Hyundai: Engine D4FA. Manual — part 6
STARTING SYSTEM
EEA -21
7.
Disconnect the planet gear(A).
A
8.
Disconnect the planet shaft assembly(A) and lever(B).
A
B
9.
Press the stop ring(A) using a socket(B).
A
B
10. After removing the stopper(A) using stopper pliers(B).
B
A
11. Disconnect the stop ring(A), overrunning clutch(B), in-
ternal gear(C) and planet shaft(D).
A
C
B
D
EEA -22
ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)
12. Reassembly is the reverse of disassembly.
NOTE
Using a suitable pulling tool(A), pull the overrunning
clutch stop ring(B) over the stopper(C).
A
C
B
INSPECTION
EB74B9B5
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 con-
tact 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).
B
A
STARTING SYSTEM
EEA -23
5.
Check the commutator diameter. If the diameter is
below the service limit, replace the armature.
Commutator diameter
Standard (New) : 29.4 mm (1.1575 in)
Service limit : 28.8 mm (1.1339 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) : 0.02mm (0.0008in.) max
Service limit : 0.05mm (0.0020in.)
A
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 com-
mutator segments. The undercut should not be too
shallow, too narrow, or v-shaped(D).
Commutator mica depth
Standard (New) : 0.5 mm (0.0197 in.)
Limit : 0.2mm (0.0079 in.)
B
D
C
A
8.
Check for continuity between the segments of the
commutator. If an open circuit exists between any
segments, replace the armature.
EEA -24
ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)
9.
Check with an ohmmeter that no continuity exists be-
tween the commutator(A) and armature coil core(B),
and between the commutator and armature shaft(C).
If continuity exists, replace the armature.
C
B
A
INSPECT STARTER BRUSH
Brushes that are worm out, or oil-soaked, should be re-
placed.
Limit line
STARTER BRUSH HOLDER TEST
Check that there is no continuity between the (+) brush
holder(A) and (-) brush holder(B). If there is no continuity,
replace the brush holder assembly.
A
B
EBBD330A
INSPECT 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 of 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 con-
verter ring gear if the starter drive gear teeth are dam-
aged.
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