TSB's

Warming up a stone cold Hyundai

Some 2009 and 2010 MY 2.4L Sonatas equipped with Valeo Mexico starters may exhibit a click with no crank from the starter during extended below-freezing weather conditions.

The engine will start after multiple attempts to crank. Starters will operate normally after a short period in warmer weather or after a car is brought from freezing conditions into a warm shop. This affects vehicles equipped with the 2.4L engine and automatic transmission, produced between 8/20/09 – 7/17/09; and between 10/20/08 – 7/17/09.

Replacing the starter solenoid is the recommended fix for this problem.

1. Record the radio presets.

2. Disconnect the negative battery cable.

3. Disconnect the starter cable (A) from the B terminal (B) on the solenoid (C), then disconnect the connector (D) from the S terminal (E).

4. Remove the two bolts that secure the starter and remove the starter.

Disconnect connections and remove the starter.
<p>Disconnect connections and remove the starter.</p>

5. Remove the starter solenoid M terminal nut (F).

6. Remove the M terminal wire (G).

Remove the starter solenoid M terminal nut and M terminal wire.
<p>Remove the starter solenoid M terminal nut and M terminal wire.</p>

7. Remove the two solenoid retaining bolts (H) and remove the solenoid assembly (I) from the starter.

Remove the solenoid from the starter.
<p>Remove the solenoid from the starter.</p>

8. Remove the plunger spring (J) and clean excess grease from the plunger (K) using a clean dry cloth. Make sure that the lever stop remains in place.

Remove the plunger spring, clean the plunger and make sure that the lever stop remains in place.
<p>Remove the plunger spring, clean the plunger and make sure that the lever stop remains in place.</p>

Tighten the two solenoid mounting bolts to 3.0 – 4.2 Nm.
<p>Tighten the two solenoid mounting bolts to 3.0 – 4.2 Nm.</p>

 

9. Install the plunger spring € onto the plunger (F).

10. Install the solenoid (A) onto the starter (B), securing the bolts (C) to 3.0 – 4.2 Nm.

11. Install M wire (G) onto solenoid M terminal (H) and secure M terminal nut (I) to 7.8 – 11.8 Nm.

Tighten the M terminal nut to 7.8 – 11.8 Nm.
<p>Tighten the M terminal nut to 7.8 – 11.8 Nm.</p>

12. Install the starter in reverse order of removal.

13. Install the negative battery cable.

14. Set the clock and radio presets.

 The P/N for the replacement starter solenoid kit is 36120-2G110.

Tags: Hyundai  Starters 
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