Kia Picanto: ISG (Idle Stop & Go) System / Starter

Kia Picanto JA 2017-2022 Service & Repair Manual / Engine Control / Fuel System / ISG (Idle Stop & Go) System / Starter

Specifications
Specification
▷12V, 1.2kW : ISG only
Item
Specification
Rated voltage
12 V, 1.2 kW
The number of pinion teeth
13
Performance
[No-load, 11.5 V]
Ampere
Max. 117 A
Speed
Min. 3,200 rpm

Components and components location
Component

1.  Front housing
2.  Stop ring
3.  Stopper
4.  Overrun clutch assembly
5.  Internal gear assembly
6.  Planetary shaft assembly
7.  Planetary gear assembly
8.  Packing
9.  Shield
10. Lever plate
11. Lever packing
12. Lever
13. Magnet switch assembly
14. Armature assembly
15. Yoke assembly
16. Brush holder assembly
17. Through bolt

Description and operation
Description
The starting system consists of 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.
When power is supplied, solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring hear, closing the contacts and cranking the starter motor.
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. Overrun clutch

Schematic diagrams
Circuit Diagram

Repair procedures
Removal
1.
Turn the ignition switch OFF and disconnect the negative (-) battery terminal.
2.
Remove the air cleaner.
(Refer to Engine Mechanical System - "Air Cleaner")
3.
Remove the intake manifold.
(Refer to Engine Mechanical System - "Intake Manifold")
4.
Remove the starter solenoid "B" terminal mounting nut (B), and then disconnect the starter cable and ST connector (A).
Tightening torque :
9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 Ib·ft)

5.
Remove the starter mounting bolts and then remove the starter (A).
Tightening torque :
42.2 - 53.9 N·m (4.3 - 5.5 kgf·m, 31.1 - 39.8 Ib·ft)

Installation
1.
Install in the reverse order of removal.
Reassembly
1.
Reassemble in the reverse order of disassembly.
Inspection
Armature Inspection And Test
1.
Remove the starter.
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.
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.
Check the commutator diameter. If the diameter is below the service limit, replace the armature.
Commutator diameter
Standard (New) : 33.0mm (1.2992in.)
Service limit : 32.4mm (1.2756in.)

6.
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 (0.002in.)

7.
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) : 0.5mm (0.0197in.)
Limit : 0.2mm (0.0079in.)

8.
Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.

9.
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.

Inspect Starter Brush
Brushes that are worn out, or oil-soaked, should be replaced.

   
The 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 Test
1.
Make sure there is no continuity between the (+) brush holder (A) and (-) plate (B). If there is continuity, replace the brush holder assembly.

   
Use a pipe (C) of suitable size for the brushes not to get removed from the brush holder.
Inspect Overrunning Clutch
1.
Slide the overrunning clutch along the shaft.
Replace if it does not slide smoothly.
2.
Rotate the overrunning clutch both ways.
Check that it locks in one direction and rotates smoothly in reverse. If it does not lock in either direction or locks in both directions, replace it.

3.
If the starter drive gear is worn or damaged, replace the overrun 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 away 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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Specifications Specification ▷ 13.5V, 130A [ISG only] Item Specification Rated voltage 13.5V, 130A Speed in use 1,000 ...

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