Hyundai i20 Quiz
Engine Electrical System

STARTER Repair Procedures

In this manual: Engine Electrical System
General Information — 17Engine Mechanical System — 79Engine Electrical System — 50Emission Control System — 22Engine/Fuel Control System — 107Clutch System — 27MANUAL TRANSMISSION SYSTEM — 21Drive Shaft and Axle — 18Suspension System — 29Steering System — 21Restraint — 41Braking System — 53Body Work (Interior and Exterior) — 190Body Electrical System — 181Heating, Ventilation and Air Conditioning — 58
42steps
~252min
4/5difficulty
0102030405011.89N·mlb·ft
Tightening torque found on this page
Done 0 of 42

DEPOSIT

  1. Turn the ignition switch to the OFF position and disconnect the negative (-) battery terminal.
  2. Remove the air cleaner. (Refer to Engine Mechanical System - "Air Cleaner")
  3. Remove the battery. (Refer to Engine Electrical System - "Battery".)
  4. Disconnect the wire from alternator terminal "B" (A).
  5. Remove the nut securing starter solenoid terminal "B", then disconnect the starter cable (B) and ST connector (A). Starter solenoid "B" terminal nut: 9.8 ~ 11.8 N·m
  6. Remove the upper starter mounting bolt (A).

    Starter mounting bolt: 42.2 – 54 N·m

  7. Raise the vehicle.
  8. Remove the engine undercover (A) after loosening the mounting bolts.
  9. Remove the side cover D (A) after loosening the lock bolts.
  10. Using a hex key, loosen the tensioner (A) by turning it clockwise.
  11. Remove the timing belt (B).
  12. Disconnect the connector (A) from the oil pressure switch.
  13. Disconnect the connector from the compressor and create space by loosening the mounting bolts between the compressor (A) and engine to remove the starter.
  14. Remove the lower starter mounting bolt (A).

    Starter mounting bolt: 42.2 – 54 N·m

  15. Remove the starter (A).

REMEDY

  1. To install, perform the removal procedure in reverse order.

DISASSEMBLY

  1. Disconnect terminal M (A) on the magnetic switch assembly.
  2. Loosen the screws (A) and disconnect the magnetic switch assembly (B).
  3. Loosen the through bolts, then remove the brush holder assembly (A), yoke (B) and frame (C).
  4. Remove the lever seal (A) and lever plate (B).
  5. Remove the protector (A) and seal (B).
  6. Disconnect the planetary gear (A).
  7. Disconnect the lever (B) and assembly (A) from the planetary shaft.
  8. Push the stopper (A) using the handle (B).
  9. Remove the snap ring (A) using snap ring pliers (B).
  10. Disconnect the thrust bearing (A), overrunning clutch (B), internal gear (C) and planetary shaft (D).
  11. For reassembly, perform the removal procedure in reverse order.

Installation

  1. For reassembly, perform the removal procedure in reverse order.

Inspection

FRAME INSPECTION AND TESTING

  1. Remove the starter motor.
  2. Disassemble the starter as shown at the beginning of this procedure.
  3. Inspect the armature for signs of wear or damage caused by contact with the permanent magnet. If worn or damaged, replace the armature.
  4. Inspect the commutator surface (A). If the surface is dirty or burnt, clean it with sandpaper or a sponge, or polish it with #500 or #600 sandpaper (B).
  5. Inspect the commutator diameter. If the diameter is less than the service limit, replace the armature. Commutator diameter Standard (new): 33.0 mm (1.2992 in.) Service limit: 32.4 mm (1.2756 in.)
  6. Measure the commutator runout (A).
    • If the commutator runout is within the service limit, check for carbon powder or copper particles between the segments.
    • If the commutator runout is not within the service limit, replace the armature.
    Commutator runout Standard (new): 0.02 mm (0.0008 in.) max. Service limit: 0.05 mm (0.002 in.)
  7. Inspect the mica depth (A). If the mica is too high (B), undercut the mica to the correct depth using a hacksaw blade. Remove all mica (C) between the commutator segments. The undercut must be deep enough, not too narrow, and not V-shaped (D). Commutator mica undercut Standard (new): 0.5 mm (0.0197 in.) Limit: 0.2 mm (0.0079 in.)
  8. Check the continuity between the commutator segments. If there is an open circuit between the segments, replace the armature.
  9. Using an ohmmeter, check that there is no continuity between the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature.
STARTER BRUSH INSPECTION: Worn or oil-contaminated brushes must be replaced.STARTER BRUSH HOLDER TEST
  1. Check that there is no continuity between the brush holder (+) (A) and the plate (-) (B). If there is continuity, replace the brush holder.
  2. Slide the overrunning clutch along the shaft. Replace it if it does not slide freely.
  3. Rotate the overrunning clutch in both directions. Check that it locks in one direction and turns smoothly in the other. If it turns freely in both directions, or binds in both directions, replace it.
  4. If the starter pinion gear is worn or damaged, replace the overrunning clutch assembly. (The pinion gear is not sold separately.) Inspect the condition of the flywheel or torque converter ring gear if the starter pinion teeth are damaged.
OVERRUNNING CLUTCH INSPECTION

CLEANING

  1. Do not immerse parts in cleaning solvent. Immersion of the entire yoke and/or armature will damage the insulation. Wipe these parts with a cloth only.
  2. Do not immerse the drive in cleaning solvent. The clutch is pre-lubricated at the factory, and solvent will remove the clutch lubricant.
  3. The drive can be cleaned by brushing with a moistened solvent and wiping with a cloth.

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