Tech Tips

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Volkswagen

1994-95 Golf or Jetta - Low or Dead Battery

It seems that VW did such a great job of insulating the terminals on 1994-95 Golfs and Jettas (AL0185X, AL0186X, AL0181X, AL0184X) that they inadvertently created some low/dead battery problems on these cars.  In some cases the eyelet connector of the wiring harness, which connects to the B+ stud of the alternator, had just enough extra insulation applied to it to keep it from making good contact.  This in turn prevents the alternator from charging properly.  To prevent a return trip to the battery charger, VW suggests that you disconnect the battery ground, remove the eyelet terminal from the alternator B+ stud, and remove approximately 6 mm of insulation from the terminal.  Then, some die electric gel should be applied to the eyelet before re-attaching to the B+ stud with a torque of 13 Nm or 10 ft. lbs.  Finally, re-attach the battery ground.

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