Starter for gasoline engines (Hyundai Elantra XD)

Contents: Removal and installation ⇓ Checking and replacing stator…⇓ Operational tests (idling) ⇓ Assembling the starter ⇓

Removal and installation

1. Disconnect the cable from the negative terminal of the battery.

2. Disconnect the speedometer and gear shift cable.

3. Disconnect the connector from the starter and the wire from the terminal.

4. Unscrew the bolts and remove the starter.

5. Installation is carried out in the reverse order of removal.

Checking and replacing stator elements

Adjusting the gear clearance

1. Disconnect the starter motor wire from the "M" terminal.

2. Using additional wires, connect the battery terminals to terminals "S" and "M".

3. Turn on the ignition, the starter gear will move forward.

Warning! This test must be performed within 10 seconds, otherwise the traction relay solenoid may burn out.

4. Use a feeler gauge to check the gap between the gear and the stopper. If the gap is different from the required one, adjust it by adding or removing shims between the traction relay and the front cover. Gear clearance: 0.5–0.2 mm.

Checking the starter traction relay

1. Disconnect the starter motor wire from the "M" terminal.

2. Using additional wires, connect the battery terminals to terminals "S" and "M".

3. Turn on the ignition, the starter gear will move forward. If the pinion does not extend, replace the traction relay.

Warning! This test must be performed within 10 seconds, otherwise the traction relay coil may burn out.

Checking the holding winding of the traction relay

1. Disconnect the starter motor wire from the "M" terminal.

2. Using additional wires, connect the battery terminals to the "S" terminal and the traction relay housing.

Warning! This test must be performed within 10 seconds, otherwise the traction relay coil may burn out.

3. If the gear remains in place, then the holding winding of the traction relay is damaged and the traction relay must be replaced.

Checking the return of the traction relay plunger

1. Disconnect the starter motor wire from the "M" terminal.

2. Using additional wires, connect the battery terminals to terminal M and the traction relay housing.

Warning! This test must be performed within 10 seconds, otherwise the traction relay coil may burn out.

3. The starter gear should move forward. Once the wires are disconnected, the starter gear should quickly return to its original position.

Operational tests (idling)

1. To perform the idle test, assemble the circuit shown in the figure.

2. Set the rheostat slider to a position where the voltmeter shows a voltage of 11.5 V, while checking the current consumed by the starter and making sure that the starter shaft turns easily and smoothly. Current: no more than 60 A.

Overrunning clutch gear

To remove the overrunning clutch from the rotor shaft, it is necessary to first remove the thrust ring.

Move the thrust ring towards the gear and remove the snap ring. The thrust ring can now be removed from the shaft.

Checking the rotor winding

1. Use an ohmmeter to check the conductivity between the collector and the rotor. If there is continuity, replace the rotor.

2. Check the rotor winding using a special device. If there are short circuits, replace the rotor. If a steel strip applied to the rotor vibrates, there are short circuits in the rotor windings.

3. Use an ohmmeter to check the conductivity between the collector segments. If there is no conductivity, replace the rotor.

Checking the stator coils

1. Use an ohmmeter to check the conductivity of the stator coils. If there is no conductivity, replace the stator coils.

2. With the coil installed in the housing, check the continuity between the coil terminal and the starter housing. If there is continuity, replace the stator coils.

Checking the brushes

If the brush is worn to the specified limit, replace it.

Checking the brush holder

Use an ohmmeter to check the conductivity between each insulated brush and the plate. If there is conductivity, replace the brush holder.

Checking the overrunning clutch

1. Check the condition of the teeth of the overrunning clutch gear and, if damaged, replace it. Also check the condition of the flywheel ring gear teeth.

2. Turn the gear. The gear should rotate freely clockwise and lock when turned counterclockwise

Replacing brushes

1. Remove the worn brush, being careful not to damage the braided wire.

2. Use sandpaper to smooth the end of the braided lead to ensure good contact with the new brush.

3. Solder the braided wire.

Replacing the rear bushing

1. Before removing the bushing, it is necessary to measure the depth of its installation.

2. The bushing can be removed using a puller as shown in the figure.

3. Install the new bushing to the pre-measured depth.

Assembling the starter

1. Install the overrunning clutch onto the front end of the rotor shaft.

2. Install the thrust ring and snap ring on the front side of the rotor shaft, then move the thrust ring all the way to the snap ring.

3. When installing the lever into the front cover, pay attention to its position. If the lever is installed the other way around, the gear will be permanently pushed out and will not work properly.

Ignition interlock switch

Check that the installation height, free play and clearance of the pin with the head and hole for the clutch pedal cotter pin are within normal limits.