Hyundai Creta: Starting System / Starter

Description and operation

Description
The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch (A/T), clutch pedal switch (M/T), 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.
In conjunction with the ISG function, the starter motor must do a great deal more work. Therefore, the starter motor is configured for a significantly higher number of start cycles. The components of the starter motor have been adapted to the higher requirements.

Specifications

Specification
Item
Specification
Rated voltage
12 V, 0.8 kW
The number of pinion teeth
9
Performance
[No-load, 11-5V]
Ampere
Max. 65 A
Speed
Min. 2715 rpm

Components and components location

Components

1. Screw
2. Front bracket assembly
3. Stop ring
4. Stopper
5. Overrunning clutch
6. Lever
7. Lever plate
8. Lever packing
9. Magnet switch assembly
10. Armature assembly
11. Yoke assembly
12. Brush (-)
13. Brush holder
14. Brush (+)
15. Rear bracket assembly
16. Through bolt
17. Screw
18. Brush holder assembly
19. Stopper set

Schematic diagrams

Circuit Diagram

Repair procedures

Removal
1.
Disconnect the battery negative terminal.
2.
Remove the air duct and air cleaner assembly.
(Refer to Engine Mechanical System - "Air Cleaner")
3.
Disconnect the starter cable (B) from the B terminal on the solenoid then disconnect the connector from the S terminal (A).

4.
Remove the 2 bolts holding the starter, then remove the starter (A).

Installation
1.
Install in the reverse order of removal.
Starter installation bolt :
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
Disassembly
1.
Disconnect the M-terminal (A) on the magnet switch assembly.

2.
After loosening the screws (A), detach the magnet switch ssembly (B).

3.
Loosen the brush holder mounting screws (A) and the trough bolts (B).

4.
Remove the rear bracket assembly (A) and brush holder assembly (B).

5.
Remove the yoke assembly (A).

6.
Remove the packing (A), lever plate (B), lever (C), armature assembly (D).

  
Beware the direction of lever (A).

7.
Press the stopper (A) using a socket (B).

8.
After removing the stop ring (A) using stop ring pliers (B).

9.
Disconnect the stopper (A), overrunning clutch (B) and internal gear (C).

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

10.
Reassembly is the reverse 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 11volts.
7.
Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely.
Current (Max.)
Speed (Min.)
65 A
2,715 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.
Check the commutator diameter. If the diameter is below the service limit, replace the armature.
Commutator diameter
Standard (New): 27.0 mm (1.06 in.)
Service limit: 26.0 mm (1.02 in.)

6.
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.)

7.
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): 0.8 mm (0.0314 in.)
Limit: 0.2 mm (0.0079 in.)

8.
Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.

9.
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
Brushes that are worm out, or oil-soaked, should be replaced.

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

Overrunning Clutch
1.
Slide the overrunning clutch along the shaft.
Replace it if 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 it 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.
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