Kia Sportage 1998-02

Solenoid or Relay

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  1. Disconnect the negative battery cable.
  2.  
  3. Remove the starter assembly from the vehicle.
  4.  
  5. Remove the nut from the solenoid M-terminal.
  6.  
  7. Remove the solenoid retaining screws and the magnetic switch.
    NOTE
    If Pinion depth shims are found between the solenoid and the drive housing, remove them and set aside.

  8.  
  9. Remove the solenoid and plunger spring.
  10.  
  11. Disengage the plunger from the lever and remove the plunger.
  12.  

To install:

  1. Connect the plunger to the plunger lever and install the plunger.
  2.  
  3. Install the plunger spring and solenoid onto the plunger.
  4.  
  5. Install the shims and magnetic switch and secure to the drive housing with the two screws.
  6.  
  7. Re-install the nut onto solenoid M-terminal.
  8.  
  9. Measure the pinion gap to ensure proper clearance as follows:
    1. Secure the starter assembly in a vise.
    2.  
    3. Apply battery voltage between the solenoid S-terminal and ground. The pinion will eject outward and then stop.
      WARNING
      Do not apply electricity for more than 10 seconds.

    4.  
    5. With the pinion fully extended, measure the clearance between the pinion and the drive housing. The clearance should be 0.020-0.079 inches.
    6.  
    7. If clearance is not as specified, adjust by adding or removing shims between the solenoid and the drive housing until proper clearance is achieved.
    8.  

  10.  
  11. Reinstall the starter assembly.
  12.  
  13. Reconnect the negative battery cable.

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    Fig. Exploded view of the starter



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    Fig. Starter solenoid and plunger spring



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    Fig. Starter magnetic switch retaining screw location



    Click image to see an enlarged view

    Fig. Starter solenoid plunger and plunger lever



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    Fig. Pinion clearance measurement location

  14.  

 
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