Replacing the VAZ-2110 generator brushes: how to do it without removing the generator

The car has long become one of the most popular vehicles, largely due to its extremely high level of comfort. Many components require replacement from time to time, and in particular the voltage generator. In some cases, you can get by with a local method, in others it is necessary to apply a radical solution. Replacing the voltage regulator of a VAZ 2110 generator seems at first glance to be a small local problem, but it can only be solved by radically resorting to generalized repairs. Replacing the voltage regulator on a VAZ 2110 generator is a task that you can handle on your own.

Replacing the VAZ-2110 generator brushes: how to do it without removing the generator

The generator in the car design is responsible for supplying voltage to all components of the on-board network. It is a fairly reliable unit, but it requires maintenance from time to time to prevent serious breakdowns. One of the stages of service work is replacing brushes. These stator elements, made of durable graphite, supply current to the rotating rotor of a car generator. Constant friction gradually wears out the brushes. It is not difficult to identify it - you will definitely notice the appearance of problems in the car's electrical supply system.

What to choose?

The choice of motorists is not limited to Katek generators. Therefore, if the old device fails, you should think about who will take its place.

There are several main options.

1. Katek. A standard, fairly reliable and very efficient generator. AvtoVAZ’s choice in its favor is due precisely to this. Plus it is a domestic manufacturer.
2. Chinese products. The attitude of motorists towards Chinese generators is quite skeptical. There are explanations for this. Compared to them, Katek is simply an ideal solution. Although in fairness, we note that you can find some pretty good Chinese-assembled options. But this is the exception rather than the rule.
3. Imported analogues. Here, first of all, you should pay attention to Bosch companies. Denso and Delphi. High build quality, impressive service life, efficient operation. They cost more than their Russian counterparts in the form of Katek, but for such a thing it makes sense to spend a little more.

Among imported devices, the following are considered good options:

• Dynamo - manufacturer Bulgaria;
• Eldix - also produced in Bulgaria;
• BATE - produced in the city of Borisov, in Belarus.

When choosing a new generator for your car, pay attention to its technical characteristics and safety margin. Then think about the manufacturer. We do not recommend looking towards China if you are doing repairs for yourself and want to achieve high quality work.

When may it be necessary to replace alternator brushes?

The manufacturer requires replacing the alternator brushes on a VAZ-2110 car every 50 thousand kilometers or every 4 years (it all depends on what comes first). But you may also need this procedure if any of the following symptoms of incorrect operation of the on-board network occur:

• spontaneous decrease in headlight brightness;
• periodic shutdown of the cigarette lighter, car radio, dashboard backlight lamps;
• sudden drop in network voltage;
• turning off all electronics on board the vehicle;
• rapid discharge of the battery and problems with restoring its charge.

If you notice at least one of these symptoms, it makes sense to check whether the generator brush is worn out and whether this device is working correctly.

In addition, you can perform a simple diagnosis using one of the following methods:

• visual assessment of the condition of the brushes. They should protrude slightly from the holder body. If this is not observed, wear is evident;
• measurement of brush resistance. It should be no more than 0.05 Ohm. Otherwise, the part needs to be replaced.

If problems are identified, it is urgent to install a new part, since further safe operation of the machine is not possible.

What is the advantage of three-phase regulators

The main advantage of such devices is the ability to preserve the life of the car battery. This is very important for any driver. The list of benefits does not end there:

1. Eliminates heating problems.
2. In cold weather the engine will start faster.
3. Problems with alarms disappear, which quite often happens to vehicle owners. Such surprises especially happen in winter.
4. The power of light emission from lamps increases. Visibility will improve both with low and high beams.
5. The regulator can also affect the operation of the vehicle's heating system. There is an established opinion among experienced drivers that the stove works much better with a fully charged battery.
6. Some car enthusiasts have noted that power windows work faster with a working battery.

As you can see, a high-quality battery with an additional three-level regulator can save you from a lot of problems.

How to replace alternator brushes on a VAZ-2110 car

Let’s immediately answer a very common question asked by domestic car enthusiasts: is it possible to replace the alternator brushes on a VAZ-2110 car without removing the alternator?
Yes, theoretically, such an operation can be performed, but we would like to warn you that there is a fairly high risk of damage to the unit, as well as breakdown of expensive parts located in the immediate vicinity of it. Replacing brushes on a car with a 16-valve engine will be a particularly difficult task, since, among other things, you will need to remove the crankcase protection, and also try to get to the generator from below, being under the bottom of the car. This is why we strongly recommend following the instructions in the video. In order to remove the generator and install new brushes, you will need to prepare all the necessary tools - keys 8 (socket), 10 and 13, as well as a flat-head screwdriver and a universal joint with a special extension. The entire procedure is performed according to the following scheme:

• disconnect the negative contact of the battery to de-energize the generator;
• unscrew the nut located on the positive contact. This is necessary to disconnect the generator from the system;
• loosen the lower and upper nuts, as well as the tensioner bolt, in order to quickly and effortlessly remove the generator belt;
• completely remove the adjusting bolt, and then remove the tension bar from the generator;
• remove the generator. All other work can be done in any convenient place, since it is now easy to provide quick access to the brushes;
• remove the battery and disconnect all wires connected to it from the generator;
• Using the cardan joint, we get to the bolt of the brush assembly and completely unscrew it from the body;
• install new brushes and reassemble the generator in the reverse order.

We install the voltage regulator of the VAZ 2110 generator

The voltage regulator on a modern car automatically and continuously adjusts the excitation current of the generator. Moreover, this process proceeds in such a way that when the current load and rotation speed of the generator changes, the value of its voltage remains in a strictly defined range.

Voltage regulator - its main functions

On a VAZ 2110 car, the voltage potential in the generator is formed under the influence of alternating current. This phenomenon becomes possible due to the presence of silicon diodes in the generating device of the vehicle. The generator rotor (the rotating component of the mechanism) operates according to the following diagram:

• First, the crankshaft begins to function, which is affected by the current;
• the crankshaft sets the movement of the rotor;
• After this, the generating device itself begins to work.

All stages of the sounded process are monitored by a voltage regulator, which is also often called a relay. It is this that is considered the main control unit of the generator.

Without a regulator, the current-generating mechanism of the VAZ 2110 will not perform its tasks, which are listed below:

1. starting the generator;
2. control (in offline mode) of current supply;
3. “holding” in a certain voltage range.

The described relay cannot be repaired. In the event of a breakdown, the regulator must be replaced, which is done after checking the functionality of this unit.

Operating principle

The voltage connection to the generator terminal from the ignition switch passes through the control light, which is located on the instrument panel:

• If the ignition is turned on, the light comes on.
• When the engine is started, the light must go out - this indicates the serviceability of the generator.

When the engine starts, the generator starts working from three additional diodes that are installed on the rectifier unit. Generator technical parameters:

• maximum recoil current at 13 V, 6000 rpm - 1, A-80;
• adjustable voltage limits - 13.2-14.7 V;
• engine-generator gear ratio - 1:2.4;
• working capacitance of the capacitor is 2.2 µF _+ 20%.

How to check the relay on a VAZ 2110?

To analyze the condition of the regulator, you need to purchase a voltmeter, which has a measuring scale in the range of 15–30 volts. The check is performed as follows:

1. start the car engine at medium speed and let it run for a quarter of an hour (the operation is carried out with the headlights on);
2. A voltmeter is used to determine the voltage between the “ground” of the generating device and the “plus” on the battery.

If the measurement shows a voltage value from 13.5 to 14.2 volts, replacing the regulator is not necessary. But in situations where the voltage has a different value, indicating a constant overcharging or undercharging of the battery, the relay needs to be replaced.

You can also remove the voltage regulator and check it together with the generator brush holder. To do this, a 12-volt light bulb with a power of 1–3 watts is placed between the brushes, a power source is connected to the “ground” and the positive terminal of the battery, from which a voltage of 12 volts is first supplied, and then 16 volts.

If the light comes on at 12 volts and goes out at 16, replacing the regulator on a VAZ 2110 is not necessary. If the lamp does not light up, this indicates that there is no required power contact between the relay terminals and the brushes, or that a break has occurred. And the burning of the lamp at 12 and 16 volts indicates a breakdown of the regulator.

How to replace the generator voltage relay?

If you have some skills, removing and disassembling the mechanism described in the article does not cause difficulties for a person. The most difficult thing is to change it for the first time, and subsequent replacements, as a rule, take place quickly and without problems.

The regulator on a VAZ 2110 is dismantled according to the following scheme:

1. disconnect the negative terminal from the battery;
2. disconnect the drive block from the terminal marked “D+”;
3. unscrew the nut, which is located under the rubber boot (it needs to be moved a little to the side);
4. disconnect all existing wires in the contact pin;
5. unscrew the nut in the generating device circuit (this fastener secures the terminal) and remove it.

Then you will need to remove the generator casing by unscrewing the nuts (there are three of them) that hold it in place, as well as dismantle the relay housing and remove the screw securing the disassembled mechanism from the rectifier compartment. Now the VAZ 2110 voltage regulator can be easily removed. You can install a new device instead. After replacing the relay, all the described steps are performed in the reverse order.

Is it worth making the regulator yourself?

If you are new to electronics, then such an undertaking will be quite difficult.

As we mentioned earlier, the main element of the circuit is a certain number of diodes. Finding three-stage switches for them is quite problematic. In addition, you need to correctly calculate and install radiators for cooling. Otherwise, the risk of diode burnout increases significantly.

During the development of the regulator, long wires will be needed, because the connection is made directly to the device through the cover.

Additionally, you will need to make or find a suitable plastic case for such equipment. All internals must be securely fastened inside the device.

Three-level generator voltage regulator for the “ten”

When the heating system, headlights and other additional loads are turned on on the VAZ 2110, the car battery discharges very quickly. This phenomenon is observed even when the “native” generator relay is functioning normally. A three-level regulator allows you to get rid of this problem. You can purchase it at any auto store, equip yourself with a simple set of tools (terminal pliers, a knife, an S10 open-end wrench and a Phillips screwdriver) and install it on the car yourself.

The three-level mechanism is mounted as follows:

1. first remove the old relay according to the algorithm given above;
2. grind the ends of the spacer bushing using a file (this operation ensures more reliable contact with the diode bridge);
3. a new element with a brush holder (sold as a set) is installed in place of the relay;
4. Sealant is used to seal the cable entry point;
5. put back the plastic casing;
6. lay the cable along the standard wiring to the area where the relay is mounted, and secure the new wire tightly with small plastic clamps.

It is recommended to connect the housing of the installed voltage relay and the autogenerator using a reliable shunt. This ensures the necessary contact of the device with ground. However, you can do without a shunt.

The mounted three-level mechanism should be checked with a tester at full consumer load (window heating, stove, headlights, etc. are turned on). At maximum, the device should show 14.5 V, in normal mode - 14.1 V, at minimum - about 13.4 V.

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Source

Modification of the relay regulator

For any modification of the generator set, you need to have at least a little knowledge in the field of electronics. To modify the “relay” for an increased battery charging voltage, you need to purchase the same relay from a foreign car with an output voltage of 14.5 volts, it is indicated on the top cover. The further order will be as follows:

• You need to disconnect the original “pill” from the domestic relay. You need to use a heated soldering iron and tweezers;
• The same procedure is carried out with imported “things”;
• After this, an imported relay must be installed on the domestic brush assembly. Here you will have to work hard, since the pins do not match and they need to be bent and soldered correctly;
• After this, it is securely fastened with screws to the body, having previously been treated with a special heat-shrink paste.
• That's it, you can install the relay regulator on the generator and test it in action, it should produce a voltage equal to 14.5 volts.

Replacing generator brushes on VAZ 2110, VAZ 2111, VAZ 2112

Brushes are an integral part of the generator. They are inexpensive and can be replaced in literally 20-30 minutes. Thanks to the brushes, the battery is charged, and current from the generator is supplied to the on-board network. Failure is fraught with consequences: the car does not drive, the battery charge lamp immediately lights up, signaling that the generator is not working properly and requires inspection. Do not operate a car with a glowing light on the dashboard, because the battery will suddenly run out in the wrong place, the car will stall and you are unlikely to start the car (current stops flowing to the ignition system, and therefore the spark disappears and the fuel-air mixture stops igniting).

Technical specifications

If the old generator fails, many motorists wonder which generator they should now replace the old one with.

There is no need to invent anything here. The most correct solution is to install the same generator as before, or a more powerful one.

Today, the VAZ 2110 provides for the use of three types of power supply devices:

1. Katek 5102.3771. The generator produces 80 Ampere power and its voltage is approximately 14V.
2. Katek 94.3701. This is a device with the same parameters. They are not seriously different.
3. Catek 120 amp. A generator that is more adapted to modern realities, when in addition to standard electrical equipment, motorists install many additional devices.

If you have a powerful audio system in your car, you use an electric pump powered by the car, as well as a number of other additional consumers, it is recommended to install a 120-amp unit instead of a standard 80-amp generator.

If we take into account the size of the devices, then we can distinguish between ordinary and compact ones. They have a certain difference in design.

To be specific, the differences are in the following components:

• Brackets;
• Anchor;
• Excitation wire;
• Drive pulley;
• Number of mounting bolts.

But in reality this does not play a special role. After all, the structure of all generators used for the VAZ 2110 is the same. Therefore, let's look at the circuit and structure of this unit.

Internal organization

The presented device is relevant for all generators used on the VAZ 2110, regardless of their power - 80-120 Amperes.

Margin of safety

If we take into account the standard Katek generator, which is installed on domestic dozens, then its resource is enough for about 10 years of operation or 140 thousand kilometers.

The specified safety margin of the device can only be relied upon if it is handled properly.

Many people fear that a powerful 120 A generator can negatively affect the condition of the battery. In practice, nothing like this happens. Moreover, installing a more powerful unit is recommended if you plan to install an impressive audio system or video equipment on the car.