Starter - Mitsubishi Hyundai Excel I

DESCRIPTION

Starter is a conventional 12-volt, 4-pole brush-type motor, with direct or reduction gear drive. The starter-mounted solenoid shifts overrunning clutch and pinion into flywheel when starter is energized.

No Load Tests

Connect starter in series with a 12-volt battery, a voltmeter and a 1000-amp ammeter. Compare readings with STARTER NO LOAD SPECIFICATIONS .

STARTER NO LOAD SPECIFICATIONS (1)

Load (Lock Torque) Test

Mount starter in a test stand to perform torque measurement test. Follow manufacturer's instructions for test stand operation. With voltage adjusted, ammeter reading and torque should be within specification.

SOLENOID TESTS

Note. Make tests with solenoid removed from starter or remove solenoid lead to starter. Ensure solenoid plunger and sleeve are clean and dry. Make tests in less than 10 seconds to prevent coil damage.

Scheme 1

1. Connect jumper between positive post of 12-volt battery and "S" terminal. Connect a second jumper to negative battery terminal and touch "M" (MT) terminal (and between terminal "S" and switch body). (Scheme 1) (Scheme 1): Connections for Conducting Solenoid Pull-In Test Remove solenoid-to-starter lead before testing.
2. If pinion moves outward (or plunger is pulled-in), pull-in coil is good. If not, replace magnetic switch.

Scheme 2

1. Connect a jumper wire between "M" (MT) terminal and solenoid case. Apply 8 volts to "S" terminal to pull in plunger. (Scheme 2) Disconnect lead to "M" (MT) terminal. (Scheme 2): Connections for Conducting Solenoid Hold-In Test Make tests in less than 10 seconds to avoid solenoid damage.
2. If pinion remains out (plunger is pulled-in), hold-in coil is good. If not, replace magnetic switch.

Scheme 3

1. Apply 12 volts between "M" (MT) terminal and solenoid case. Pull pinion out and release it (push plunger into solenoid body by hand). (Scheme 3) (Scheme 3): Connections for Conducting Return Test Connect battery to "M" terminal and solenoid case.
2. If case is short-circuited, pinion will remain out (plunger will be attracted). If nothing happens, solenoid is good.

Brushes & Springs

Check brush spring tension using a spring scale. Check brush contact surface condition and brush length. Check lead clip and wire connections and condition of brush holders. Replace as required. See BRUSH SPRING TENSION and MINIMUM BRUSH LENGTH tables.

BRUSH SPRING TENSION

MINIMUM BRUSH LENGTH

Armature

Check external condition of armature for scoring or other damage. Measure shaft runout with dial indicator. Replace armature if shaft runout exceeds .004" (.10 mm).

Commutator

1. Inspect commutator for roughness, grooves, burns or pitting. Sand lightly with 500-600 grit sandpaper if necessary. Check commutator for out-of-round and mica insulators undercut to a depth of .020-.031" (.50-.80 mm).
2. If necessary, commutator may be turned less than .04" (1.0 mm) from original size and mica undercut. Replace if excessively worn.

Field Coil

1. Check field coil continuity by connecting test probe of circuit tester or an ohmmeter to the field coil positive terminal and brush holder. If circuit is open, replace field coil.
2. Check for grounding of field coils by placing one probe of circuit tester on starter housing and other probe to field coil positive terminal. If little or no resistance is present, field coil is grounded and must be replaced.

Overrunning Clutch Assembly

1. Inspect pinion assembly and sleeve. Sleeve should slide freely on armature shaft and spline. If damage or resistance is noted, replace assembly.
2. Check pinion and flywheel teeth for excessive rubbing or damaged teeth. Replace as required.

Pinion Gear Clearance

The clearance between pinion gear and pinion stopper collar should be.012-.098" (.3-2.5 mm) on Hitachi starters, or.02-.08" (.51-2.03 mm) on Mitsubishi starters, when solenoid is engaged. Adjust as necessary by changing shims between solenoid and starter yoke. (Scheme 4)

Measuring Pinion Gear-to-Pinion Stopper Collar Clearance. Scheme 4

Pinion Case Bearing

Inspect bearing for wear and check side play. If clearance exceeds .008" (.20 mm), replace bearing. New bearing clearance should be .001-.004" (.025-.10 mm) for Hitachi or .002-.004" (.05-.10 mm) for Mitsubishi starters.

Note. Ensure bearing is installed so it is flush with gear case end.

Removal & Installation

On all models, remove negative battery cable. If necessary, raise vehicle on hoist. Remove starter mounting bolts. Remove starter from vehicle. To install, reverse removal procedure.

See also:
• STARTER NO LOAD SPECIFICATIONS