Replacing generator brushes on a VAZ 2107 without removing the generator

The generator in any car is an integral part, since it charges the battery and powers consumers while the engine is running. If any breakdown occurs with the generator, charging problems immediately appear, which requires an immediate search for the cause and elimination of the malfunction.

• Checking the brushes
  Video: checking the brushes of the VAZ 2107 generator

• Generator repair

  Dismantling the generator

  Video: dismantling the generator on a “classic”

Tips and recommendations for replacing brushes on a VAZ 2107

Welcome, friends, to the DIY car repair website. Despite the large number of foreign cars, cars of the VAZ family are still in demand and find their use among motorists who know a lot about technology and appreciate the advantages of the domestic automotive industry.

As you know, operation and repair are inseparable concepts, and in the event of failure of any component, identifying and repairing the fault can be done on your own. Let's look at a simple repair using the example of a VAZ 2107 car generator.

Malfunctions and principle of operation of generator brushes

The electrical system of your iron horse provides a fault indication when the VAZ 2107 generator does not work; a red warning light with a battery symbol lights up on the instrument panel.

Quite often the cause is wear or sticking of the brushes. Those who are familiar with the principle of operation of a generator know that an excitation voltage is supplied to the armature through the brushes, which not only starts the electric machine (generator) into operation, but also regulates its output power.

The regulation itself occurs due to a special device, a relay-regulator, which can be implemented directly on the brush holder or installed separately (on earlier models).

As a rule, such a malfunction manifests itself gradually, initially accompanied by short interruptions in the operation of the generator, gradually leading to its complete failure, but other options are also possible, for example, a sudden failure.

Replacing the VAZ 2107 generator brushes yourself

The brush repair itself usually boils down to replacing them, but first you need to remove the brush assembly from the generator housing and assess the degree of wear, inspect for chips and cracks.

Replacing the brushes of a VAZ 2107 generator is a simple procedure and usually takes a few minutes; replacing the brushes does not require removing the generator, just disconnect the power wire, unscrew the two screws securing the brush holder housing and carefully remove this unit, do not forget to disconnect the negative terminal of the battery first.

Attention! The battery should be disconnected during any work related to the electrical equipment of the car!

Check the dismantled assembly for freezing, jamming of the brushes and their protruding working part, which should be at least 12 millimeters. In case of discrepancy, the part must be replaced; brushes for the VAZ 2107 generator can be purchased at almost any auto parts store.

After eliminating the malfunction, or purchasing new ones (it’s better to buy small parts with a sample of old ones, so that you don’t have to change them later), you need to install them in the reverse order.

Where are the generator brushes located?

Changing generator brushes is not difficult. They are located in the rear half of the device and are held in place by a single bolt. The brush assembly itself is located next to the slip rings and is connected to the voltage regulator. The brushes are held in place by springs next to the rings. Knowing the circuit diagram of the generator, it is not difficult to find the brushes. To replace, you will need a standard set of tools:

• Several wrenches;
• A pair of screwdrivers;
• New brushes;
• Liquid WD-40 (in order not to strip the threads of the bolts).

The brushes can be replaced in two ways, by removing the generator or without removing it. The design of the car, or rather the location in the engine compartment, will tell you which method is best to use. If there is free space, it is not difficult to repair the generator brushes without removing the unit, and if the engine occupies the entire engine compartment, it is impossible to do without removing the generator.

Tips and tricks

If, before repairing the generator brushes of your car, you noticed noise in its operation, this may indicate that the bearings of the VAZ 2107 generator may be worn out, and in this case, it is necessary to remove and disassemble the VAZ 2107 generator.

A worn bearing has increased play of the rolling elements and must, in this case, be replaced with a new one. You should know that premature bearing failure is not only due to lack of lubrication.

Often an over-tightened generator drive belt contributes to this, and an over-tightened belt can damage the cooling system pump bearing.

Therefore, check this unit regularly in accordance with the manufacturer's recommendations. It is better to get into the habit of regularly inspecting the engine compartment with the engine running, this will allow you to detect and eliminate the problem earlier and at minimal cost.

Correct diagnosis will help you avoid additional work and unexpected breakdowns.

Replacing the alternator belt and tensioning it

Having determined that the belt requires tightening or replacement, you need to prepare the appropriate tools for the job:

• open-end wrench 17;
• open-end or socket wrench 19.

The procedure for replacing the belt is as follows:

1. We unscrew the top mount of the generator, but not all the way.
2. We get down under the car and loosen the lower mounting nut.
3. We move the nut to the right, you can lightly tap with a hammer, loosening the belt tension.

If you just need to tighten the belt, then simply loosen the upper nut securing the generator and make an adjustment, for which the unit is moved away from the engine using a pry bar. To weaken, on the contrary, the generator is moved towards the motor. After completing the procedure, tighten both nuts, start the engine and check the charge at the battery terminals.

From my own experience with the generator belt, I can add that if the tension is too strong, the load on the generator bearings and pump increases, reducing their service life. Weak tension also does not bode well, since the battery may be undercharged, during which a characteristic whistle can sometimes be heard, indicating that the belt is slipping.

Generator brushes - why are they needed?

Quite often (especially in older models) there are cases when, with a sharp increase in driving speed, various seemingly inexplicable things happen: the light of the dashboard or headlights dims, the cigarette lighter and (or) radio work intermittently. Drivers who have not been hardened by many years of experience in the cold lake may mistakenly think about burnt fuses, wiring, or shorted devices. It can take a whole day or more to work through all these versions. But what will be the driver’s surprise when the true cause of the malfunction becomes clear, that the whole essence of the problem is due to some small pieces of black metal called generator brushes.

Generator device

Based on 9th or 8th grade physics lessons, everyone knows that any generator must include two main parts, one of which is movable (rotor), and the second, correspondingly, stationary (stator). Each part has a copper (in most cases) winding. Under the influence of magnetic force, the rotor begins to rotate, powered by electricity through the armature and two other metal parts. And they are called generator brushes. Due to the constant impact of friction, all parts gradually wear out due to the constant rotation of the rotor. This happens in any case, regardless of the quality of the material of the parts (and it is really strong).

How to determine the malfunction?

If, while warming up the car, you begin to notice strange actions on the dashboard (the voltmeter readings change greatly with minimal engine load or the battery charging light lights up), then this can only mean one thing - the alternator brushes are worn out and need to be replaced.

How to determine a generator malfunction

In some cases, a good warm-up of the engine allows you to “extinguish” the indicator. At the same time, the car drives on the autobahn quite calmly and normally, without any signs of malfunction. But you shouldn’t be such an optimist, because your car may break down at the most inopportune time. Don't forget to check the condition of the alternator winding and belt, although the absence of sparks and smoke suggests that the brushes are the cause of the breakdown.

Monitoring the performance of components

To perform this operation, it is necessary to remove the device from the vehicle and clean it of dirt. The verification procedure is as follows:

1. We switch the multimeter to resistance measurement mode. We install the positive probe on terminal “30”, and the negative probe on ground. Readings close to zero indicate that the bridge or generator stator has failed.
2. Positive diodes are checked by installing a positive probe on the terminal of one of the rectifier unit mounting bolts, and a negative probe on ground. Zero or close to zero instrument readings indicate that the diode bridge is faulty.
3. To check the rotor, it is necessary to measure the resistance between the slip rings. In working condition it should be within a few ohms. If the resistance is near zero, then a short circuit has occurred in the winding.

The diode bridge and other faulty elements of the generator must be replaced with new ones from spare parts.

The generator is a miniature electrical station that supplies power to many components of the car: ignition, cooling, electrical wiring. Therefore, its failure will certainly entail other malfunctions. To prevent problems, you need to have this part diagnosed and repaired from time to time.

It will be useful for any motorist to know how to check the operation of a generator in a car, but first you need to understand the possible signs of a breakdown.

Replacing brushes on a VAZ-2107 and other similar models - is there a difference?

To begin with, it is worth clarifying that generator brushes are the parts that require replacement most often. For this reason, developers create special generator designs so that the driver can make the replacement without any problems. The process of their wear is quite long, it depends on the life of the car, as well as on the intensity of the load. When purchasing a used car with a fairly high mileage, you should not wait until the parts wear out and stop functioning fully. It's better to replace it right away. Fortunately, the low cost allows this.

Replacing old parts

People who are far from the structural features of their vehicle may well think that the production of different models at the same plant makes the replacement process the same (we are talking about popular domestic models). To be honest, this guess is correct. One can say even more: almost all models with an internal combustion engine have the same replacement process.

Tip: You can install brushes from VAZ on some Audi or BMW models, and they will function perfectly. The appearance, however, is slightly different with a rougher edging, but this does not affect the operation.

Let's start the replacement process

We are gradually approaching how to carry out the replacement. The procedure is much more complicated than, say, replacing a windshield, so you initially need to protect yourself from possible electric shock. To do this, you need to disconnect the ground terminal on the battery. Despite the fact that the voltage in the electrical circuit of a car is not as high as, for example, in an electric train, even one random spark that hits you can become quite noticeable.

The location of the generator on the VAZ-2107 model and its other “colleagues” (2110 and 2114) is almost the same - it is installed in the right half of the engine compartment. In other words, it is located next to the main light on the passenger side. Moreover, there is absolutely no difference whether the car has front-wheel drive or rear-wheel drive - the developers of the Zhiguli do not change their style, adhering to their own traditions. The metal body is attached to the engine with several fastening nuts. You can recognize the generator by the flywheel and the drive belt stretched over it.

Now you need to decide on the choice of replacement procedure. For those who are not in the know, replacing generator brushes can be done in two ways:

• with removal of the generator;
• without removal.

The main difference between these methods is that after replacement you will need to adjust the tension of the drive belt. But if for the VAZ-2110 and 2114 the adjustment will not be any difficulty, then the owners of the VAZ-2107 will encounter difficulties due to the poor layout of the mechanisms. Choose the method that suits you best.

Next you need to adhere to a certain order.

Step 1. Remove the protective cover installed on the generator housing.

Remove the protective cover

Step 2: Remove the power terminal from the female connector.

Disconnection is important for safety reasons!

Step 3. In order to remove the parts of interest in this case, you need to unscrew the 2 fastening bolts. Then remove the brush holder with holder.

Don't lose the mounting bolts. They will still be useful to you.

Step 4. Conduct a visual assessment of the condition of the brushes: the protrusion from its socket should be no more than 5 millimeters. After this, make a replacement.

Visual inspection of old brushes

Step 5: Reassemble.

The final stage is reinstallation

Important! Install the brushes into the holder with extreme care and precision. They must “sit” freely in the nest.

Representatives of the automotive industry have long decided to meet drivers halfway by creating a special holder, which includes brushes and a voltage regulator. Its cost is about 150-200 rubles higher than the cost of the kit. Of course, everyone tries to save money whenever possible, but before making a purchase, think about how much you can save this way? In addition, you will not carry out such a replacement very often (in some cases, brushes are replaced only a few times during the entire period of use of the car).

The voltage regulator may also be the cause of the malfunction. Before installing the unit into the generator, connect the battery cable (positive) to the plug connector of the unit, and the negative lead to the housing. After connecting the wires, you need to connect a rheostat and a 3-volt light bulb to the brushes. If connected correctly, the light should light up. Change the voltage little by little, moving its indicator from 12 to 16 V. After you reach 16 V, the connected light bulb should go out. If the light is still on, the voltage regulator is most likely faulty.

Work order

It is more convenient to replace the brushes of the VAZ 2107 injector generator in the inspection pit. First you need to fully study the instructions on how to repair the unit in order to carry out the work without stopping to read the next step. If you are absolutely sure that it is the brushes that need to be changed, the repair can be done without dismantling the generator. The unit on the VAZ 2107 is located under the hood (on the right, next to the headlight on the passenger side). You can find it by the drive belt stretched over the flywheel. The brush assembly is located on the rear of the unit, and is secured with bolts.

Let's get started without removing the generator:

1. Disconnect the negative terminal from the battery.
2. Unscrew the fasteners and remove the assembly.
3. We check the mechanism for integrity, measure the protruding part of the brushes.
4. We change the brushes or the entire assembly.

But if this procedure is difficult, or there is a suspicion that other parts are faulty, the generator needs to be changed. Here the procedure is as follows:

We disconnect the battery by removing the negative terminal and remove the battery.

Now you need to remove the adjusting bar; to do this, first unscrew the nut.

Next, access is blocked by a protective casing; you need to move it aside, then unscrew the fastening nut of the wires at the outlet of the unit, and disconnect the wires.

The block is disconnected from terminal 61, and the nut of the lower fastening of the unit is unscrewed.

Remove the belt from the pulley, remove the bolt and bushing. The unit is now supported only by a bracket.

We lower the generator between the front axle beam and the bracket and remove it from the car.

We unscrew the brush holder bolts and remove the unit. Let's check it out. If only the brushes have become unusable, we replace them. If the whole unit is installed, install a new brush holder. Installation of brushes into the holder must be done carefully and accurately. They should fit freely into the nests.

For greater clarity of work on a VAZ 2107 to replace alternator brushes, watch the video:

Useful tips

If, before replacing the brushes, you begin to notice noise when the generator is running, then this malfunction may indicate wear on the generator bearings.

Increased play may indicate premature bearing wear. In this case, you need to replace it.

Important! Premature bearing wear can occur for many reasons, not just due to insufficient lubrication.

Often, an overtightened alternator belt leads to bearing failure.

To prevent breakdowns of vehicle systems, it is advisable to regularly check components according to the manufacturer’s recommendations. Try to create a habit of periodically inspecting the engine compartment for noise. This will avoid serious damage and solve existing problems with minimal financial costs. It’s better to do everything right than to do it “as always.” Good luck on your journey!

Video - Replacing generator brushes on a VAZ-2107

Basic problems

There are several main problems specific to a generator. If you study them, it will be quite possible to carry out repairs even on your own.

We will list them and also tell you about the necessary additional actions to eliminate them.

Your actions

To fix this problem, simply replace the old fuse with a new one. But be sure to determine the reason why the problem arose

The circuit supplying the devices has broken

In this situation, be sure to make sure that the neutral wire is connected securely to the other contacts

Having problems with the ignition switch

Check if the ignition switch board is working

The control lamp has failed

Just change the device to a new one if the lamp just burns out

You will have to change the brushes themselves, as well as their holders. Check the contacts for oxidation. They can be treated with WD40 or cleaned with gasoline

Voltage regulator does not work

This unit must be replaced. It is impossible to repair it

The alternator belt is damaged or faulty

Restoring an electric motor at a VAZ

Let's first look at how to replace the brushes of a VAZ 2107 generator. For work, we will be equipped with the following tools:

• set of spanners;
• screwdrivers - set;
• rubber hammer.

So, we begin work on changing the generator brushes on the VAZ 2107.

1. We disconnect the terminals of the battery, and also unscrew the cables from the terminals of the electric motor, dismantle it by unscrewing the fasteners. Loosen the belt and remove the electric motor.
2. Unscrew the pulley mount while holding the rotor with a tool.
3. Disconnect the traction relay.
4. After unscrewing the nuts, remove the front cover of the assembly unit using a rubber hammer.
5. We also use a rubber hammer to push the rotor out.
6. We detach the back cover from the stator.
7. We remove the brush holder from the stator and reinstall the worn parts.
8. The electric motor is assembled in the reverse order.

This process, if something is not clear, you can also visually study the video called “replacing VAZ 2107 brushes.” Replacing brushes in a VAZ 2106 generator is done in exactly the same way.

If we turn to VAZ models with front-wheel drive, then there are not so many differences in the procedure. For example, let’s first consider how to replace brushes on a VAZ 2110, for which we first take this:

• spanners;
• Screwdriver Set;
• hammer, block, or rubber-tipped mallet.

1. Having loosened the belt, disconnected the wires and unscrewed the three bolts, we dismantle the electric motor.
2. Having taken the unit out of the car, remove the pulley, holding the rotor with a screwdriver. In principle, the traction relay and rotor do not need to be dismantled; for the “seven” we did this for ease of work.
3. Next, unclip the latches on the back of the electric motor, and then remove the plastic casing.
4. We immediately see the voltage regulator assembly along with the brush holder.
5. Unscrew the two screws and remove the brush holder.
6. We renew worn parts.
7. We do the assembly in reverse.

By the way, changing brushes on the VAZ 2112 is carried out one by one according to the same instructions.

Now let’s figure out how to replace an element on a VAZ 2109.

We will need to prepare:

• set of spanners;
• Phillips and slotted screwdrivers;
• rubber hammer.

Here's what we do (this is an option without removing the traction relay).

1. After loosening the belt and removing the tensioner bar, we dismantle the entire unit.
2. On the dismantled unit, unscrew the pulley.
3. After unscrewing the nuts, remove the front cover of the electric motor.
4. Push the rotor out with a rubber hammer.
5. We detach the stator from the back of the electric motor.
6. We unfasten the diode bridge, take out our failed graphite tips and install new ones.
7. Assembly is done on the way back.

It must be said that the work of replacing brushes on a VAZ 2114 takes place in exactly the same sequence. The same applies to work on the VAZ 2115.

In general, all VAZ electric motors for generating current have almost the same design. We have only discussed different methods of how to get to the treasured details.

There is even a way without dismantling the unit. Let's say, to replace the alternator brushes on a Priora, without removing the alternator, you need to do this: take a screwdriver and wrenches and open the hood.

1. Disconnect the battery.
2. Unfasten the wires from the electric motor.
3. Remove the field circuit terminal.
4. Remove the rear plastic casing of the electric motor by unscrewing the screws.
5. Unfasten the voltage regulator, and then remove it complete with the brush assembly.
6. Now we can reinstall our parts.
7. Then you need to assemble everything in reverse order.

So, changing the alternator brushes on a Priora can be done directly on the car by opening the hood.

At the same time, it is better to change the Lada Kalina by removing the electric motor from the car. After all, it is compact and is attached to the bracket with just two bolts. Taking the same tools as in the previous case, you need to reproduce the following steps.

1. Disconnect the battery and electric motor wires.
2. Loosen the belt and unscrew the two fasteners and remove the electric motor.
3. Remove the rear casing.
4. After unscrewing the screws, remove the brush holder with the regulator and reinstall the parts.
5. Put everything back together.

These are the simple steps you need to perform to change the generator brushes on the Lada Kalina.

Repairing an electric motor at Renault

And now, in order to get a complete picture of such an important operation, let’s consider its production on a foreign car. To replace an element on a Renault Megane 2 car, we will need:

We start by dismantling the electric motor.

1. Having loosened the belt drive, unscrew the three fastenings of the unit.
2. On the removed assembly unit, remove the connector and unscrew the cable.
3. Remove the plastic cover.
4. After unscrewing the two bolts, remove the relay with the brush holder.
5. We update defective parts.
6. We do the assembly, moving back point by point.

Tools required for repairs

To work, the master will need a few tools:

• set of nozzles;
• set of spanners;
• Phillips and flat head screwdriver;
• ratchet;
• rags and penetrating liquid.

The average price for these works in car repair shops as of November 8, 2019 is 500 rubles. Not much, but self-repair will allow you not to waste time traveling and inspect the condition of the generator, battery and other related components.

On-board network problems are indicated by the battery charging arrow.

Replacing Generator Brushes VAZ 2107 Injector

Replacing brush

VAZ
2107
Welcome friends to the car repair site. Detailed instructions on how to replace the generator on a VAZ 2101, 2102, 2103, 2104, 2105, 2106, 2107 with your own hands (video). Replacing brake pads on a VAZ 2107 (rear and VAZ 2107, VAZ 2107) Replacing brushes Repairing a VAZ 2107. Duration: 21:40. Despite the huge number of foreign cars, cars of the VAZ family are still needed and used by motorists who know a lot about mechanical engineering and appreciate the advantages of the Russian automobile industry.

Of course, operation and repair are indivisible concepts, and in the event of a failure of a particular unit, fault identification and troubleshooting can be carried out completely independently. Replacement of VAZ 2107 Brush (WITHOUT REPLACEMENT). YouTube This article contains a detailed description of how to remove a VAZ 2107 generator. A step-by-step guide to removing a VAZ 2107 generator with your own hands. Replacing VAZ 2107 Engine Locks Easy and simple. Let's look at a simple example of generator

VAZ car
2107.

Malfunctions and principle of operation of generator brushes

The electrical system of your iron horse indicates a malfunction when the VAZ generator is turned off 2107. A red indicator with a battery symbol lights up on the instrument panel.

Quite often the cause is wear or freezing of the brush. Those who are familiar with the principle of operation of the generator . It is known that because of the brushes, the excitation voltage enters the valve, which not only starts the electric machine (generator) into operation, but also regulates its output power.

Generator repair

The VAZ 2107 generator is a rather complex unit, the repair of which involves partial or complete disassembly, but first the device must be removed from the car. To work you will need the following tools:

• keys for 17 and 19;
• heads for 10, 17 and 19;
• ratchet handles and knobs;
• extension with cardan joint.

Dismantling the generator

We carry out work on removing the generator in the following order:

We remove the negative terminal from the battery and disconnect all the wires coming from the generator.

Video: dismantling the generator on a “classic”

Disassembly

To disassemble the unit you need the following tools:

• spanner or open-end wrench 19;
• ratchet with extension;
• heads for 8 and 10;
• hammer.

The disassembly sequence is as follows:

We unscrew the 4 nuts that secure the back of the housing.

If the diode bridge needs to be replaced, then we perform the described sequence of actions, after which we install a new part and reassemble the unit in the reverse order.

Generator bearings

Before you start replacing generator bearings, you need to know what their dimensions are and whether it is possible to install analogues. In addition, it is worth considering that such bearings can be structurally open, closed on one side with a steel washer and closed on both sides with rubber seals, which prevent dust from entering and lubricant leakage.

Table: dimensions and analogues of generator bearings

Replacing bearings

Replacing the bearings on the “seven” generator is carried out on a disassembled device using a special puller and a key 8. The procedure is performed as follows:

On the front cover, unscrew the nuts securing the linings located on both sides and holding the bearing.

Regardless of which bearings I change on my car, I always open the protective washer and add grease before installing a new part. I explain such actions by the fact that not every manufacturer is conscientious about filling bearings with lubricant. There have been cases where the lubricant was practically absent. Naturally, such a part would simply fail in the near future. I use Litol-24 as lubricants for generator bearings.

Voltage regulator

A relay regulator, like any other device, can fail at the most inopportune moment. Therefore, it is important to know not only how to replace it, but also what options there are for this product.

Which one can I put?

Various relay regulators were installed on the VAZ 2107: external and internal three-level ones. The first are a separate device, which is located on the left side of the front wheel arch. Such regulators are convenient to change, and their cost is low. However, the external structure is unreliable and large. The second version of the regulator began to be installed on the “Seven” in 1999. The device has a compact size, is located on the generator, and is highly reliable. However, it is much more difficult to replace than an external part.

Regulator replacement

First you need to decide on the set of tools that you will need for the job:

• open-end wrench 10;
• flat screwdriver;
• Phillips screwdriver.

If you discover during testing that the device is not working correctly, you need to replace it with a known good one. To do this, perform the following steps:

If the generator has an external regulator, then to dismantle it, remove the terminals and unscrew the fasteners with a 10 mm wrench.

The voltage regulator is a part that I always carry with me as a spare, especially since it does not take up much space in the glove compartment. The device can fail at the most inopportune moment, for example, in the middle of the highway and even at night. If you don’t have a replacement regulator at hand, you can try to get to the nearest populated area by turning off all unnecessary consumers (music, stove, etc.), leaving only the headlights and headlights on.

Generator brushes

It is most convenient to replace the brushes on a removed generator, but no one specifically dismantles it. The part has catalog number 21013701470. An analogue is the brush holder from UTM (HE0703A). In addition, similar parts from a VAZ 2110 or 2114 are suitable. Due to the unique design of the internal voltage regulator, when replacing it, the brushes are also changed at the same time.

When installed in place, the brushes must fit in without distortion, and rotation of the generator by the pulley must be free.

Video: dismantling the brushes of the “seven” generator