Hyundai Coupes/Sedans 1994-1998 Repair Guide

General Information

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The starting system includes the battery, starter motor, solenoid switch, ignition switch, wiring and battery cables. If the vehicle is equipped with an automatic transaxle, an inhibitor switch is included in the starting system to prevent the vehicle from being started with the car 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 over 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



The easiest way to test the performance of the starter is to perform a voltage drop test.

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

  1. Connect a voltmeter between the positive and negative terminals of the battery.
  2.  
  3. Turn the ignition key to the START position and note the voltage drop on the meter.
  4.  
  5. If voltage drops below 11.5 volts, there is high resistance in the starting system.
  6.  
  7. Check for proper connections at the battery and starter.
  8.  
  9. Check the resistance of the battery cables and replace as necessary.
  10.  
  11. If all other components in the system are functional, the starter can assumed faulty.
  12.  

REMOVAL & INSTALLATION



See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: The starter is mounted to the transaxle bell housing and is easily accessible from the top side of the engine compartment



Click image to see an enlarged view

Fig. Fig. 2: Remove the starter by loosening the two attaching bolts

Sonata and 1994-95 Elantra
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the starter motor electrical harness.
  4.  
  5. Remove the starter motor from the vehicle.
  6.  

To install:
  1. Install the starter assembly and tighten mounting bolts to 20-25 ft. lbs. (26-33 Nm).
  2.  
  3. Connect the starter motor electrical harness. Tighten B+ wire terminal nut to 7-11 ft. lbs. (10-16 Nm).
  4.  
  5. Connect the negative battery cable
  6.  
  7. Check the starting system for proper operation.
  8.  

Tiburon and 1996-98 Elantra
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the speedometer cable.
  4.  
  5. Remove the air cleaner duct and air cleaner assembly.
  6.  
  7. Disconnect the starter motor electrical harness.
  8.  
  9. Remove the starter motor from the vehicle.
  10.  

To install:
  1. Install the starter assembly and tighten mounting bolts to 20-25 ft. lbs. (26-33 Nm).
  2.  
  3. Connect the starter motor electrical harness. Tighten B+ wire terminal nut to 7-11 ft. lbs. (10-16 Nm).
  4.  
  5. Install the air cleaner duct and air cleaner assembly.
  6.  
  7. Install the speedometer cable.
  8.  
  9. Connect the negative battery cable
  10.  
  11. Check the starting system for proper operation.
  12.  

Accent and Scoupe
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the speedometer cable and shift cable.
  4.  
  5. On Scoupe, disconnect the high tension wire from the ignition coil to the distributor.
  6.  
  7. Disconnect the starter motor electrical harness.
  8.  
  9. Remove the starter motor from the vehicle.
  10.  

To install:
  1. Install the starter assembly and tighten mounting bolts to 20-25 ft. lbs. (26-33 Nm).
  2.  
  3. Connect the starter motor electrical harness. Tighten B+ wire terminal nut to 9-11 ft. lbs. (10-16 Nm).
  4.  
  5. Install the speedometer cable and shift cable.
  6.  
  7. Connect the high tension wire from the ignition coil to the distributor, as required.
  8.  
  9. Connect the negative battery cable
  10.  
  11. Check the starting system for proper operation.
  12.  

Excel
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the EGR valve assembly, as required.
  4.  
  5. Remove the speedometer cable.
  6.  
  7. Disconnect the starter motor electrical harness.
  8.  
  9. Remove the starter motor from the vehicle.
  10.  

To install:
  1. Install the starter assembly and tighten mounting bolts to 20-25 ft. lbs. (26-33 Nm).
  2.  
  3. Connect the starter motor electrical harness. Tighten B+ wire terminal nut to 9-11 ft. lbs. (10-16 Nm).
  4.  
  5. Install the speedometer cable.
  6.  
  7. Install the EGR valve assembly and tighten retaining bolts to 7-11 ft. lbs. (10-15 Nm).
  8.  
  9. Connect the negative battery cable
  10.  
  11. Check the starting system for proper operation.
  12.  

SOLENOID REPLACEMENT



See Figure 3



Click image to see an enlarged view

Fig. Fig. 3: The starter solenoid must be engaged with the overunning clutch lever for the starter to operate

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the starter from the vehicle.
  4.  
  5. Remove the solenoid attaching screws.
  6.  
  7. Disconnect the starter solenoid from the overrunning clutch lever.
  8.  
  9. Remove the solenoid from the starter.
  10.  

Note the amount of shims between the solenoid and starter. These will be used during assembly to adjust the starter pinion gap.

To install:
  1. Install the proper amount of shims between the solenoid and the starter housing.
  2.  
  3. Connect the starter solenoid to the overrunning clutch lever.
  4.  
  5. Install the solenoid on the starter.
  6.  
  7. Install the solenoid attaching screws and tighten securely.
  8.  
  9. Check pinion gap and adjust as necessary.
  10.  
  11. Install the starter.
  12.  
  13. Connect the negative battery cable
  14.  
  15. Check the starting system for proper operation.
  16.  

PINION GAP ADJUSTMENT



See Figures 4 and 5

Pinion gap is the only adjustable specification on the starter motor. The pinion gap is the clearance between the drive pinion and the stop ring when the starter is engaged.



Click image to see an enlarged view

Fig. Fig. 4: Connect a battery as illustrated to check the starter pinion gap



Click image to see an enlarged view

Fig. Fig. 5: Using a feeler gauge, check starter pinion gap between the pinion gear and stopper

To properly check pinion gap, the starter must be removed from the vehicle.

  1. Have a set of feeler gauges ready.
  2.  
  3. Remove the wire nut and disconnect the field coil wire from the M terminal of the starter solenoid.
  4.  
  5. Connect the negative lead of a 12V car battery to the M terminal and the positive lead of the battery to the S terminal. When this is done the pinion will move out in an attempt to engage the flywheel.
  6.  
  7. Keep the battery voltage applied to the starter until a feeler gauge can be inserted between the stopper and the drive pinion to measure the gap. Pinion gap clearance should be between 0.02-0.079 in. (0.5-2.0mm).
  8.  


WARNING
DO NOT apply voltage to the starter for more than 10 seconds to prevent the solenoid coil from burning out.

  1. If the pinion gap clearance is not as specified, adjust it by either adding or removing the gaskets between the solenoid and starter.
  2.  

 
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