Hyundai Coupes/Sedans 1986-1993 Repair Guide

Starter

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GENERAL INFORMATION



The starting system includes the battery, starter motor, solenoid, ignition switch, circuit protection and wiring connecting the components. An inhibitor switch located in the Transmission Range (TR) sensor is included in the starting system to prevent the vehicle from being started with the vehicle in gear.

When the ignition key is turned to the START position, current flows and energizes the starter's solenoid coil. The solenoid plunger and clutch shift lever are activated and the clutch pinion engages the ring gear on the flywheel. The switch contacts close and the starter cranks the engine until it starts.

To prevent damage caused by excessive starter armature rotation when the engine starts, the starter incorporates an over-running clutch in the pinion gear.

TESTING



Voltage Drop Test

The battery must be in good condition and fully charged prior to performing this test.

  1. Disable the ignition system by unplugging the coil pack. Verify that the vehicle will not start.
  2.  
  3. Connect a voltmeter between the positive terminal of the battery and the starter B+ circuit.
  4.  
  5. Turn the ignition key to the START position and note the voltage on the meter.
  6.  
  7. If voltage reads 0.5 volts or more, there is high resistance in the starter cables or the cable ground, repair as necessary. If the voltage reading is ok proceed to the next step.
  8.  
  9. Connect a voltmeter between the positive terminal of the battery and the starter M circuit.
  10.  
  11. Turn the ignition key to the START position and note the voltage on the meter.
  12.  
  13. If voltage reads 0.5 volts or more, there is high resistance in the starter. Repair or replace the starter as necessary.
  14.  

Many automotive parts stores have starter bench testers available for use by customers. A starter bench test is the most definitive way to determine the condition of your starter.

REMOVAL & INSTALLATION



Except Scoupe

See Figure 1

  1. Disconnect the negative battery cable. On some models, it may be helpful to remove the battery and the battery tray from the engine compartment during this procedure.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Starter mounting-Excel

  1. Raise and support the vehicle safely.
  2.  
  3. Remove the engine under cover. Disconnect the electrical harness from the starter solenoid, noting position of wires for correct installation.
  4.  
  5. Remove the starter mounting bolts and the starter from the vehicle.
  6.  
  7. Clean the surfaces of the starter motor flange and the flywheel housing where the starter attaches.
  8.  

To install:
  1. Install the starter motor and secure with the retainer bolts. Tighten the bolts to 23 ft. lbs. (30 Nm) for 4 cylinder engines and 20-25 ft. lbs. (27-34 Nm) for the V6 engine.
  2.  
  3. Connect the electrical harness to the starter solenoid. Install the battery and tray, if removed.
  4.  
  5. Reconnect the negative battery cable.
  6.  

Scoupe
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the EGR valve assembly.
  4.  
  5. Remove the speedometer cable and the heater valve.
  6.  
  7. Disconnect the starter motor connector and terminal.
  8.  
  9. Remove the starter motor retainer bolts and the starter assembly from the vehicle.
  10.  

To install:
  1. Install the starter assembly to the engine and secure using the retainer bolts, tightening to 20-25 ft. lbs. (26-33 Nm).
  2.  
  3. Connect the starter motor electrical connector and terminal.
  4.  
  5. Install the speedometer cable and the heater valve.
  6.  
  7. Install the EGR valve assembly and torque the retaining bolts to 7-11 ft. lbs. (10-15 Nm).
  8.  
  9. Connect the negative battery cable and check the starting system for proper operation.
  10.  

 
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