Any friction pairs in a car require periodic replacement, therefore they are considered consumable (non-repairable) parts. The battery only starts the internal combustion engine, after which the generator begins to generate electricity for the on-board system and recharging the battery.
Rice. 1 Replacing the generator belt tension system roller
Therefore, the level of battery recharging depends on the quality of the belt tensioner, which transmits speed to the generator shaft, that is, whether the car will start after stopping the engine next time. The main “consumable” – the generator belt tensioner roller – can be replaced by the car owner on his own if he knows where it is located and what parts need to be removed before doing so.
General information and site resource
Our machine uses an automatic belt tensioner. Same for engines 1.4 and 1.6. Convenient, no need to worry about checking the tension and tightening the belt. But it also has disadvantages.
- Low resource for such a node. Not for all cars. Details below.
- Quite a high price. A good analog costs about the same as the original. Cheap takes are wasted money.
According to repair statistics, everyone's resource is different. Moreover, there is no connection with the year of manufacture or engine size. It has been noticed that if the lower right plastic protection is missing or broken, the service life is shorter, and on machines without air conditioning, other things being equal, the service life is always longer.
Plastic right guard extends the life of the tensioner
The main problems are in the range of 60,000 - 180,000, but it should be noted that there are cars with mileages of 200,000 - 300,000.
Interesting fact: on the new Solaris 2 with a 1.6L engine, the automatic tensioner was abandoned. The belt began to be tensioned the old fashioned way by a generator.
Solaris 2 with 1.6l combustion engine, belt tensioned by generator
Typical generator failures
A car generator is a rather complex device, including various parts, components and mechanisms. But if we talk about breakdowns of this unit, they happen mainly not with internal, but with external parts and components.
One of the most common malfunctions in the operation of a car generator is usually considered to be damage to the drive belt. Moreover, the weakest point is not the circuit itself, which has a fairly large margin of safety, but the generator belt tensioner roller, which needs replacement over time.
It would seem like a very insignificant detail, which is also very inexpensive (the cost of tension rollers will be discussed below), but what a great significance it has! This article will discuss whether it is possible to replace the generator belt tensioner roller with your own hands and how to correctly carry out this procedure.
Why does the belt whistle, rustle, and squeak?
In most cases, the belt squealing is due to the tensioner, not the roller bearing or the belt itself. Dirt and dust from our roads gets inside the part and leads to wear.
The central hole has a groove
The tensioner housing halves move apart
Pay attention to the mark left by the belt. You can see from the development on the video that the right edge is darker than the central part. The planes of operation of the roller and belt do not coincide. This occurs due to wear on the tensioner itself. This is how a whistle and squeak appears from the belt. It can either appear or disappear. But over time it will become permanent.
Is it dangerous? If you drive for a long time with a whistle, the following will happen: the belt begins to move more and more along the roller, part of it simply slides off the edge. Eventually it will fly off or be torn. It happens this way and that. IF YOUR BELT HAS FELL OFF, YOU CANNOT CONTINUE DRIVING! The pump is driven by a belt; without it, the engine will quickly overheat.
We tell you more about wear and tear in our video.
Which bearing grease to choose?
The global market is replete with lubricants produced by well-known companies and start-up industries.
The following holdings achieved the greatest success in this:
1. Castrol Limited
3.British Petroleum
The first company has a wide range of synthetic and traditional materials with good lubricating properties, which are designed for cars, motorcycles and various trailers. Their products are characterized by an innovative spirit focused on customer needs. The company's engineers are constantly looking for new solutions in the field of lubrication.
Luqui Moly is a German brand and is known to many for its oils, additives and other auto chemicals. Operating since 1957 and gaining worldwide recognition, the company is a leader in this field in Europe. Its two largest factories are located in Ulyem and Saarlouis.
British Petroleum is a British holding company that has existed since 1909. The board focuses the activities of the huge structure on oil and gas production, and the associated production products are lubricants.
Valvoline is one of the oldest manufacturers of automotive oils and viscous mixtures for bearings. It began in 1866. Now the headquarters is in London. The products are distinguished by bio-based developments that have the least impact on nature.
Mobil is an American brand specializing in fuels and lubricants. In the United States alone, the company has more than 400 stores.
Replacing the belt tensioner
The replacement is simple. You can change it from above, through the engine compartment. So they change it to a hundred. But if you decide to do everything yourself, without experience it is better to do it from below the car. First you need to remove the right plastic protection.
4 bolts for 10, if there is metal protection you will have to remove it too
Now you will need a 14mm wrench to move the roller away and loosen the belt tension so that you can remove it.
A long key of 14 is much more convenient
We pull the key up, the roller is pressed from the belt to the engine shield
When the tension weakens, remove the belt from the generator pulley
Now you can unscrew the tensioner itself
Assembly is carried out in reverse order.
Belt installation diagram for cars with air conditioning
Which bearing grease to buy
To choose the right lubricant, you need to determine the place of its use and the temperature regime of this unit. An important role is played by the amount of moisture entering and shock loads.
Therefore, the choice of lubricant can be summarized as follows:
1. For construction equipment whose bearings are subject to severe vibration and overload, Mobil Mobilgrease Special is best suited.
2. Where temperatures are high, for example, in blowers and various heaters, it is worth applying Fuchs Titan Renolit Duraplex EP2 to their bearings.
3. For industrial machines, BP Energrease LS-EP 2 will be sufficient, which will not fall out, and one package will last for a long time.
4. For car hubs, you should use the expensive but time-tested Luqui Moly LM 50.
5. In very humid conditions, such as for equipment in car washes or equipment that is washed frequently, VALVOLINE MOLY FORTIFIED MP GREASE is suitable.
6. For construction tools where vibration and pressure are frequent, Castrol LMX Li-Komplexfett will be reliable.
Tensioner roller
When the bearing in the roller wears out, you will not hear a whistling noise. Severe wear reveals itself as increased noise when the motor is running.
Exactly the same noise can be made by the bearing of the generator, power steering and idler roller. The air conditioner pump and compressor sound a little different.
You can try to determine the source of the noise yourself. To do this, just remove the belt. How to do this is described above. When the belt is removed, all pulleys are accessible. Now you can twist and swing them. A serviceable bearing spins quietly, a worn one makes rustling and noise. There should also not be much play.
If the bearing on the roller is worn out, then unscrew it clockwise, the thread is reversed!
Next you have a choice: change the entire roller, or simply replace the bearing. If the pulley itself is not worn out, only the bearing can be replaced. Articles of verified manufacturers: 6203ZZCM (NSK), 62032RSH (SKF), 62032RS, 6203ZZC3 (KOYO), 6203LLU, 6203ZZC35K (NTN/SNR).
Bearing dimensions: outer diameter 40mm, inner 17mm, width 12mm
According to the video, the situation is as follows. It would seem that take the original and close the question. But this is the biggest risk because there are a lot of counterfeits. The packaging and appearance of the part today do not differ from the original. Below are the brands of rollers tested at service stations. Low quality for SAT, AMD, ASVA, AMIWA, DAYCO, FEBEST, JUST DRIVE, NSP, PARTS MALL, PATRON, STELLOX, UNITED MOTORS. Good quality GATES, GMB, NTN/SNR, SKF.
The best bearing lubricants for general loads
Such mixtures are intended for friction components of bicycles, mopeds or electric motors at low speeds. They can be pushed into machines in production or used in rotating devices in private workshops. They are also good in agricultural machinery.
The substances in their composition are designed for low temperatures and loads. Here are the best general purpose lubricants, according to users.
BP Energrease LS-EP 2 – for machine tools
This product from British Petroleum is based on highly refined oils with oxidation inhibitors and anti-friction components. Universal lubricant can be used everywhere, but it is best suited for machine tools of any purpose (lathes, milling), as well as conveyor mechanisms. Manufacturers recommend it for all equipment for textile, woodworking, paper and plastic products.
The lubricant has good pumpability and shows resistance to shear or vibration on bearings. The product has good viscosity, and its breakdown into oil and additives begins only after 18 hours of continuous operation at a temperature of 40 degrees. But the drop begins already at the thermometer mark of 195 degrees, so the maximum temperature limit of the lubricant is 140.
Advantages:
- versatility of the product;
- easy to pump;
- does not fall out during shifts;
- resistant to decay.
Flaws:
- small temperature range;
- The minimum packaging volume is 15 kg.
Luqui Moly LM 50 – the best for hubs
German developers have created a lithium complex-based grease with good extreme pressure properties. This product can be used in a variety of applications, including central distribution systems, but is best used for hub lubrication. The composition is resistant to water, which is important for wheels. The product does not quickly become soft and remains in the bearing for a long time.
Anti-corrosion properties protect the metal on the rotating elements of the hubs. The temperature range varies from -30 to +160, which is good for wheels. The product promotes high loads on rotating parts while ensuring minimal wear from friction and pressure. This German lubricant retains all its properties for a long time when other similar substances age. Disintegration into oil occurs after 18 hours of operation. Viscosity corresponds to DIN 51562.
Alternative to tensioner
Another option is to switch to manual belt tensioning. To do this, you need a generator bracket and a mechanical tensioner itself. Kit article number 37460-2B006. Using this number you can order it in any online spare parts store. Approximate price from 1200 rub. You will also need a different size belt 6pk2075.
Mechanical tensioner
This is what it looks like
Keep in mind that the belt must be of high quality, as this option is demanding in terms of tension. Cheap belts stretch out very quickly. At our service station we use GATES.
The best lubricants for bearings under special loads
Such lubricants have a lower kinematic viscosity, which allows them to better penetrate between the rubbing elements, maintaining sliding and preventing wear. Manufacturers add special additives to their composition to improve their quality. This has found its way into construction machinery and equipment as well as racing vehicles.
Mobil Mobilgrease Special – for construction equipment
This American product is designed for use in bearings subject to constant vibration. Often such loads are experienced by excavators and cranes on construction sites or mining equipment. In its composition, the developers used molybdenum disulfide, due to which the wear of parts becomes minimal. To prevent the mixture from leaking out of the rotating units, lithium hydroxystearate was used. The thick consistency allows the product to be securely held inside the bearing.
Thanks to its thoughtful composition, the product well protects metal elements from corrosion, as well as wear during translational or oscillatory movements. The optimal application is bearings and hubs on truck chassis. But this lubricant will leak if the metal temperature rises above 130 degrees. Therefore, regular monitoring and refilling of the product is required.
Advantages:
- protects well from corrosion if moisture gets into the unit;
- lithium based thickener;
- designed for vibration and fluctuations;
- The consistency is convenient for pumping.
Flaws:
- low temperature range (from -20 to +130);
- fast consumption;
- price.
Fuchs Titan Renolit Duraplex EP2 – for high temperatures
This grease combines selected oils and lithium soap thickeners. The developers have introduced an additional package of additives into it, which gives the mixture stability and stability at extreme operating temperatures arising from high speeds and strong friction of the weight of the structure rotating on bearings. This lubricant is best suited for hot air blowers and electric motors from large industrial machines.
It also has good anti-corrosion properties. Water resistance does not allow the lubricant to be washed out when cleaning equipment with a stream of water under pressure. The mixture has good colloidal stability at a temperature of 80 degrees for 18 hours.
Typically it can be used in the range -30 to +160. If temperatures are briefly exceeded up to 200 degrees, nothing will happen, since the drop of the substance starts at 250. Packaging can be 400 and 500 grams or 25 and 180 kg for wholesale purchases by large enterprises.
Advantages:
- additional additive package;
- work at temperatures up to 200 degrees;
- colloidal stability at 18 hours;
- waterproof;
- large selection of packaging sizes.
Flaws:
- soap as a thickener;
- The tube is not very convenient for driving grease into the bearing.
VALVOLINE MOLY FORTIFIED MP GREASE – where it is very humid
Products from Dutch developers received an EP complex of additives that reduce friction, and molybdenum disulfide was taken as the basis. Its most important advantage was its high resistance to water. It does not oxidize when washed under pressure, does not get knocked out of components and reliably blocks the access of corrosion. This lubricant also performed well under shock loads. Its beneficial mechanical properties are maintained for a long time.
This composition allows it to be used in bearings of industrial equipment, agricultural machinery and cars, which are operated in conditions of increased humidity.
Manufacturers were able to achieve record temperature values for this product, ranging from -150 to +1200 degrees. The black-gray substance can easily become lodged in the bearing.
Advantages:
- high temperatures;
- designed for high humidity;
- promotes the transfer of shock loads;
- wide application in technology;
- anti-scuff properties;
- cheap;
- variety of packaging.
Flaws:
- Despite the water resistance, they require a dust cover.
Cross device
As you may have already guessed, this detail looks like a cross. Yes, the core is made in the shape of a cross, cylindrical cups are put on all 4 ends of this cross, inside these cups there is a bearing called a needle. Because it is not balls that spin in it, but thin steel cylinders - needles.
To prevent dust from getting into the needle bearing, there is a rubber or plastic ring between it and the cross, called an oil seal or cuff. Although the sizes of the spiders vary, depending on the make, model and size of the machine. In terms of their structure, they are the same.
