Kia Carnival (2009+). Instruction — part 227

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 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. 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.

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.