Ignition switch making loud grinding sound

Hi,

If you smelled something like rubber, it may have been the belt. Have you checked that? When you try to start it now, what happens? Could you tell approximately where the smoke was coming from?

I can't see how the ignition switch caused this. Also, on a starter, there are two primary wires. Once comes directly from the battery and has 12v all the time. The other is a smaller wire that goes to the S terminal. It only gets power when the key is in the start position. Once it gets power, the starter is engaged. There isn't a different wire that causes the Bendix (starter gear) to engage. It happens at the same time based on power from that one wire.

So, if you are hearing a grinding, my first suspect is there is a problem with the teeth on the flywheel itself. When you had the starter removed, did you check the condition of the teeth on the flywheel?

Let me know.

Joe

The idea that you get two clicks leads me to believe the battery is weak. Also, you may have fried the alternator doing the jump start. Anything is possible.

Lets do this. I suggest starting at the beginning, the battery. Although you have lights, it may either have a loose or bad connection or may just be weak or bad in general.

First, make sure terminals are clean and tight.

https://www.2carpros.com/articles/everything-goes-dead-when-engine-is-cranked

Next, I want you to load test the battery. Here is a link explaining how to do it:

https://www.2carpros.com/articles/car-battery-load-test

Lets start with that. It will only take a couple minutes to do. Also, if it is possible, you may want to even remove the battery and have it load tested at a parts store.

Once we establish the battery is good and has a good connection, then we will move on. The smoke has me a bit concerned. Don't laugh. Put your nose near the alternator and see if there is anything that smells funny. Also, confirm the cables at the starter are tight.

I will watch for your reply.

Take care,
Joe

Hi,

Have you load tested the battery? Are you able to turn the engine by hand at the crank shaft?

Let me know.

Joe

As far as seeing if you can turn the engine by hand, I ask because I'm questioning if the engine has locked and that's why the starter can't turn it.

As far as removal of the starter, here are the directions. This one is somewhat a pain to remove because of location. Also, make sure none of the wiring to the starter has been melted on the exhaust manifold or damaged in any way. Plus, make sure you disconnect the battery before you start this job.

Here is a link that shows in general how one is removed:

https://www.2carpros.com/articles/how-to-replace-a-starter-motor

Here are the directions specific to your vehicle for replacement. The attached pics correlate with the directions.
____________________________________________
2008 Kia Truck Sorento 4WD V6-3.3L
Repair Procedures
Vehicle Starting and Charging Starting System Starter Motor Service and Repair Removal and Replacement Repair Procedures
REPAIR PROCEDURES
REMOVAL

1. Remove the LH exhaust manifold assembly.
2. Supporting the engine with a safety jack, remove the LH side engine mounting bracket.

pic 1

3. Disconnect the starter cable from the B terminal on the solenoid, and the connector from the S terminal.
4. Remove the 2 bolts (D) holding the starter, then remove the starter (E).

TORQUE :
49.0 - 63.7 Nm (5.0 - 6.5 kgf.m, 36.2 - 47.0 lb-ft) - starter mounting(D)

pic 2

5. Installation is the reverse of removal.
6. Connect the battery negative cable to the battery.

____________________________________

Let me know what you find

Joe