Contents: Disassembling the generator ↓ Replacing the voltage regulator or…↓ Replacing rotor bearings ↓ Replacing additional diodes ↓
Disassembling the generator
Remove the casing 8 (Fig. 9-13) by pressing the latches that connect it to the rear cover. Unscrew the screws that secure the brush holder 12 to the rear cover together with the voltage regulator and remove it. Disconnect the wire from the "D+" terminal of the voltage regulator.
Fig. 9-13. Generator parts:
1 - pulley; 2 - washer; 3 - front cover; 4 - distance ring; 5 - rotor; 6 - stator; 7 - back cover; 8 - casing; 9 - gasket; 10 - protective sleeve; 11 - rectifier block with capacitor; 12 - brush holder with voltage regulator.
Remove the protective sleeve 10 together with the gasket 9. Remove the rectifier unit with the capacitor from the rear cover by unscrewing the screws securing the phase terminals of the stator winding and the screw securing the capacitor to the cover. After this, if necessary, you can disconnect the capacitor from the rectifier unit by unscrewing the nut securing the capacitor wire to the "B+" terminal of the rectifier unit.
Unscrew the four tightening screws and detach the rear cover 7 with the stator 6 from the front cover 3 with the rotor 5. Detach the stator from the rear cover. If necessary, remove the bushing with the rear bearing of the rotor shaft from the rear cover.
Clamp the rotor in a vice and use a socket wrench to loosen the pulley 1 mounting nut. Remove the pulley, washer 2, front cover and spacer ring 4 from the rotor shaft.
The generator is assembled in the reverse order of disassembly. The spring washer of the pulley with its convex side should touch the nut.
[Information taken from the website vazbook.ru]
Replacing the voltage regulator or brushes
The voltage regulator assembly with the brush holder is a non-separable unit. Therefore, if the voltage regulator fails or the brushes are worn out (protrude from the brush holder by less than 5 mm), the entire unit is replaced.
Replacing rotor bearings
The front bearing of the rotor shaft is pressed and rolled into the front cover. Therefore, in case of its failure, it is necessary to replace the front cover together with the bearing.
The rear bearing is pressed onto the rotor shaft. To replace it, use a puller to remove the bearing from the rotor shaft and press a new bearing onto the press.
Replacing additional diodes
To replace, unsolder the leads of the damaged diode and carefully remove it from the plastic holder, avoiding sharp blows to the rectifier unit. Then clean the diode installation site from the remains of epoxy resin, install and solder the new diode.
Solder the diode lead with the color mark to the common bus. After soldering, glue the diode body to the holder with epoxy resin.