Hyundai Santa Fe (TM): Starting System - Engine Electrical SystemHyundai Santa Fe (TM): Starting System

Description and operation

Description
The starting system includes the battery, starter, solenoid switch, ignition switch, ignition lock switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor's solenoid coil.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks.
In order to prevent damage caused by excessive rotation of the starter armature when the engine starts, the clutch pinion gear overruns.

Troubleshooting

Troubleshooting
  
The battery must be in good condition and fully charged for this troubleshooting.

Trouble symptom
Probable cause
Remedy
Engine will not crank
Battery charge low
Charge or replace battery
Battery cables loose, corroded or worn out
Repair or replace cables
Transaxle range switch
(Vehicle with automatic transaxle only)
Refer to AT group-automatic transaxle
Fuse blown
Replace fuse
Starter motor faulty
Replace
Ignition switch faulty
Replace
Engine cranks slowly
Battery charge low
Charge or replace battery
Battery cables loose, corroded or worn out
Repair or replace cables
Starter motor faulty
Replace
Starter keeps running
Starter motor faulty
Replace
Ignition switch
Replace
Starter spins but engine will not crank
Short in wiring
Repair or replace wiring
Pinion gear teeth broken or starter motor
Replace
Ring gear teeth broken
Replace fly wheel or torque converter

Starter. Description and operation

Description
The starting system includes the battery, starter, solenoid switch, ignition switch, ignition lock switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor's solenoid coil.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks.
In order to prevent damage caused by excessive rotation of the starter armature when the engine starts, the clutch pinion gear overruns.

1. Solenoid
2. Brush assembly
3. Armature
4. Overrun clutch

Starter. Specifications

Specification
Starter
Item
Specification
Rated voltage
12V, 1.2 kW
The number of pinion teeth
11
Performance
Ampere
Max. 80 A
[No-load, 11.0V]
Speed
Min. 3,100 RPM

Starter. Schematic diagrams

Circuit Diagram

Starter. Repair procedures

Removal
  
Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift.
(Refer to General Information - "Lift and Support Points")
1.
Turn the ignition switch OFF and disconnect the battery (-) terminal.
2.
Remove the engine room under cover.
(Refer to Engine Mechanical System - "Engine Room Under Cover")
3.
Disconnect the starter ST connector (A).
4.
Remove the stater "B" terminal cable mounting nut (B).
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 Ib-ft)

5.
Remove the starter mounting bolt (A).
Tightening torque :
49.0 - 63.7 N.m (5.0 - 6.5 kgf.m, 36.2 - 47.0 Ib-ft)

6.
Remove the starter.
Installation
1.
Install in the reverse order of removal.
Disassembly
1.
Disconnect the M-terminal (A) on the magnetic switch assembly.

2.
After loosening the screws (A), remove the magnetic switch assembly (B).

3.
Loosen the through bolts (A) and then separate the brush holder assembly & rear bracket assembly from the front bracket assembly.

4.
Remove the lever lest (A).

5.
Remove the lever (A).

6.
Detach the planet gear shaft assembly (A), brush holder assembly (B), armature assembly (C) and yoke assembly (D).

7.
Remove the shield (A).

8.
Remove the planet gears (A).

9.
Press the stopper (A) using a socket (B).

10.
Remove the stop ring (A) using the stop ring pliers (B).

11.
Remove the stopper (A), overrunning clutch (B), internal gear (C) and planet shaft (D).

  
Using a suitable pulling tool (A), pull the overrunning clutch stop ring (B) over the stopper (C).

Reassembly
1.
Reassemble in the reverse order of disassembly.
Inspection
Starter Solenoid 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.

Free Running Inspection
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 11.5 and 11 volts.
7.
Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely.
Items
Specification
Current (Max.)
Max. 80 A
Speed (Min.)
Min. 3,100 RPM

Armature Inspection and Test
1.
Remove the starter.
2.
Disassemble the starter as shown at the beginning of this procedure.
3.
Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.

4.
Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with #500 or #600 sandpaper (B).

5.
Measure the commutator (A) runout.
If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments.
If the commutator run out is not within the service limit, replace the armature.
Commutator runout
Standard (New) : 0.05 mm (0.0019 in.) max
Service limit : 0.08 mm (0.0031 in.)

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 (0.0276 in.)
Limit : 0.2 mm (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.

Inspect Starter Brush
Any worn out or oil-soaked brushes should be replaced.

Starter Brush Holder Test
1.
Check that there is no continuity between the (+) brush holder (A) and (-) plate (B). If there is continuity, replace the brush holder assembly.

Inspect Overrunning Clutch
1.
Slide the overrunning clutch along the shaft.
Replace 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 locks in both directions, replace it.

3.
If the starter drive gear is worn 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 in cleaning solvent.
The overrun clutch is pre-lubricated at the factory and solvent will wash lubrication from the clutch.
3.
The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.

Starter Relay. Repair procedures

Inspection
1.
Turn ignition switch OFF and disconnect the battery negative (-) terminal.
2.
Remove the fuse box cover.
3.
Remove the starter relay (A).

4.
Check for continuity between the terminals (30 and 87) using an ohmmeter.
Terminal
Resistance
Measure
30 - 87
1 MΩ or higher
If there is continuity between the terminals, replace the relay.

5.
Apply 12V to the terminal 85 and ground to the terminal 86 and then check for continuity between the terminals (30 and 87).
Terminal
Resistance
Measure
30 - 87
1Ω or less
If there is no continuity between the terminals, replace the relay.

6.
Install the starter relay.
7.
Install the fuse box cover.
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