Difference between revisions of "VW Electrics main cables"
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Good connections and good cable are essential for effective charging and starting. However, after 30 years work, the main heavy-guage cables that go from alternator to starter and battery can be subject to deterioration. | Good connections and good cable are essential for effective charging and starting. However, after 30 years work, the main heavy-guage cables that go from alternator to starter and battery can be subject to deterioration. | ||
The photo below shows the not untypical state of | The photo below shows the terrible (although not untypical) state of a cable at the rear of an alternator. Most alternator connections terminate in a plug rather than like this (and possibly unseen), the cable itself can become brittle and corroded within any remaining sheath, potentially creating resistance and reducing the alternator's ability to charge. The same can happen to the cable that runs from battery to starter, reducing the starter's ability to turn the engine over. | ||
[[File:cab1x.jpg]] | [[File:cab1x.jpg]] | ||
This particular engine uses a golf alternator and has a single nut which holds the main cable | This particular engine uses a golf alternator and only has a single nut which holds the main cable. I removed the corroded cable (which has been twisted around the post and clamped between two washers!!) and replaced it with a brand new 25mm cable and soldered ring connector on the end (see photos below). | ||
Generally, when things have become this bad, the only thing you can do is replace the cables completely and solder new connectors as required. You can crimp (if you have access to oversized crimps) but soldering makes for a more reliable connection and helps seal the cable. | The vehicle is a 1.9DG and wiring layouts do vary. | ||
Generally, when things have become this bad though, the only thing you can do is replace the cables completely and solder new connectors as required. You can crimp (if you have access to oversized crimps) but soldering makes for a more reliable connection and helps seal the cable. | |||
[[File:cab2x.jpg]] | [[File:cab2x.jpg]] | ||
Revision as of 12:03, 31 May 2014
Introduction - Good Connections
(Under construction)
Intro by Covkid:
Good connections and good cable are essential for effective charging and starting. However, after 30 years work, the main heavy-guage cables that go from alternator to starter and battery can be subject to deterioration.
The photo below shows the terrible (although not untypical) state of a cable at the rear of an alternator. Most alternator connections terminate in a plug rather than like this (and possibly unseen), the cable itself can become brittle and corroded within any remaining sheath, potentially creating resistance and reducing the alternator's ability to charge. The same can happen to the cable that runs from battery to starter, reducing the starter's ability to turn the engine over.
This particular engine uses a golf alternator and only has a single nut which holds the main cable. I removed the corroded cable (which has been twisted around the post and clamped between two washers!!) and replaced it with a brand new 25mm cable and soldered ring connector on the end (see photos below).
The vehicle is a 1.9DG and wiring layouts do vary.
Generally, when things have become this bad though, the only thing you can do is replace the cables completely and solder new connectors as required. You can crimp (if you have access to oversized crimps) but soldering makes for a more reliable connection and helps seal the cable.
