Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSHYUNDAI1991SONATA V6-3.0LREPAIR AND DIAGNOSISSTARTING AND CHARGINGSTARTING SYSTEMSTARTER MOTORADJUSTMENTS
1991 Hyundai Sonata V6-3.0L
Starter Motor: Adjustments
1991 Hyundai Sonata V6-3.0LSECTION Adjustments
The following diagnosis and testing procedure is made after removal.
1. Disconnect wire from M terminal.
2. Connect battery voltage between S terminal and M terminal, Fig. 4.
3. As voltage is applied, the pinion will move out. Do not perform this test for longer than 10 seconds, to prevent the coil burnout.
4. Check pinion to stopper clearance (pinion gap .0197-.079 inch) with a feeler gauge. If pinion gap is not within specifications, adjust by adding or removing washers between solenoid and front bracket.
Fig. 4 Pinion Gap Adjustment (Part 1 Of 3):
Fig. 4 Pinion Gap Adjustment (Part 2 Of 3):
Fig. 4 Pinion Gap Adjustment (Part 3 Of 3):
1. Disconnect wire from M terminal.
2. Connect battery voltage between S terminal and M terminal, Fig. 4.
3. As voltage is applied, the pinion will move out. Do not perform this test for longer than 10 seconds, to prevent the coil burnout.
4. Check pinion to stopper clearance (pinion gap .0197-.079 inch) with a feeler gauge. If pinion gap is not within specifications, adjust by adding or removing washers between solenoid and front bracket.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.