Starter - Hitachi & Mitsubishi Hyundai Elantra I

DESCRIPTION

Starters are conventional 12-volt, 4-pole brush-type motors. Excel and Scoupe starters are direct drive. Elantra and Sonata starters are reduction gear drive. The starter-mounted solenoid shifts overrunning clutch and pinion into flywheel when starter is energized.

STARTER TYPE IDENTIFICATION

Manual Transmission Models

1. Starter relay is located in relay panel under left side of dash. Sonata starter relay is at lower left corner of relay panel. All others are at top left corner of relay panel. Remove relay. Check for continuity between terminals No. 1 and 3 of relay.
2. If continuity exists, apply 12 volts to terminals No. 1 and 3 (No. 3 is relay ground terminal) to energize relay. Continuity should exist between terminals No. 2 and 4. If relay does not perform as described, replace relay.

Automatic Transmission Models

Vehicles equipped with automatic transmissions do not utilize a starter relay. Transmission inhibitor switch completes ignition switch-to-starter circuit when transmission selector lever is in Neutral or Park. Testing information is not available from manufacturer. See appropriate chassis wiring diagram in the WIRING DIAGRAMS section.

CLUTCH START SWITCH TEST

Switch is mounted on bracket near top of clutch pedal. Disconnect switch harness connector. Using ohmmeter, ensure continuity exists between switch connector terminals when clutch pedal is depressed. If continuity does not exist, adjust or replace switch.

1. Switch is mounted on steering column's ignition lock cylinder assembly. Remove lower steering column cover. Disconnect switch 2-wire harness connector.
2. Using an ohmmeter, ensure continuity exists between switch connector terminals when switch plunger is pressed, and continuity does not exist when switch plunger is released. If continuity does not exist when switch plunger is pressed, adjust or replace switch.

BENCH TESTING

NO-LOAD TEST

1. Install starter in soft-jawed vise. Connect starter in series with a fully charged 12-volt battery. (Scheme 1) Connect ammeter (100-amp scale) and carbon pile rheostat in series with positive battery terminal and starter motor terminal.
2. Install voltmeter across starter motor. (Scheme 1) Adjust carbon pile rheostat until voltmeter reads test voltage. See «STARTER NO-LOAD SPECIFICATIONS»(/hyundai/elantra/i-1990-1995/remont/starter/#starter-hitachi-mitsubishi) table. Install jumper wire across solenoid terminals "B" and "S" (maximum 10 seconds).
3. Ensure maximum amperage draw is within specification and starter rotates smoothly. See «STARTER NO-LOAD SPECIFICATIONS»(/hyundai/elantra/i-1990-1995/remont/starter/#starter-hitachi-mitsubishi) table. If starter is not within specification, overhaul or replace starter as required.

STARTER NO-LOAD SPECIFICATIONS

Scheme 1

SOLENOID TESTS

Pull-In Test

Disconnect solenoid "M" terminal connector. Apply 12 volts to solenoid "S" terminal and ground solenoid "M" terminal connector to cause solenoid plunger to pull-in and extend pinion drive. (Scheme 2) If pinion drive moves outward, pull-in coil is good. If pinion does not move outward, replace solenoid.

Scheme 2

Hold-In Test

With solenoid "M" terminal connector still disconnected, apply 12 volts to solenoid "S" terminal and ground starter case to pull-in solenoid plunger. (Scheme 3) If pinion drive remains out when plunger is pulled in, hold-in circuit is good. If pinion drive moves in, hold-in circuit is open. Replace solenoid.

Scheme 3

Return Test

Apply 12 volts to solenoid "M" terminal and ground starter case. Manually pull pinion drive out and then release it. (Scheme 4) Pinion drive should return quickly to original position. If pinion drive does not return to original position, replace solenoid.

Scheme 4

PINION GAP

1. Disconnect field coil wire from starter solenoid "M" terminal. Connect jumper wire from positive battery terminal to terminal "S" of starter solenoid.
2. Connect a second jumper wire from negative battery terminal to terminal "M" of starter solenoid. Using feeler gauge, measure clearance between pinion and stopper.
3. Clearance should be within specification. See «PINION GAP SPECIFICATIONS»(/hyundai/elantra/i-1990-1995/remont/starter/#starter-hitachi-mitsubishi) table. Adjust clearance by adding or removing shims between solenoid and front housing.

PINION GAP SPECIFICATIONS

ARMATURE TEST

With starter motor disassembled, check external condition of armature for scoring or other damage. Measure shaft runout with dial indicator. Standard runout is .002" (.05 mm). Replace armature if shaft runout exceeds .004" (.10 mm). Ensure no continuity exists between armature core and commutator segments. Ensure continuity exists between commutator segments. Replace armature if continuity is not as indicated.

BRUSH ASSEMBLY

With starter motor disassembled, check brush spring tension and brush contact surface condition. Ensure brush maximum wear line is visible. Check lead clip, wire connections and brush holders.

COMMUTATOR

With starter motor disassembled, inspect commutator segments for roughness, grooves, burns or pitting. If necessary, sand lightly with 500-600 grit crocus cloth. Check commutator for out-of-round and for proper mica insulators undercut depth. Mica depth between commutator segments may be undercut as per specifications. See STARTER SPECIFICATIONS table. Replace armature if commutator is excessively worn.

STARTER SPECIFICATIONS (1)

FIELD COIL TEST

1. Check field coil continuity by connecting ohmmeter probes to field coil positive terminal and to brush holder. If circuit is open (no continuity), replace field coil.
2. Check for grounded field coils by placing one ohmmeter probe on starter housing and other probe on field coil positive terminal. If continuity is present, field coil is grounded and must be replaced.

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

Removal & Installation (Excel & Scoupe)

Disconnect negative battery cable. Remove EGR valve. Remove speedometer cable and heater valve. Disconnect starter wires and remove starter mounting bolts. To install, reverse removal procedure. Tighten starter mounting bolts to 19-24 ft. lbs. (26-33 N.m). Tighten EGR valve mounting bolts to 7-11 ft. lbs. (10-15 N.m). (Scheme 5)

Removal & Installation (Elantra & Sonata)

Disconnect negative battery cable. Disconnect starter wires and remove starter mounting bolts. To install, reverse removal procedure. Tighten starter mounting bolts to 19-24 ft. lbs. (26-33 N.m). (Scheme 6)

OVERHAUL

Note. Overhaul procedures are not available from manufacturer. For exploded views of starters (Scheme 5)or (Scheme 6).

Scheme 5

Scheme 6

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• STARTER NO-LOAD SPECIFICATIONS