Bench Testing: Brushes

Replace brushes if worn to limit line. See Fig 1 . Measure length of brush protrusion out of brush holder. Replace brush if protrusion is 0.8" (2.0 mm) or less. Replace all brush springs if any springs are damaged or corroded.
To remove brushes from holder, unsolder pigtail from terminal. On 2.4L to replace, install brush and spring so that space between limit line and brush holder end is 0.079-0.118" (2.0-3.0 mm), and solder pigtail to brush holder. On 2.7L, install brush into brush holder and solder pigtail to brush holder.

Fig 1: Checking Brush Wear Limit

Courtesy of HYUNDAI MOTOR CO.