Replacing the VAZ 2110 generator manifold

Generator rotor commutator 2110 KZATE

Delivery to regions

Delivery of an order worth over 5,000 rubles is free if the delivery cost does not exceed 500 rubles; in other cases, delivery of goods is paid upon receipt of the goods.
Delivery to the transport company is FREE.
The timing, cost and method of delivery depend on the weight, dimensions and cost of the ordered product.
Delivery options can be selected by the online store manager.

Orders are processed daily from 07:00 to 19:00 (Moscow time).

Order of shipment to regions of the Russian Federation:

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After receiving the money (usually money arrives instantly), we will almost immediately deliver the order to the transport station.

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Navigator stores (Tolyatti, Syzran and Dimitrovgrad)

In most cases, the order can be picked up almost immediately at any of the 15 stores of the Navigator network. The goods are issued only upon presentation of an identification document (passport, driver's license, etc.).

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If you cooperate with a transport company not represented in this list, then write to us and we will deliver your cargo to any transport center within the city of Tolyatti.

The order will be shipped within 1 to 5 business days, depending on the availability of the ordered product.

Replacing the slip rings of the VAZ 2110 generator on your own

Replacing the slip rings of the VAZ 2110 generator is necessary if there are various types of defects on their surface. Because of them, the rings cannot efficiently perform their most important function - tightly connecting the parts to each other so that contact occurs between them. Very often, individual parts of the generator break. If you change it completely, you will have to spend a considerable amount of money. Therefore, you can repair it by replacing broken parts. On a VAZ 2110, replacing the slip rings of the generator is a simple procedure and you can handle it yourself.

Replacing the rotor with rings

Replacement on the VAZ 2110 generator

Sometimes it is not possible to replace the rings separately. The rotor also has to be replaced. This situation occurs when the rings reliably “stick” to the rotor. But you can try to restore the rings by placing them in a sulfuric acid solution. They cannot be kept in solution for a long time, as whole particles may disintegrate. To replace the rotor and rings, you must:

Place markings on the covers of the generator (to make it easier to assemble them later, otherwise you can confuse their location).
Remove the plastic casing. This is easier to do after the three latches securing it are bent away.

Note: you need to bend them very carefully, as they are quite delicate. Moving too quickly can cause them to break.

Remove the two screws that secure the electronic voltage regulator.
After this, you will have access to the generator relay. It must be removed, otherwise it will interfere with the work process.
Remove all fastenings of the unit and condenser.
Then unhook the three winding tips coming from the stator.
Remove the block and capacitor. If you need to replace the capacitor, you need to unscrew the nut that secures it. Then remove the washer along with the bushing. Now it’s the turn of the wires that attach the capacitor to the contact bolt. After this, you can remove and replace the capacitor itself.
Unscrew the generator coupling bolts. There are four of them in total. There are usually flat washers and spring washers underneath the screw heads. They are very small, but perform an important function. You can’t lose them, otherwise you’ll have to buy new ones, but finding them on sale is not easy.
Remove the generator cover from the side where the slip rings are located. In this case, you can help slightly with a screwdriver, as if pulling the lid towards you.

VAZ 2110 in the generator slip rings

Remove the nut securing the generator pulley. Remove the washer and pulley.

Note: the rotor must be stationary. To prevent it from spinning, it should be clamped as much as possible, and a small piece of plywood should be placed under it.

Disconnect the thrust washer.
Remove the generator rotor.
It has a spacer ring that needs to be removed.
At this stage, you need to carefully inspect the slip rings. It is possible that they will also have to be replaced. If they are worn out or there are scratches on their surface, then replacement cannot be avoided (by the way, it is not necessary to install new rings - they can be thoroughly sanded).
A multimeter should measure the resistance of the rotor winding.

Note: if this tool shows that there is a break in the rotor winding, then it urgently needs to be changed. You can also try to rewind it, eliminating the break. But this process is quite complicated.

You should also check if there is a short circuit between the winding and the rotor housing. To do this, you need to use a 220 V lamp. One of its wires must be connected to the body, and the other must be connected in turn to each of the slip rings. Moreover, if there are no short circuits, the lamp will not light.
Insert the new rotor into place.
Assemble everything in the opposite order.

About the principle of operation of a car generator

The operation of the Lada Kalina generator unit is based on the following principle: an alternating current is induced in the stator winding, which is subsequently transformed into direct current through a rectifier module located on the body of the unit. The generator cover is also equipped with an electronic voltage regulator and a brush holder. The rotor of the device receives torque from the crankshaft pulley. The transmission link is a poly V-belt.

The basic characteristics of the generator set include the following parameters:

maximum generated current – 85-90 Amperes;
operating range of on-board voltage – 14.4-15.1 Volts;
rotation ratio of the motor and rotor – 1:2.4;
right-hand direction of rotation.

The housing of the unit is held together by pins that tighten the stator with the covers. The mounting sockets of the indicated covers contain bearings, which ensure the ability of the rotor to rotate. The rear bearing is installed inside the cover with a minimum gap. The front element is equipped with the ability to slide along the surface of the rotor shaft. It is fixed inside the front cover with a slight interference fit, and a pressure plate covers it from the outside. The back of the device is protected by a plastic casing.

Let's move on to the switching diagram of the generator with the on-board network. The connection diagram is very simple. After turning on the ignition, power begins to flow to the voltage regulator through the battery discharge lamp circuit. When the motor starts, the excitation winding is supplied with supply voltage from three diodes mounted in the rectifier unit.

Using the indicated signal lamp, the generator unit can be checked. If the device is working properly, the lamp lights up when the ignition is on. It goes out when the engine starts. When this phenomenon is not observed and the lamp continues to shine, the generator set should be diagnosed for the presence of malfunctions. In some cases, replacement is required, and many are interested in how to remove the generator?

1 way

First, you need to check whether voltage is supplied to the battery. To do this, you need to take a voltmeter, the next step is to start the car, and connect the device itself to the terminals. If at the same time the device itself shows a low indicator of the incoming voltage and the car volts drop when the engine is started, then this indicates that the generator is not working properly. And it's best to change it.

Method 2

You need to start the car and leave it in working condition for a while. Then the choke is removed halfway, the negative terminal is disconnected from the battery, and if it stalls, this will confirm that the generator needs repair or complete replacement. On cars with injection and carburetor engines, this method of checking cannot be done for one reason: the diode bridge on them can completely burn out.

3 way

If the battery charge light comes on while the engine is running, then in most cases this means that the generator does not recharge the battery, but rather takes all the charge from it. And this also indicates a malfunction of the generator.

Disassembling the generating device

It is noteworthy that generators come in two types: old and new. The differences between them are in the diameter of the shaft. A 15 mm shaft is installed on old generators, 17 mm on new ones. This means that different bearings should be selected for replacement. The 302nd is suitable for a 15mm shaft, and the 303rd for a 17mm shaft. As for the rear bearing, it goes with all generators and is marked as 202.

So, disassembling the generator begins:

First, remove the plastic cover;
then the diode bridge is dismantled;
remove the tablet (regulator with brushes);
To unscrew the pulley nut, you will have to clamp the generator in a vice, and then use a 24mm socket.

Advice. The gene must be clamped in a vice very carefully so as not to damage its parts. To avoid damage, the pulley is clamped using rubber gaskets.

the relative position of the covers of the generating device is marked;
then the tightening screws are unscrewed.

Note. The fastening screws are tightened very tightly. They are made of soft metal, so the usual methods of turning out oxidized bolts will not work. Here you will need an impact screwdriver or a shaped one, but with a large tip. Fasteners must be pre-treated with WD-40 or brake fluid and wait a little.

It is also recommended to treat the joints of the covers with the device body with WD-40.

take a mounting spatula or an ordinary, but flat screwdriver, and halve the gene.

Possible malfunctions and ways to eliminate them

So, why does the generator unit heat up and hum, and how can you protect the unit from exposure to water?

We suggest that you familiarize yourself with the main causes of unit malfunctions:

Brush wear. This problem is relevant for many generators, not only “decimal” generators. When the brushes wear out, they will need to be replaced.
Pulley damage or failure will also require repair. If the pulley starts to work incorrectly, the unit will not be able to produce the required amount of voltage. Failure of this element is usually associated with wear of the teeth. In addition, various wear-related damage may occur on the device itself.
Slip rings and the commutator are two components that also often wear out. If these components fail, the unit will not be able to perform its assigned functions. If the brushes wear out, the unit will be forced to operate with high power consumption, which leads to its overheating.
Voltage regulator. As stated above, if this element fails, the voltage in the vehicle’s on-board network will increase, and this will not result in anything good.
Short circuit of the winding of the stator mechanism. If such a malfunction occurs, you will either have to rewind the windings, which is very labor-intensive, or completely replace the stator. The second option is more appropriate.
The hum and appearance of third-party sounds during operation of the generator unit may be due to wear of the bearing devices. The unit will not be able to work properly, and it will also begin to heat up over time.
Failure of the rectifier unit.
Worn drive belt. This item belongs to the category of consumables, so sooner or later it will wear out in any case. When worn, the belt must be replaced.
Broken or damaged power wiring.

Steel rings and their advantages

Replacing slip rings on a VAZ 2110 generator

There is no point in installing copper rings, as they wear out very quickly. Therefore, it is better to opt for steel rings, which have a number of advantages:

They hardly wear out, so the brushes remain in almost perfect condition for a long time.
They are easy to install.

Note: by the way, for more reliable fixation, they are first lubricated with a flux solution, and then washed with soda.

 Once installed, they are securely fixed, remaining motionless in all situations.

Troubleshooting

The first step is to determine whether your generator is actually the source of the problem. To check, you need to carry out a series of sequential activities.

Start the engine and let it warm up to operating temperature.
Increase the crankshaft speed to approximately 3 thousand rpm.
Turn on all the headlights, activate the high beams, start the heater, emergency lights, heated glass, and wiper blades. That is, all electricity consumers should be turned on as much as possible.
Measure the voltage on the battery.
If the device shows less than 13V, then a short circuit or break has most likely occurred in the generator windings.
Another option is a breakdown of the voltage regulator, oxidation of the contacts of the excitation winding ring.

You can check for breaks and the condition of other elements of the generator only by dismantling it. But if you don’t have any experience in disassembling a generator, then you shouldn’t try to go there with your own hands. Replace the entire assembly or entrust the repair to professionals.

Delivery to regions

Delivery of an order worth over 3,000 rubles is free if the delivery cost does not exceed 500 rubles; in other cases, delivery of goods is paid upon receipt of the goods. If the delivery cost exceeds 500 rubles, we make a discount of 500 rubles on the delivery cost.
Delivery to the transport company is FREE.
The timing, cost and method of delivery depend on the weight, dimensions and cost of the ordered product.
Delivery options can be selected by the online store manager.

Orders are processed daily from 08:00 to 20:00 (local time).

Examination

It happens that the generator begins to act up ahead of schedule and the battery does not charge properly. Actually, it serves to ensure the operation of the source of electricity to power all cars - the battery.

We advise you to rely not only on our instructions, but also on video lessons that will allow you to carry out repairs and replacements with your own hands, even without much experience.

Troubleshooting

The first step is to determine whether your generator is actually the source of the problem. To check, you need to carry out a series of sequential activities.

Start the engine and let it warm up to operating temperature.
Increase the crankshaft speed to approximately 3 thousand rpm.
Turn on all the headlights, activate the high beams, start the heater, emergency lights, heated glass, and wiper blades. That is, all electricity consumers should be turned on as much as possible.
Measure the voltage on the battery.
If the device shows less than 13V, then a short circuit or break has most likely occurred in the generator windings.
Another option is a breakdown of the voltage regulator, oxidation of the contacts of the excitation winding ring.

Generator replacement and repair

Replacing the VAZ 21124 generator
As it becomes clear, there can be no talk of any normal operation of the vehicle if the generator is faulty. This part must undergo technical inspection every 15 thousand kilometers. If comments are identified at the diagnostic stage, they should be addressed urgently.

Dismantling the generator

Replacing the VAZ 2112 generator
Removing the generator on your own will not be difficult. Let's consider the algorithm of actions:

First of all, you should disconnect the negative cable from the battery.
We take the keys for 10 and 13.
We find the wire that goes to the generator and disconnect it.
We also unscrew the nut securing the wire to the positive terminal.
Remove the output wire.
Now you need to remove the generator tension bar.

Signs of a generator malfunction

The generator on the VAZ 2110 has an average resource of about 80-100 thousand km, after which failures in its operation are possible. There can be many reasons for breakdowns: generator bearings, brushes, windings, etc.

As a result of malfunctions, a weak current is supplied to the on-board network. In this case, it is important to pay attention to the following signs:

a battery icon appears on the dashboard (indicating that the battery is not charging);
when the lights are turned on, the headlights burn dimly or the light pulsates (unstable voltage);
turning on additional equipment causes the dashboard backlight to dim;
the load on the on-board network leads to the heater fan working weakly, etc.

Ultimately, the lack of spark at the spark plugs will cause the engine to stall. In such a situation, it is necessary to remove the generator, since after dismantling the device, you can disassemble the generator, check it, repair it (for example, replace the brushes) or completely replace it with a new or working device.

What causes rings to wear off?

Alternator rings for VAZ 2110

The following generator parts can cause slip ring failure.

Stator

 On its inside there should be no traces from the rotor that would appear during its operation. Otherwise you will have to change it.

Note: You also need to check the bearings, as this problem often appears when they are broken. Sometimes even the generator cover can also get broken. This problem urgently needs to be fixed by replacing the damaged part with a new one.

After this, you should check whether there is a break in the stator winding. It needs to be checked in the same way as the rotor.

Generator VAZ 2110

Of course, if you are sure that the stator is completely intact, then you should not carry out such manipulation. But if there is even the slightest suspicion that it is malfunctioning, then it is better to check it. A faulty stator can lead to rotor failure again.

Bearing

See if the generator bearing located on the rotor rotates correctly. It should rotate freely on the slip ring side without jamming.
If it dangles too much or, on the contrary, is very tightly clamped, then it needs to be compressed.

Lid

The generator cover on the slip ring side may have damage, cracks or other defects.
In this case, it needs to be replaced, otherwise it will have a bad effect on the contact rings, leading to their abrasion.

Dismantling

To disassemble, remove and repair or replace the generator, you will need to do the following.

Drive onto an inspection hole or overpass to have access to the bottom and engine compartment.
Remove the battery, otherwise it will not allow you to get to the nut that holds the generator you are looking for.
Next, the same nut and adjustment bar are removed. Here you will need a 17 mm wrench. Use an extension cord. This will make the task easier; you will have to apply less force to unscrew the fastener.
In the engine compartment, remove the shield that performs dirt protection functions.
Now the drive belt is removed and the wires are disconnected.
Be sure to remove the protective cap and use a 10mm wrench to unscrew the nut that holds the tip and positive cable of your battery.
There is another nut on the fixing bracket, which will also have to be unscrewed.
That's it, you can remove the generator. Just remember to pull out the long bolt first.
When removing, keep an eye on the buffer sleeve. It won't be good if you lose it.

Dismantling work
This completes the procedure for removing the generator. You can proceed with partial repairs or complete replacement of the unit.

Belt

Often, the solution to a poorly functioning alternator is simply adjusting the belt.

Belt

For the device to work effectively, it is necessary to ensure normal deflection of the belt;
The deflection size should be 6-10 millimeters with a force of 98 N or 10 kgf;
To adjust or replace the belt, you need to move the generator slightly to the side, towards the cylinder block;
By rotating the adjusting bolt, you can adjust the belt tension.

If this measure does not help, you will have to pay attention to the voltage regulator and brushes.

Brushes and regulator

It is not recommended to repair the generator brushes, as well as the voltage regulator if they are worn out.

Experienced specialists advise purchasing a complete unit that includes both elements. Replacement is completed in a matter of minutes.

Brushes

How to remove the generator on a Priora with air conditioning through the headlight

On Prioras, where an air conditioner is installed, the process of dismantling the generator is also complicated by the fact that the climate system pipes interfere with its removal. However, dismantling is quite possible, and there are different ways to do this. The most time-consuming option is to remove the generator through the headlight. How to do this correctly, we will consider in detail below.

We de-energize the car by disconnecting the negative terminal from the battery.
Next, you need to remove the right headlight, and also dismantle the adsorber. How to do this correctly is described in detail in this manual (for 8 and 16 valve models).
After the headlight and adsorber have been removed, we continue to further describe the process of removing the generator on a Priora with air conditioning. Using a “10” wrench, unscrew the bolt securing the air conditioner pipes (shown in the photo).
Lift the tubes out.
Unscrew the bolt securing the air conditioner pipes next to the right engine mount.
Remove the belt from the generator pulley by unscrewing the tensioner pulley bolt with a 17 key.
Disconnect the wires from the generator. It is most convenient to do this from below, so we remove the protection (if it has not already been dismantled). Having gained access to the rear cover of the generator, disconnect the first connector “L” by removing the plug. To turn it off, you need to press the corresponding tab (latch or flag).
Next, we move aside the protective cover from the other contact “B+” of the generator, and unscrew the nut with a wrench set to “13”.
Using two “13” keys, you need to unscrew the upper mount of the generator and remove the bolt. The instructions from Avto-VAZ indicate that you need to unscrew the lower fastening first, but in reality there is no difference.
After this, unscrew the lower mount of the generator using keys “13” (nut) and “17” (bolt head). We take out the bolt.
We remove the generator through the vacated headlight hole.
It is installed back in a similar way.

As noted above, removing the generator on a Priora through the headlight is one of the most labor-intensive processes, since many parts need to be removed. However, there are other options for dismantling the unit. Let's consider other methods.