Starting System: Other Hyundai Tucson I

CHECK FOR WEAR AND DAMAGE

The starter should crank the engine smoothly and steadily. If the starter engages, but cranks the engine erratically, remove it, and inspect the starter drive gear and torque converter ring gear for damage.

Check the drive gear overrunning clutch for binding or slipping when the armature is rotated with the drive gear held. If damaged, replace the gears.

Scheme 8

Scheme 9

Scheme 10

1. Disconnect the wires from the S terminal and the M terminal.
2. Connect the battery as shown. If the starter pinion pops out, it is working properly. To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.
3. Disconnect the battery from the M terminal. If the pinion does not retract, the hold-in coil is working properly. To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.
4. Disconnect the battery also from the body. If the pinion retracts immediately, it is working properly. To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.

Scheme 11

1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter motor as follows
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat as shown in the illustration.
3. Connect a voltmeter (15-volt scale) across the starter motor.
4. Rotate carbon pile to the off position.
5. Connect the battery cable from battery's negative post to the starter motor body.
6. Adjust until battery voltage shown on the voltmeter reads 11 volts.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely: 2.7 Current : Max. 90 Amps Speed : Min. 2,800 RPM 2.0 Current : Max. 90 Amps Speed : Min. 3,000 RPM

CLEANING

1. Do not immerse parts in cleaning solvent. Immersing the yoke assembly and/or armature will damage the insulation. Wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent. The overrun clutch is pre-lubricated at the factory and solvent will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.

Scheme 12

1. Disconnect the battery negative cable.
2. Disconnect the starter cable (A) from the B terminal (B) on the solenoid (C), then disconnect the connector (D) from the S terminal (E).
3. Remove the 2 bolts holding the starter, then remove the starter.
4. Installation is the reverse of removal.
5. Connect the battery positive cable and negative cable to the battery.

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

1. Disconnect the M-terminal (A) on the magnet switch assembly (B).
2. After loosening the 2 screws (A), detach the magnet switch assembly (B).
3. Loosen the brush holder mounting screws (A) and through bolts (B).
4. Remove the rear bracket (A) and brush holder assembly (B).
5. Remove the yoke (A) and armature (B).
6. Remove the, lever plate (A) and planet shaft packing (B).
7. Disconnect the planet gear (A).
8. Disconnect the planet shaft assembly (A) and lever (B).
9. Press the stop ring (A) using a socket (B).
10. After removing the stopper (A) using stopper pliers (B).
11. Disconnect the stop ring (A), overrunning clutch (B), internal gear (C) and planet shaft (D).
12. Reassembly is the reverse of disassembly. NOTE: Using a suitable pulling tool (A), pull the overrunning clutch stop ring (B) over the stopper (C).

Scheme 26

Scheme 27

Scheme 28

Scheme 29

1. Remove the starter (see «STARTER»(ref-276687-S16324852072008011000000) ).
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. 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 runout is not within the service limit, replace the armature. Commutator Runout Standard (New): 0.02mm (0.001 in.) max. Service limit: 0.05mm (0.002 in.)
5. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.
6. 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.