KIA CARNIVAL 2007 Workshop Manual

4.Remove the brush holder assembly (A), yoke (b) and armature (C).
5.Remove the shield (A) and packing (B).
6.Remove the lever plate (A) and lever packing (B).
7.Disconnect the planet gear (A).

8.Disconnect the planet shaft assembly (A) and lever (B).
9.Press the stop ring (A) using a socket (B).
10. After removing the stopper (A) using stopper pliers (B).
11.Disconnect the stop ring (A), overrunning clutch (B), internal gear (C) and planet shaft (D).
12.Reassembly is the reverse of disassembly.
Using a suitable pulling tool (A), pull the overrunning clutch stop ring (B) over the stopper (C).

INSPECTION
ARMATURE INSPECTION AND TEST1. 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.Measure the commutator (A) runout.
a. If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips
between the segments.
b. 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 (0.0020in.)

6.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) : 0.5 mm (0.0197 in.)
Limit : 0.2mm (0.0079 in.)
7.Check for continuity between the segments of the commutator. If an open circuit exists between any segments,
replace the armature.
8.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 worm out, or oil - soaked, should be replaced.

STARTER BRUSH HOLDER TEST
1.Check that there is no continuity between the (+) brush holder (A) and ( - ) brush holder (B). If there is no continuity,
replace the brush holder assembly.
2.Pry back each brush spring (A) with a screwdriver, then position the brush (B) about halfway out of its holder, and
release the spring to hold it there.
3.Install the armature in the housing, and install the brush holder. Next, pry back each brush spring again, and push
the brush down until it seats against the commutator, then release the spring against the end of the brush.
To 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.

INSPECT OVERRUNNING CLUTCH
1.Slide the overrunning clutch along the shaft.
Replace it if does not slide smoothly.
2. Rotate the overrunning clutch both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction of it locks in both
directions, replace it.
3.If the starter drive gear is worn or damaged, replace the overrunning 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 lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.

Starter Relay

2007 > 2.7L V6 GASOLINE >
INSPECTION
1.Remove the fuse box cover.
2. Remove the starter relay.
3. Using an ohmmeter, check that there is continuity between each terminal.
Terminal Continuity
30 - 87 NO
85 - 86 YES
4. Apply 12V to terminal 85 and ground to terminal 86.
Check for continuity between terminals 30 and 87.
5.If there is no continuity, replace the starter relay.
6. Install the starter relay.
7. Install the fuse box cover.

CHAPTER 4:
Emission Control System

2007 > 2.7L V6 GASOLINE >
SCHEMATIC DIAGRAM