along the shaft drive.

- Turn the drive gear. It should rotate with light effort relative to the coupling hub in the direction of rotation of the armature and should not rotate in the opposite direction.

- Connect the negative terminal of the battery dismantled from the car with the starter housing using the lighting wires. Connect the second cable with one tip to the positive terminal of the same storage battery, and the second to the terminal of the control wire of the starter traction relay. With a working traction relay, a click should be heard, followed by the extension of the drive clutch. If this does not happen, the traction relay is faulty and must be replaced.

- Disconnect the tip of the wire from the control terminal of the traction relay, and then connect it to the contact bolt of the traction relay. The starter rotor should start rotating at a frequency of more than 3500 min ^ (- 1). If this does not happen, the starter must be repaired or replaced as an assembly.

11. Unscrew and remove the power rail retaining nut to the traction relay contact bolt.

12. Remove the power rail from the starter contact bolt.

13. Unscrew and remove the two mounting screws of the starter traction relay to its front cover.

14. Remove the traction relay.

15. Unscrew and remove the two tie bolts.

16. Remove the freewheel clutch lever support from the cover.

17.Separate the stator from the front starter cover.

18. Dismantle the freewheel drive arm.

19. Slide the stop ring along the rotor shaft.

20. Pry the retaining ring with a screwdriver.

21. Remove the circlip from the rotor shaft.

22. Remove the stop ring from the rotor shaft.

23. Remove the freewheel from the rotor shaft.

24. Dismantle the brush holder assembly together with the starter rear cover.

25. Remove the spacer ring from the rotor shaft.

26. Unscrew and remove the two starter rear cover retaining screws to the brush holder assembly.

27. Disconnect the starter rear cover and brush holder assembly.

28. Remove the power bus assembly with brushes, if necessary.

29. Remove the rotor from the stator.

30. Inspect the starter rear cover. Replace the cap if there are any scuffs, pits, or other defects on the bushing.

31. Inspect the brush holder assembly. Check the height of the brushes in the brush holder. The measured value should not be less than 7 millimeters.

32. Inspect the rotor. There should be no damage (nicks, scoring) on the spline surface and on the rotor shaft journals. There must be no burning on the rotary manifold. Slight burns can be removed with a cloth soaked in gasoline or fine-grained emery cloth.

33. Check each rotor winding for a short circuit with an ohmmeter. The measured value should tend to infinity.

34. Check the ease of movement of the starter traction relay armature.

35. Check if the contact bolts of the contact plate are closed. Use an ohmmeter.

36. Check the freewheel drive clutch. Gear teeth should be free from significant wear. This gear should turn with light effort relative to the coupling hub in the direction of rotation of the rotor and should not turn in the opposite direction. Replace the clutch if one of the above defects is found.

37. The drive arm of the freewheel clutch should be free of cracks and signs of significant fork wear.

38. Assemble the starter in reverse disassembly in sequence, taking into account the following features:

- Apply a silicon-based lubricant to the spline surface of the rotor shaft.

- Use pliers to install the stop ring.

Note: during operation, the freewheel clutch does not need to be lubricated, but it is necessary to clean it from dirt. The use of agents capable of washing out the lubricant in the coupling is strictly prohibited.

- Apply engine oil to the bearings (bushings) in which the starter rotor rotates.

- During the installation of the brush holder assembly, spread the brushes to the sides and fix them in the obtained position using a suitable mandrel (for example, using the “24” socket). Then install the assembly onto the starter rotor by sliding it off the mandrel onto the rotor manifold.

- Before installing the traction relay, apply a thin layer of silicone sealant to the surface of the relay mating with the starter cover.

39. Mount the starter in the reverse order to dismantling.

The starter on any engine is on the flywheel side. In particular, in the Kia Rio 2 on the G4EE engine, it stands on the left in the direction of travel, from the side of the passenger compartment.

First, remove the terminal of the negative wire from the battery. Then plus. Having removed the air filter housing together with the branch pipe, we free up space for further work.

We also remove the gearbox drive mechanism from the mounts (there are two bolts) and move it to the side.

Disconnect all wires from the starter contacts.

Unscrew the starter mounting bolts.

The starter can be removed both down and up. Take it down in the photo.

Also watch a video about removing the Hyundai Accent starter. This model is based on the Kia Rio. This video shows the removal of the starter upwards.

We disassemble the starter to replace the traction relay, brush holder with brushes and drive elements.

Turn off the nut with the "10" head ...

... and remove the tip of the wire from the output of the traction relay.

Use the Torx T ‑ 20 wrench to unscrew the two screws ...

Using the "8" head, unscrew the two tie bolts.

Remove the front starter cover.

Remove the lever seal.

Remove the back cover with a brush holder.

Use a Phillips screwdriver to unscrew the two screws securing the brush holder.

We take out the anchor from the starter housing.

Remove the anchor thrust ring.

With a mandrel (you can use a suitable high head), press the stop ring of the drive gear.

… Remove the circlip from the armature shaft groove.

Remove the stop ring from the armature shaft.

Remove the drive assembly.
By external inspection we check the condition of the collector and the armature windings.
Charring of the windings is not permitted.
The ends of the windings should be well soldered to the lamellas. Blackening of windings and separation of varnish insulation from them is not allowed.
If the collector is slightly burned, we clean its plates with a fine abrasive cloth. In case of severe burning and severe wear of the collector, the armature should be replaced. Seizure and enveloping of the plain bearing material on the shaft journals are eliminated with the finest-grained sandpaper followed by polishing.
With an ohmmeter, we check the short circuit of the armature winding to its core.
For this…

… We connect the ohmmeter probes to the collector and the armature core.
The ohmmeter should show infinity. Otherwise, the armature winding is shorted to the core and the armature must be replaced.
We check the short circuit of the insulated brush holders to ground.
For this…

… Connect the ohmmeter probes to the holder and the brush holder plate.
The ohmmeter should show infinity. Otherwise, replace the complete brush holder.
We assemble the starter in the reverse order.

We install the stop ring of the drive gear on the stop ring using sliding pliers.
We mount the brush holder before installing the armature in the starter housing.
Before installing the brush holder on the armature collector, slide the brushes into the guides and tie them with wire. After installing the brush holder on the armature collector ...

… Install the back cover and attach the brush holder to it.
After that, we untie the wire, and the brushes will move to the collector under the action of the springs.

Symptoms: the starter motor turns, but the engine does not start.

Possible reason: defective starter.

Tools and materials: cloth gloves, a set of heads and wrenches, a set of screwdrivers.

Spare parts and fuels and lubricants: starter assembly:

Note. Work is carried out on a lift or on a viewing ditch.

1. Disconnect the negative cable from the battery.

2. Dismantle the trim of the gearbox selector, floor and handbrake.

4. Disconnect the tip of the transmission control cable from the selector lever.

Note. To dismantle the starter, it is necessary to disconnect the engagement and gear selection cables from the gearbox. Since the equipment of this car model can include both automatic and manual gearboxes, this manual will describe the necessary operations for disconnecting the cables in turn for both gearboxes.

A. To disconnect the manual transmission control cables, follow these steps:

6. Press out the cotter pin retaining element.

7. Remove the securing pin of the tip of the control cable of the gearbox from the hole in the axle of the gearshift lever.

9. Disconnect the tip of the transmission control cable from the shaft of the gear shift lever.

10. Withdraw the tip of the cable sheath from the slot located in the bracket that is installed in the gearbox and move the gear shift cable to the side.

11. Remove the cable-end retaining pin from the hole located in the shaft of the select lever.

13. Remove the tip of the transmission control cable from the shaft of the gear selector lever.

14. Withdraw the end of the cable sheath from the slot located in the bracket that is installed on the checkpoint and move the cable to the side.

B.To disconnect the automatic transmission control cables, follow these steps:

15. Press out the plastic retaining element.

16. Remove the tip of the sheath of the control cable of the gearbox from the socket located in the body of the rocker of the gear selector.

19. Disconnect the tip of the transmission control cable from the transmission lever on the transmission control unit.

20. Remove the tip of the gearbox control cable from the slot located in the bracket that is installed on the gearbox housing.

Note. After the gearbox control cables are disconnected, you can proceed to the operations directly to dismantle the starter.

21. Unscrew and remove the upper starter mounting bolt to the clutch housing.

22. Disconnect the wire block from the output of the electromagnetic relay.

23. Remove the cover protecting the wire end, then slide it down the wire.

24. Unscrew and remove the wire lug attachment nut to the contact bolt and remove the wire lug from the contact bolt.

25. Unscrew and remove the lower starter mounting bolt to the clutch housing.

26. Remove the starter from the vehicle.

27. Install the new starter and all removed parts in reverse order.

The Kia Rio 2 starter provides rotation of the shaft of the internal combustion engine to start the car. If a malfunction occurs in its operation, it will be quite difficult to start the Kia Rio 2 engine, so any signs of a malfunction of the starter become a serious reason for checking it and, if problems are found, replacing it. Let us examine the question of how to change the starter on the Kia Rio 2 on our own and what tools are required to carry out the work.

The Kia Rio 2 starter has a classic structure - its main components are the rotor and stator. It is these details that most often fail. It is quite problematic to purchase them separately and replace them, therefore, they usually purchase a new starter assembly for replacement - especially since the cost of the whole starter and the separately taken stator and rotor are almost identical.

The main symptom of a starter malfunction is the lack of starting the engine when the part rotates.
Also, a sign of a malfunction may be the lack of rotation of the starter.

For a car with a gasoline engine (DOHC MPI 1.4 or 1.6) - article number 3610026800 (36100265850, 3610026810, 36100265860);
For a car with a diesel engine (DOHC TCI 1.5) - article number 361002A100 (or 361002A300).

You can remove the starter of the Kia Rio (as well as any other car) on an inspection pit or a lift.

Disconnect the negative terminal of the battery
Remove the trim from the parking brake, floor and gear selector
Remove the cotter pin and disconnect the gearbox drive cable end from the selector lever

Since a manual and automatic transmission can be installed on the Kia Rio 2, we will sequentially describe the process of removing the cables on each of them.

Remove air filter
Detach the cotter pin retainer
Remove the cotter pin with which the tip of the manual transmission control cable is attached from the hole in the lever shaft
Remove the washer and the end of the transmission control cable from the lever shaft
Take out the tip of the cable sheath from the slot - it is located in the bracket mounted in the gearbox
Move the shift cable to the side
Remove the cotter pin, which secures the end of the cable located in the axis of the gear detection lever from the hole and remove the washer
Remove the end of the transmission control cable from the shaft of the gear selector lever
Take out the end of the cable sheath from the slot located in the gearbox bracket and move the cable to the side

Remove the plastic retainer
Remove the end of the cable sheath from the body of the rocker of the gear selector
Pull out the air filter
Remove the cotter pin
Remove the end of the cable from the lever of the control unit of the gearbox
Remove the tip from the socket, which is located in the bracket on the gearbox housing

Remove the upper bolt to the starter clutch housing
Disconnect the wire harness from the solenoid relay terminal
Remove the protective cover from the wire end and slide down the wire
Unscrew the nut securing the wire tip to the contact bolt and remove the wire tip from the contact bolt
Remove the bottom bolt to the starter clutch housing
Remove starter Kia Rio 2

Change the starter to the Kia Rio 2 and reassemble all previously removed parts in reverse order.

In this article, we examined how to change the starter on the Kia Rio 2, what sequence of actions should be followed and what features of the operation can be distinguished when removing and replacing the starter on the Kia Rio with automatic and manual gearboxes.

Any, even the most reliable unit and unit, may fail over time. Unfortunately, this also applies to the Hyundai Solaris starter, regardless of the year of manufacture.

The unit is interchangeable with the starter installed on the Kia Rio, and has a catalog number 36100-2V602 , gear type. In the event of a malfunction or failure in work, you need to know how to remove a starter on a Hyundai Solaris with your own hands quickly and without unnecessary fuss.

The original new catalog starter on Solaris costs about 15-16 thousand rubles ... However, it does not always require replacement in the event of failure or failure.

The first and main symptom, indicating a malfunction of the unit, is the starter's refusal to turn the flywheel. In this case, the starter may not react at all to the turn of the ignition key or to the start button, it may emit characteristic sounds.

In the first case, the cause of failure can be not only the starter, but also the fuse, the starter relay, the ignition switch itself.

This can be diagnosed as follows:

If the starter does not turn the crankshaft flywheel it is possible that the battery is not supplying enough voltage to operate the starter motor. In this case, you need to check the battery charge level with a multimeter, it should be within 12-13 V.
No contact in the ignition switch ... The contact group of the Hyundai Solaris ignition switch supplies power to the starter when contacts 50 and 30 are closed. They need to be closed together for a few seconds, while the starter should start rotating the crankshaft flywheel.

The ignition switch can show signs of life, including the dashboard and the fuel pump. But the starter contact group may be faulty.

Location of the starter relay on the Hyundai Solaris

In most cases, when the starter does not work or does not work correctly, it will need to be dismantled and repaired. The starter motor is located at the front of the cylinder block above the oil filter. The unit is fixed to the tide of the cylinder block with two wrench nuts for 14. The algorithm for dismantling the starter is as follows:

First of all, it is necessary to remove the negative terminal from the battery to avoid a short circuit.

Remove the negative terminal from the battery.

Depress the retainer and disconnect the harness block from the oil pressure sensor.

Remove the wires and lay to the side.

Unscrew the two bolts and remove the starter while supporting.

After repair or replacement, installation is carried out upside-down. So you can quickly and independently remove and put the starter on the Hyundai Solaris. Confident start-up and smooth roads to everyone!

Kia cars have been pleasing drivers for several years. They are not only elegant and practical, but also pleasant to use. But everything does not last forever, and sooner or later any car crashes. Our company specializes in Kia starter repair, as well as the sale of spare parts and components.

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There are times when you can do auto repairs yourself, but sometimes, not having the necessary equipment at hand, you should turn to the help of our car service professionals. Here, your car will be thoroughly diagnosed and the cause of the malfunction will be pinpointed. In addition, the specialists of our company will perform high-quality Kia starter repair in a very short period, so that your "swallow" will soon be able to please you again.

Starter repair cost for Kia - from 500 rubles.

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we agree with the client on all stages of the repair
removal and installation of spare parts takes place in the service
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If you like our conditions, then call, come when it is convenient for you. Our masters will provide the necessary transformations for the car, which will quickly put your car on its feet and, most likely, you will return to us again to eliminate the next breakdown or buy the necessary spare part.

Dear author of the video, can you remove the retractor catfish without removing the starter from the engine?

Is the relay suitable for the st-230a starter?

About six years ago I did this on a Japanese. I cleaned five millimeters from rolling, tinned it with tin, then follow the video. I found suitable terminals in the store. At the end of the assembly I squeezed it with my hand, and I went through it with a soldering iron. I forgot it now. It works and works.

What a stupidity with a grinder, everything is done in an elementary way. We take a soldering iron, take the tin from the two contacts of the coil and unscrew the bolts and this cover can be removed without much effort and the grinder. But this is sadism over the relay. It's just kapets!

And it was not possible to simply order a lid for a turner with a thread.

It flares very well without problems, I have already remade hundreds of such starters with a simple screwdriver

This is done when the garage masturbators have nothing to occupy themselves with.

We are usually like that for a replacement. We mainly repair gearboxes. And we don't get involved with this hemorrhoid.

the output saw the relay in the sealant, throw it out and buy a new one