VW Electrics main cables

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 not untypical state of the cable at rear of an alternator. Although most 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 has a single nut which holds the main cable from the alternator. I removed the existing corroded cable (which has been twisted around the post and clamped between two washers!!) and replaced it with a brand new 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.