Hyundai Tucson Quiz
Engine Electrical System

STARTER

In this manual: Engine Electrical System
General Information — 17Engine Mechanical System — 51Engine Electrical System — 26Emission Control System — 23Engine/Fuel Control System — 44Clutch System — 12MANUAL TRANSMISSION SYSTEM — 12AUTOMATIC TRANSMISSION SYSTEM — 42Four-Wheel Drive (4WD) System — 14Drive Shaft and Axle — 22Suspension System — 30Steering System — 16Restraint — 21Braking System — 47Body Work (Interior and Exterior) — 145Body Electrical System — 162Heating, Ventilation and Air Conditioning — 39
39steps
~234min
4/5difficulty
02040608010063.747N·mlb·ft
Tightening torque found on this page
Done 0 of 39

Description and Operation

Description

The starting system includes the battery, starter motor, ignition switch, starter solenoid, neutral/park switch (TM), clutch pedal switch, starter inhibitor switch, wiring harness connectors and battery cables. When the ignition key is turned to the START position, current flows and supplies power to the starter solenoid coil. The solenoid plunger and shift lever operate, and the pinion gear engages with the ring gear, the contact closes and the starter cranks the engine. The pinion gear disengages when the engine starts, to prevent damage caused by excessive rotation of the starter armature.

1. Switch 2. Fork 3. Pinion shaft 4. Clutch overrun


Specifications

Specification

Item Specification
Rated Voltage 12V, 1.2kW
Number of sprocket teeth 13
Performance
[No load, 11 V]		 Current Max. 70 A
SPEED Min. 2400 rpm

Components and Component Location

COMPONENTS

1. Front bearing assembly
2. Magnetic switch
3. Connecting plate
4. Gear reduction assembly
5. Stop lever		 6. Sealing plate
7. Fork
8. Pinion shaft
9. Brush holder assembly

Circuit Diagrams

Wiring Diagram

Repair Procedures

DEPOSIT

  1. Disconnect the negative battery cable.
  2. Remove the air duct and air cleaner assembly. (Refer to Engine Mechanical System - "Air Cleaner")
  3. Disconnect the starter cable (A) from terminal B on the solenoid, then disconnect the connector (B) from terminal S.
  4. Remove the two starter mounting bolts and remove the starter (A).

REMEDY

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

    Starter mounting bolt: 49.0 ~ 64 N·m

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 (A).
  4. Remove the brush holder assembly (A), armature (B) and fork. (Reverse).
  5. Remove the packing plate (A) and the lever stopper (B).
  6. Remove the gear reduction unit (A) and lever (B).
  7. Push the stopper (A) using the handle (B).
  8. After removing the snap ring (A) with pliers, stop (B).
  9. Separate the thrust bearing (A), overrunning clutch (B) and internal gear (C).

Installation

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

Inspection

Starter Solenoid Inspection

  1. Disconnect the lead wire from terminal M of the magnetic switch.
  2. Connect the battery as shown in the illustration. If the pinion gear engages automatically, it is operating correctly.
  3. Disconnect the battery from terminal M. If the pinion does not retract, the hold-in coil is operating correctly.
  4. Disconnect the battery from the housing. If the pinion retracts immediately, it is operating correctly.

Bench inspection

  1. Place the starter in a vise with soft jaws and fully charge the 12 V battery through the starter as follows:
  2. Connect a test ammeter (150 A range) and a carbon pile rheostat to the battery as shown in the illustration.
  3. Connect a voltmeter (15 V range) to the starter terminals.
  4. Turn the carbon pile to the OFF position.
  5. Connect the negative battery cable to the starter housing.
  6. Adjust until the battery voltage on the voltmeter reads 11 V.
  7. Make sure the maximum current is within specification and that the starter rotates smoothly and freely.
    Item Specification
    Current (A) 70 max.
    Speed (rpm) Min. 2400
  8. Remove the starter motor.
  9. Disassemble the starter as shown at the beginning of this procedure.
  10. Inspect the armature for signs of wear or damage caused by contact with the permanent magnet. If worn or damaged, replace the armature.
  11. 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).
  12. Measure the commutator diameter. If the diameter is less than the service limit, replace the armature. Commutator diameter. Standard (new): 27.0 mm (1.06 in). Service limit: 26.0 mm (1.02 in)
  13. 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): 0.05 mm (0.0019 in) max. Service limit: 0.08 mm (0.0031 in)
  14. Check the mica undercut 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 depth. Standard (new): 0.8 mm (0.0314 in). Limit: 0.2 mm (0.0079 in)
  15. Check the continuity between the commutator segments. If there is an open circuit between the segments, replace the armature.
  16. 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.
  17. Slide the overrunning clutch along the shaft. Replace it if it does not slide freely.
  18. Rotate the overrunning clutch in both directions. Does it lock in one direction and rotate freely in the other? If it does not lock in either direction, or locks in both directions, replace it.
  19. If the starter pinion gear is worn or damaged, replace the overrunning clutch assembly (the pinion gear is not sold separately). Inspect the flywheel ring gear or torque converter drive plate if the starter pinion teeth are damaged.
FRAME INSPECTION AND TESTING. BRUSH SPRING INSPECTION. Worn or oily brushes must be replaced. STARTER BRUSH HOLDER TEST. Make sure there is no continuity between the (+) brush holder (A) and the (-) plate (B). If there is continuity, replace the brush holder. Overrunning clutch

CLEANING

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

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