Tucson 2006-2008

Starter

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Removal & Installation



Specific to:

Hyundai Tucson 2006-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the negative battery cable and wait at least 3 minutes
  4.  
  5. Disconnect the starter cable (A) from the B terminal (B) on the solenoid (C).
  6.  
  7. Disconnect the connector (D) from the S terminal (E).
  8.  
  9. Remove the 2 bolts holding the starter.
  10.  
  11. Remove the starter motor assembly.

    Click image to see an enlarged view

    Fig. Remove the starter motor assembly

  12.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Tighten the starter motor bolts to 20-25 ft. lbs. (27-34 Nm).
  4.  

Testing & Troubleshooting



Specific to:

Hyundai Tucson 2006-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    The battery must be in good condition and fully charged.

  2.  
  3. Remove the fuel pump relay(A) from the fuse box.  

    Click image to see an enlarged view

    Fig. Fuel pump relay location

  4.  
  5. With the shift lever in N or P (Automatic Transaxle) or clutch pedal pressed (Manual Transaxle), turn the ignition switch to "START." If the starter normally cranks the engine, starting system is OK.
  6.  
  7. If the starter will not crank the engine at all, go to the next step.
  8.  
  9. If it won't disengage from the ring gear when you release the key, check for the following until you find the cause:
    1. Solenoid plunger and switch malfunction.
    2.  
    3. Dirty pinion gear or damaged overrunning clutch.  
    4.  

  10.  

Check the battery condition. Check electrical connections at the battery, battery negative cable connected to the body, engine ground cables, and the starter for looseness and corrosion. Then try starting the engine again. If the starter cranks the engine normally, repairing the loose connection repaired the problem. The starting system is now OK.

  1. If the starter still does not crank the engine, go to the next step.
  2.  
  3. Disconnect the connector from the S-terminal of solenoid. Connect a jumper wire from the B-terminal of solenoid to the S-terminal of solenoid. If the starter cranks the engine, go to the next step. If the starter still does not crank the engine, remove the starter, and repair or replace as necessary.
  4.  
  5. Check the following items in the order listed until you find the open circuit:
    1. Check the wire and connectors between the driver's under-dash fuse/relay box and the ignition switch, and between the driver's under-dash fuse/relay box and the starter.
    2.  
    3. Check the ignition switch.
    4.  
    5. Check the transaxle range switch connector or ignition lock switch connector.
    6.  
    7. Inspect the starter relay.
    8.  

  6.  

Free Running Test
  1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to the starter motor as follows:
    1. Connect a test ammeter (100-ampere scale) and carbon pile rheostats as shown in the illustration.
    2.  
    3. Connect a voltmeter (15-volt scale) across starter motor.  

      Click image to see an enlarged view

      Fig. Starter free-running test

    4.  

  2.  
  3. Rotate the carbon pile to the off position.
  4.  
  5. Connect the battery cable from the battery's negative post to the starter motor body.
  6.  
  7. Adjust until battery voltage shown on the voltmeter reads 11 volts.
  8.  
  9. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely. Specifications: Current draw-85 Amp MAX; Speed-2,600 rpm MIN.
  10.  

 
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