Hyundai Genesis: Starting System / Starter Repair procedures

Removal

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Remove the RH engine manifold. (Refer to Engine Mechanical System - "Exhaust Manifold")

3.	Remove the engine support bracket (A) after loosening the install bolt and nut.

4.	Disconnect the starter connector (A) and cable (B) from the 'B' terminal.

5.	Remove the starter (B) after removing the mounting bolts (A).

Installation

1.	Install in the reverse order of removal. Starter installation bolt: 49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft) Starter cover installation bolt: 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft) Engine mounting insulator upper nut : 63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)

Disassembly

1.	Disconnect the M-terminal from the magnet switch assembly.

2.	After loosening the 3 screws (A), detach the magnet switch assembly (B).

3.	Loosen the through bolts (A).

4.	Remove the brush holder assembly (A), yoke (B) and armature (C).

5.	Remove the shield (A).

6.	Remove the lever plate (A) and lever 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.	Remove the stopper (A) using the stopper pliers (B).

11.	Disconnect the stop ring (A), overrunning clutch (B), internal gear (C) and planet shaft (D).

12.	To reassemble, reverse the order of disassembly. Using a suitable pulling tool (A), pull the overrunning clutch stop ring (B) over the stopper (C).

Inspection

1.	Disconnect the lead wire from the M-terminal of solenoid switch.

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.

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 (150-ampere scale) and carbon pile rheostats shown is the illustration.

3.	Connect a voltmeter (15-volt scale) across 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 11volts.

7.	Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely. Items Specification Current (Max.) 105 A Speed (Min.) 2,800 rpm

1.	Remove the starter.

2.	Disassemble the starter and detach the armature from the starter.

3.	Inspect the armature in contact with the permanent magnet for wear or damage. If there is wear or damage, replace the armature.

4.	Inspect the commutator (A) surface. If the surface is dirty or burnt, adjust the surface within the specification using abrasive materials or #500 or #600 sandpaper (B).

5.

Measure the commutator (A) runout. A. If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments. B. If the commutator run out is out of the service limit, replace the armature. Commutator runout Standard (New): 0.05mm (0.0019in.) max Service limit: 0.08mm (0.0031in.)

6.

Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or v-shaped (D). Commutator mica depth Standard (New) : 0.7 mm (0.0275in.) Limit : 0.2mm (0.0079 in.)

7.	Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.

8.	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.

1.	Make sure there is no continuity between the (+) brush holder (A) and (-) plate (B). If there is continuity, replace the brush holder assembly.

1.	Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.

2.	Rotate the overrunning clutch both ways. Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it locks in both directions, replace it.

3.	If the starter drive gear is worn out or damaged, replace the overrunning clutch assembly. (the gear is not available separately). Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.

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 parts in cleaning solvent. The overrun clutch is pre-lubricated at the factory and solvent will wash lubrication from the clutch.

3.	Clean the drive unit parts with a brush soaked with cleaning solvent and then wipe off them with a dry cloth.

Starter Schematic Diagrams

Circuit Diagram ...

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