Kia Carens. Manual - part 17

(2) Check continuity between commutator and shaft with ohmmeter. Replace armature if there is continuity.

(3) Place armature on V-blocks, and measure runout with a dial indicator.

if runout is not within specification, repair armature with a lathe or replace armature.

Runout : 0.002in (0.05mm)
Maximum : 0.016in (0.4mm)

(4) Replace armature if diameter or commutator mutator is at, or less than, grind limit.

(5) If commutator surface is dirty, wipe it with a cloth ; if it is rough, repair it with a lathe or fine sandpaper.

Grind limit : 1.22in (31mm)

(6) If depth of mold between segments is at, or less than minmum, replace armature.

Depth : 0.02~0.03in (0.5~0.8mm)
Minimum : 0.008in (0.2mm)

REASSEMBLY

1. Reassembly armature washers to the end of armature.

2. Reassembly armature in field coil housing.

3. Reassembly rear cover and tighten two brush two bruch plate screws.

Tightening torque : 1.7~3.2lb-ft (2.4~4.4N·m)

4. Reassembly drive pinion and stopper on pinion shaft.

5. Place snap ring on its groove in pinion shaft.

6. Reassemble stopper.

7. Reassemble lever on drive pinion.

8. If present, reassembly planetary gear set to motor assembly.

9. Reassembly motor assembly in drive end housing.

10. Place bolts in rear cover and tighten.

Tightening torque : 2.8~5.2lb-ft (3.8~7.1N·m, 0.39~0.72kg-m)

11. Engage plunger in lever.

12. Insert solenoid plunger spring.

13. Reassemble magnetic switch and tighten solenoid screws.

Tightening torque : 3.0~5.6lb-ft (4.1~7.6N·m, 0.42~0.77kg-m)

14. Apply battery power to the S terminal and ground starter motor body. Pinion will eject outward and then

stop.

15. Measure clearance (pinion gap) between pinion and stopper.

Pinion gap : 0.020~0.079in (0.5~2.0mm)

Be careful not to let electricity flow continuously for more than 10 seconds.

16. If pinion gap is not within specified range, adjust it by increasing or decreasing the number of washers

used between ordecreasing the number of washers used between solenoid and drive housing. The gap will
become smaller if the number of washers increased.

Do not use washers than plates.

17. Connect field wire to M terminal.