2002 Kia Rio Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Repair and Diagnosis: Electrical: Starters: Overhaul: Reassembly

  1. Reassemble armature gaskets to the end of armature.
  2. Reassemble armature in field coil housing.
  3. Reassemble rear cover and tighten two brush plate.
  4. Reassemble drive pinion and stopper on pinion shaft.
  5. Place snap ring on its groove in pinion shaft.
  6. Reassemble stopper.
  7. Reassemble lever on drive pinion.
  8. If present, reassemble planetary gear set to motor assembly.
  9. Reassemble motor assembly in drive end housing.
  10. Place bolts in rear cover and tighten.
  11. Engage plunger in lever.
  12. Insert solenoid plunger spring.
  13. Reassemble magnetic switch and tighten solenoid screws.
  14. Apply battery power to the "S" terminal and ground starter motor body. Pinion will eject outward and then stop.
  15. Measure clearance (pinion gap) between pinion and stopper.
    NOTE: Be careful not to let electricity flow continuously for more than 10 seconds.
  16. If pinion gap is not within specified range, adjust it by increasing or decreasing the number of gaskets used between solenoid and drive housing. The gap will become smaller if the number of gaskets is increased.
    NOTE: DO NOT use more gaskets than plates.
  17. Connect field wire to "M" terminal.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.