Starting System - 2.0L: Overhaul Kia Optima III

Disassembly

1. Disconnect the M-terminal (A) on the magnet switch assembly (B).

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1. 2. After loosening the screws (A), detach the magnet switch assembly (B).

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1. 3. Loosen the through bolts (A).

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1. 4. Remove the brush holder assembly (A), yoke (B) and armature (C).

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1. 5. REMY : Remove the lever plate (B) and lever packing (A). VALEO : Remove the lever stop (A).
2. 6. Remove the packing (A) and shield (B). (REMY only)
3. 7. Disconnect the planet gear (A). (REMY only)
4. 8. Disconnect the planet shaft assembly (or reducer assembly) (A) and lever (B).

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1. 9. Press the stopper (A) using a socket (B).
2. 10. Remove the stop ring (A) using stop ring pliers (B).
3. 11. Disconnect the stopper (A), overrunning clutch (B), internal gear (C), planet shaft (or drive shaft) (D) and/or gasket sheet (E).

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1. 12. Reassembly is the reverse of disassembly. NOTE: Using a suitable pulling tool (A), pull the overrunning clutch stopper (C) over the stop ring (B).

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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. If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments. If the commutator run out is not within the service limit, replace the armature. Commutator runout Standard (New): 0.02 mm (0.0007 in.) max Service limit: 0.05 mm (0.0020 in.)
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) : 0.7 ~ 0.9 mm (0.0276 ~ 0.0354 in) Limit : 0.4 mm (0.0157 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.