Kia Carnival (2007 year). Manual — part 573

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