Diy device, purpose, diagnostics and repair of a VAZ 2101 generator

Any car, including the VAZ 2101, has two sources of power supply - a battery and a generator. The generator ensures the operation of all electrical appliances while driving. Its failure can cause a lot of trouble to the car owner. However, diagnosing a malfunction and repairing a VAZ 2101 generator with your own hands is quite simple.

Features of the VAZ 2101 generator

VAZ 2101 has two sources of electricity - a battery and a generator. The first is used when the engine is off, and the second is used while driving. The principle of operation of the VAZ 2101 generator is based on the phenomenon of electromagnetic induction. It generates only alternating current, for which a special device is used to convert it into direct current.

VAZ 2101 is considered one of the longest-lived models, largely due to the efficiency of the generator

The main task of the generator is the uninterrupted generation of electric current to maintain the performance of all electronic devices in the car, including for recharging the battery.

Technical characteristics of the VAZ 2101 generator

The generator is connected to a crankshaft pulley that drives a water pump. Therefore, in the VAZ 2101 it is installed in the engine compartment to the right of the engine. The generator has the following specifications:

• rated voltage - 12 V;
• maximum current - 52 A;
• the direction of rotation of the rotor is to the right (relative to the motor housing);
• weight (without adjustment block) - 4.28 kg.

The manufacturer installed G-2101 generators on the VAZ 221

Choosing a generator for the VAZ 2101

The manufacturer completed the VAZ 2101 with generators of the G-221 model. The maximum current strength of 52 A was enough for the operation of all standard electrical appliances. However, the installation of additional equipment by car owners (powerful acoustics, a navigator, additional headlights, etc.) led to the fact that the G-221 could no longer cope with increased loads. There was a need to replace the generator with a more powerful one.

Without any problems, the following devices can be installed on the VAZ 2101:

1. Generator from VAZ 2105 with a maximum current of 55 A. The power is enough to operate a conventional speaker system and, for example, an additional LED strip for lighting. It is installed on regular mounts for the VAZ 2101 generator. The only difference is that the regulator relay is built into the generator housing, and on the G-221 it is located separately.
2. Generator from VAZ 2106 with a maximum current of 55 A. Withstands small overloads. It is installed on standard G-221 mounts.
3. Generator from VAZ 21074 with a maximum current of 73 A. Its power is enough to operate any additional electrical equipment. It is installed on standard VAZ 2101 mounts, but the connection diagram is slightly different.
4. Generator from VAZ 2121 "Niva" with a maximum current of 80 A. The most powerful among analogues. However, its installation on the VAZ 2101 will require significant improvements.
5. Generators from foreign cars. The best option is generators from Fiat. The installation of such a device on the VAZ 2101 will require significant changes in the design of the generator mounting and its connection scheme without guarantees of high-quality work.

Photo gallery: generators for VAZ 2101

The generator from the VAZ 2105 is installed on the standard mounts of the VAZ 2101

The generator from the VAZ 2106 can withstand small overloads and is installed on standard G-221 mounts

The power of the generator from the VAZ 21074 is enough to operate any additional electrical equipment

It is quite difficult to install a generator from Niva on a VAZ 2101

In fact, it will be enough for the driver of the VAZ 2101 to install a generator from the "six" or "seven" to satisfy all their electricity needs. Even with complex tuning, a power of 60–70 amperes is enough to maintain the operation of all devices.

Wiring diagram for a VAZ 2101 generator

The connection of the VAZ 2101 generator is carried out according to a single-wire scheme - one wire from the generator is connected to each device. This makes it easy to connect the generator with your own hands.

The connection of the VAZ 2101 generator is carried out according to a single-wire circuit

Features of connecting the VAZ 2101 generator

Several multi-colored wires are connected to the VAZ 2101 generator:

• the yellow wire goes from the control lamp on the dashboard;
• a thick gray wire goes from the regulator relay to the brushes;
• thin gray wire goes to the relay;
• the orange wire acts as an additional connector and is usually connected to a thin gray wire during installation.

Incorrect wiring can cause a short circuit or power surges in the VAZ 2101 electrical circuit.

For ease of installation, the wires for connecting the VAZ 2101 generator are painted in different colors

Generator device VAZ 2101

For its time, the design of the G-221 generator turned out to be quite successful. It was installed without modifications on subsequent models of the plant - VAZ 2102 and VAZ 2103. With proper maintenance and timely replacement of failed elements, it could be used for many years.

Structurally, the G-221 generator consists of the following main elements:

• rotor;
• stator;
• regulator relay;
• semiconductor bridge;
• brushes;
• pulley.

The G-221 generator is attached to the engine on a special bracket. This allows you to firmly fix the device and at the same time protect it from high temperatures.

The bracket firmly fixes the generator even when driving on rough roads

Rotor

The rotor is the moving part of the generator. It consists of a shaft, on the corrugated surface of which a steel sleeve and beak-shaped poles are pressed. This design serves as the core of an electromagnet rotating in two ball bearings. The bearings must be of the closed type. Otherwise, due to lack of lubrication, they will quickly fail.

The rotor (armature) is the moving part of the generator

Pulley

The pulley can be considered as part of the generator, as well as a separate element. It is mounted on the rotor shaft and can be easily removed if necessary. The pulley, when the engine is running, is rotated by the crankshaft through the belt and transmits torque to the rotor. To prevent the pulley from overheating, there are special blades on its surface that provide natural ventilation.

The alternator pulley is driven by the crankshaft through a belt

Stator with windings

The stator consists of a number of special plates made of electrical steel. To increase resistance to loads in four places along the outer surface, these plates are connected by welding. A winding of copper wire is laid on them in special grooves. In total, the stator contains three windings, each of which consists of two coils. Thus, six coils are used to generate electricity by the generator.

The stator consists of plates made of electrical steel, on which a winding of copper wire is laid.

Regulator relay

The regulator relay is a small plate with an electrical circuit inside, designed to control the voltage at the output of the generator. On the VAZ 2101, the relay is located outside the generator and is mounted on the back cover from the outside.

The regulator relay is designed to control the voltage at the output of the generator

Brushes

The generation of electricity by a generator is impossible without brushes. They are located in the brush holder and are attached to the stator.

Only two brushes are fixed in the brush holder of the G-221 generator

Diode bridge

The rectifier (or diode bridge) is a horseshoe-shaped plate with built-in six diodes that converts alternating current to direct current. It is important that all diodes are in good condition - otherwise the generator will not be able to provide power to all electrical appliances.

The diode bridge is a horseshoe-shaped plate

Diagnostics and troubleshooting of the VAZ 2101 generator

There are a number of signs and signals by which you can determine that it is the generator that is faulty.

The charging indicator lamp lights up

On the dashboard of the VAZ 2101 there is a battery charging indicator. It lights up when the battery charge is close to zero. This, as a rule, occurs with a faulty generator, when electrical appliances are powered from the battery. Most often, the light bulb lights up for the following reasons:

1. Slippage of the V-belt on the alternator pulley. It is recommended to check the tension of the belt, and in case of severe wear, replace it with a new one.
2. Failure of the battery charging indicator relay. You should check the health of the relay with a multimeter.
3. Break in the stator winding. It is necessary to disassemble the generator and clean all its elements.
4. Severe brush wear. You will need to replace all the brushes in the holder, even if only one of them is worn out.
5. Short circuit in the diode bridge circuit. It is necessary to replace a burned-out diode or the entire bridge.

The battery indicator lights up when the battery charge is close to zero.

The battery does not charge

One of the tasks of the generator is to recharge the battery while driving. If this does not happen, you should pay attention to the following points.

1. Slack V-belt. It needs to be adjusted or replaced.
2. Loose wire lugs connecting the alternator to the battery. Clean all contacts or replace damaged tips.
3. Battery failure. It is checked and eliminated by installing a new battery.
4. Damage to the voltage regulator. It is recommended to clean all contacts of the regulator and check the integrity of the wires.

The problem with the lack of battery charge is most often associated with a malfunction of the battery itself.

Battery boils away

If the battery starts to boil away, then, as a rule, its service life is coming to an end. In order not to risk a new battery, it is recommended to pinpoint the cause of the boil. It could be:

1. Lack of constant contact between the generator voltage regulator housing and ground. It is recommended to clean the contacts and replace them if necessary.
2. Short circuit in the regulator. The voltage regulator needs to be replaced.
3. Battery failure. A new battery should be installed.

If the battery starts to boil away, it will need to be replaced in the near future

Loud noise while driving

The VAZ 2101 generator is usually quite noisy. The reason for the noise is the presence of contacting and rubbing elements in the design of the generator. If this noise became unusually loud, there were knocks, whistles and roars, it is necessary to identify the cause of such a situation. This is usually associated with the following problems.

1. Loosening the fixing nut on the alternator pulley. Tighten the nut and check all fastener joints.
2. Bearing failure. You will need to disassemble the generator and replace the bearings.
3. Short circuit in the stator winding. The stator assembly needs to be replaced.
4. The creak of brushes. It is recommended to clean the contacts and surfaces of the brushes.

Any extraneous noise from the generator is a reason for troubleshooting

Checking the performance of the VAZ 2101 generator

The output and building of the generator is a rather unpleasant situation. Experts recommend periodically (at least twice a year) to assess its performance to determine the remaining resource.

It is impossible to check the operability of the generator on the VAZ 2101 when disconnected from the battery while the engine is running, since there is a high probability of a power surge.

This can be done both at the stand in the service station, and with the help of an oscilloscope. However, no less accurate results can be obtained in garage conditions using a conventional multimeter.

Checking the generator with a multimeter

To test the generator, you can use both an analog and a digital multimeter.

The specificity of the check does not allow you to work alone. Therefore, it is necessary to invite a friend in advance, since one person will have to be in the cabin, and the other will control the readings of the multimeter in the engine compartment of the car.

You can check the performance of the VAZ 2101 generator using a multimeter

The verification algorithm is extremely simple and consists in performing the following steps.

1. The multimeter is set to DC current measurement mode.
2. The device is connected to the battery terminals. With the engine off, it should show between 11.9 and 12.6 V.
3. An assistant from the passenger compartment starts the engine and leaves it to idle.
4. At the time of starting the engine, the readings of the multimeter are recorded. If the voltage drops sharply, the generator resource is negligible. If, on the contrary, the voltage jumped (up to about 14.5 V), then the excess charge in the near future will lead to the battery boiling away.

Video: checking the VAZ 2101 generator

How to check the VAZ generator

The norm is a small voltage drop at the time of starting the motor and a quick recovery of performance.

DIY VAZ 2101 generator repair

Do-it-yourself repair of the VAZ 2101 generator is quite simple. All work can be divided into five stages:

1. Dismantling the generator from the car.
2. Generator disassembly.
3. Troubleshooting.
4. Replacement of worn and defective elements with new ones.
5. Assembly of the generator.

First stage: dismantling the generator

To dismantle the VAZ 2101 generator, you will need:

• open-end wrenches for 10, 17 and 19;
• mounting blade.

Before dismantling the generator, it is necessary to disconnect the negative cable from the battery

To remove the generator, you will need to perform the following steps:

1. Remove the right front wheel from the vehicle.
2. Securely fix the car on the jack and additional supports.
3. Crawl under the car on the right side and find the generator housing.
4. Loosen, but do not completely unscrew the housing fixing nut.
5. Loosen, but do not completely unscrew the nut on the bracket stud.
6. To loosen the V-belt, slightly move the alternator housing.
7. Disconnect the power cable going to the generator.
8. Disconnect all wires and contact connections.
9. Remove the fixing nuts, pull the generator towards you and remove it from the studs.

Video: dismantling the VAZ 2101 generator

How to remove the generator VAZ 2101 - VAZ 2107

Second stage: generator disassembly

The removed generator should be wiped with a soft cloth, clearing the main layer of dirt. To disassemble the device you will need:

• open-end and box wrenches for 19;
• extension;
• heads for 8 and 10;
• a hammer.

Before disassembling the generator, it is best to prepare small containers for storing washers, screws and bolts. Because there are a lot of small details in the design of the generator, and in order to understand them later, it is better to classify the elements in advance.

Disassembling the VAZ 2101 generator is quite simple

The disassembly itself is carried out in the following order:

1. Unscrew the four nuts on the rear cover of the generator.
2. The nuts securing the pulley to the housing are unscrewed.
3. The pulley is removed.
4. The body is divided into two parts (the stator will remain in one, the rotor will remain in the other).
5. The winding is removed from the part with the stator.
6. A shaft with bearings will be pulled out from the part with the rotor.

Further disassembly involves pressing out the bearings.

Video: disassembly of the VAZ 2101 generator

Third stage: generator troubleshooting

At the troubleshooting stage, malfunctions of individual elements of the generator are identified and eliminated. At the same time, part of the work can be performed at the disassembly stage. Particular attention should be paid to:

• traces of wear on the surfaces of parts;
• the appearance of soot on wires and contacts;
• the presence of dirt and working fluids inside the generator housing;
• cracks, notches and other mechanical damage to parts.

All damaged and worn elements must be replaced with new ones.

When troubleshooting, you do not need to pay attention to the generator case: after several years of service, it may have an unsightly appearance, but at the same time it is good to protect the inside of the device

Fourth stage: generator repair

The complexity of repairing the G-221 generator lies in the fact that it is difficult to find spare parts for it. If bearings can still be purchased on the Internet, then it will be very difficult to find a suitable winding or rectifier.

Video: VAZ 2101 generator repair

VAZ 2101 GENERATOR REPAIR DISASSEMBLY, CLEANING, REPLACEMENT OF PARTS

"Kopeyka" left the factory assembly line in 1970. Mass production ended in 1983. Since Soviet times, AvtoVAZ has not produced spare parts for the repair of a rare model.

Therefore, the list of situations for repairing a VAZ 2101 generator is very limited. So, when the bearings are jammed or the brushes are worn out, replacement elements can be easily found in car dealerships.

Alternator belt VAZ 2101

In classic VAZ models, the generator is driven by a V-belt 944 mm long. A 2101 mm long belt can also be installed on the VAZ 930, but other options will no longer work.

The factory equipment of the generator implies the use of a belt 2101-1308020 with a smooth surface and dimensions of 10x8x944 mm.

The old-style VAZ 2101 generator belt has a smooth surface

The alternator belt is located in front of the car and connects three pulleys at once:

• generator pulley;
• water pump pulley;
• crankshaft pulley.

How to properly tension the alternator belt

When replacing the alternator belt, it is extremely important to properly tension it. Any deviation from the norm will affect the operation of the VAZ 2101 electrical appliances.

To tension the belt of the VAZ 2101 generator, use a crowbar, spatula or a thick screwdriver

The reasons for replacing the alternator belt are:

• the appearance of cracks and signs of severe wear on the belt;
• broken belt;
• manufacturing defects.

To replace the belt you will need:

• mounting blade (or metal crowbar);
• wrenches 17 and 19.

The work is carried out in the following order:

1. Install the alternator in place by half-tightening the two fastening nuts. It is necessary to tighten the nuts until the stroke of the generator housing does not exceed 2 cm.
2. Insert a pry bar or spatula between the generator housing and the water pump housing.
3. Put a belt on the pulleys.
4. Without relieving the pressure of the mount, tighten the strap.
5. Tighten the top nut of the alternator.
6. Check belt tension. It should not be too tight or, conversely, sag.
7. Tighten the bottom nut.

Video: VAZ 2101 alternator belt tension

How to tension the alternator belt.

To make sure that the belt has a working degree of tension, it is necessary to sell its free space with your finger after completion of work. Rubber should give in no more than 1.5 centimeters.

Thus, even an inexperienced motorist can independently diagnose a malfunction, repair and replace the VAZ 2101 generator. This does not require any special skills or exclusive tools. However, one should not overestimate one's strength either. It must be remembered that the generator is an electrical device, and in the event of a mistake, the consequences for the machine can be quite serious.