2007 KIA CARNIVAL Workshop Manual

4.Disconnect the battery also from the body. If the pinion retracts immediately, it is working properly. To avoid
damaging the starter, do not leave the battery connected for more than 10 seconds.
FREE RUNNING TEST
1.Place the starter motor in a vise equipped with soft jaws and connect a fully - charged 12- volt battery to starter
motor as follows.
2. Connect a test ammeter (100 - ampere scale) and carbon pile rheostats shown is the illustration.
3. Connect a voltmeter (15- volt scale) across starter motor.
4.Rotate carbon pile to the off position.
5. Connect the battery cable from battery's negative post to the starter motor body.
6. Adjust until battery voltage shown on the voltmeter reads 11volts.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and
freely.
Current : 900A
Speed : 2,800 rpm

Starter

2007 > 2.7L V6 GASOLINE >
COMPONENT

2007 > 2.7L V6 GASOLINE >
REMOVAL
STATATER
1. Disconnect the battery negative cable.
2. Disconnect the starter cable (A) from the B terminal (B) on the solenoid (C), then disconnect the connector (D)
from the S terminal (E).
3.Remove the 2 bolts holding the starter, then remove the starter.
4. Installation is the reverse of removal.
5. Connect the battery negative cable to the battery.
DISASSEMBLY
1.Disconnect the M- terminal (A) on the magnet switch assembly (B).
2.After loosening the 3 screws (A), detach the magnet switch assembly (B).
3.Loosen the through bolts (A).

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.