9 out of 10 based on 969 ratings. 4,107 user reviews.

VW BEETLE FUSE BOX MELTING


electrical - Fuse box above battery melting - Motor
I have a 2001 VW Beetle which has a nasty habit of melting the above battery high voltage fuse box. I've replaced it three times already and replaced the alternator as well, but I'm at a complete loss as to what's causing the problem.As I understand it, there was a fundamental redesign in the cars from around 2002 onwards. Unfortunately that doesn't help you but I wonder if it is possible to retrofit the later model fuse box. Thank you for the picture, this has cleared things up. The fuse that has melted in your unit is S177 which is wired to the alternator. Apparently as the cable which goes from this fuse to the alternator gets old it begins to corrode, resistance increases as does the temperatures. The tried and tested solution amongst the VW guys and gals seems to be to replace this cable with some new, heavy duty shrouded cable to bring the resistance (and associated temperature) back down. The cable runs from this box down through the battery tray, around the back of your inlet manifold and to your alternator. Make sure you disconnect the battery before changing this cable and if in doubt, seek assistance from an auto-electrician.Best answer · 12I had to deal with this problem some years ago on a VW. What I noticed is that the fusible link ran slack, causing the connection to arc and as a result burnt out the plastic housing below. I couldn't get a fuse box so I by passed the burnt area, had a link fabricated and secured it with a bolt and nut.7Replace the wire between the alternator and the fuse box. It's called the alternator harness , but I haven't found it for sale online. It is just a simple (large) wire with two ring connectors crimped on the ends. It tends to get a break in the wire near the fuse box that then arcs and overheats; this is not a problem with a short otherwise the fuse would blow, this is an arc.6I have a 2005 Golf MKIV and it did this also. Lost a/c, fans, overheated. The B+ wire from the alternator to the battery appears to be too small a gauge. I went to a larger gauge wire and replaced the fuse block on top of the battery. It also appears that the contacts for the three green fuses are not to tight fitting. My wife's a/c went out again last week. I moved the fuse around in it's socket and the fans and a/c clutch would then go on and off. I pulled out the fuse to slightly warp the contacts for better contact and I got the ends of my finger blistered for my effort. There was also a black arc literally burnt into the fuse contact. So when you see a company marketing their fuse block as good as the original, you might want to question that. A very shabby condition for such a technologically advanced company. Just no conscience. the TDIs of late, and this too. Very disappointing. This is the only problem we have had with this car in 11 years and 112,000 miles.3An overheated electrical connection has but one cause, resistance to electron flow. Find the cause of this and fix it. The test for this is voltage drop under load. 1) Repair first. Replace all the burned parts with new high quality units, including the wire to the alternator. All bolted connections are to be torqued to specification. Consider reinforcing crimped connections with solder. All connections are to be cleaned to bright metal. Stabilant 22 will be painted on the faces of the bolted connections. Ensure that the bolted connections are not subject to vibration that could loosen them over time. Consider adding tie downs for the wires near the fuse box if none exist. 2) Now test the circuit. This will determine if the electrical resistance is fixed or is still present. Using a high quality volt meter measure the voltage loss of the circuit from the battery side of the fuse to the alternator connection. During this test the engine will need to be running and the high power use vehicle electrical systems will be on, heater blower, headlight, rear window defrost, etc This value needs to be less than 0.1 volts, but a high quality circuit will have less than 0 volts. If this value is low then repairs are complete, if not narrow the search by testing shorter sections of the circuit until the problem is located. 3) To ensure the repair over time test the circuit in the manner listed above as often as you like, as long as the voltage drop remains low the repairs are holding. If not test for and repair the connection with the elevated voltage drop.2The B+ wire is likely alright if you noticed it on time, but the problem is due to the drained battery and the bad connection around the fuse. If it was the wrong gauge or something, it wouldn't melt around the fuse but likely elsewhere or wouldn't provide enough current to cause any damage. This happened to me on 2002 Beetle a week ago. After my alternator died, I, apparently, drove on battery till it died in turn and I had to be towed. Alternators are meant to maintain battery charge and not to charge a totally dead battery as it would draw a very high current that may damage the alternator and, yes, melt the fuse. I replaced the fuse box, sanded well all the contacts, replaced 110A fuse, and greased everything up while charging the removed battery by a dedicated battery charger. The ammeter on the charger was showing very high current for a first couple of hours. While replacing $150 worth harness won't hurt, get a peace of mind and buy a battery charger to use next time alternator dies.0Replace the box. Get a 49" #4 battery cable from parts supply house. The wire will have eyelets on each end. Use one eyelet and remove the other. Replace the missing end with one with a smaller hole; I found one at tractor supply. Next remove part of the stock so the end will fit the new fuse box. The old cable is shot do not try to remove it just cut off the ends and as you follow it with the new wire use pull ties to secure. Be careful that you have all wires and plugs connected before turning on the switch. This mess is caused by bad wire ( VW & MB don't use the good stuff) then they went from a 90A to a 120A alt. with the same wire. This fix worked on my wife's 2006 tdi. Note: feel the wire if it is hot it is 1. overload 2 connection 3. bad wire.
I've got a 2002 vw beetle with a melted battery fuse panel
I've got a 2002 vw beetle with a melted battery fuse panel. 30 amp fuse that runs cooling fans and a/c gets hot and sometimes will blow. Fans have been replaced by a show and so has cooling fan module. Problem still happens with a/c compressor unplugged.
diagram: 2000 Volkswagen Beetle Fuse Box Diagram 2010 Vw Tiguan Fuse Box Diagram Somurich 2011 Jetta Melted Need a Fuse Box Diagram: Four Cylinder Two Wheel Drive 2000 Vw Beetle Fuse Box Under Hood : 34 Wiring Diagram Vw Fuse Diagram Smart Wiring Diagrams Ac Box Melted Volvo L Wiring Diagram Torzone Org. Volvo. Auto Wiring Diagram 2012 Vw Jetta Fuse Box Diagram Unique 2003 Volkswagen Volkswagen Beetle Fuse Box Youtube. Volkswagen. Auto Fuse On A 97 Dodge Stratus Starter Location, On, Free Engine 33 Impressive 2003 Nissan Altima Fuse Box Location 33 Impressive 2003 Nissan Altima Fuse Box Location 33 Impressive 2003 Nissan Altima Fuse Box Location 2005 Volkswagen Touareg Engine Diagram 2004 Volkswagen I have a 2000 Volkswagen Beetle 1.8L. I've been having ABS fault Skoda Fabia in Israel: September 2011 2005 Volkswagen Touareg Engine Diagram 2004 Volkswagen Vw Beetle Engine Tin Diagram. Images. Auto Fuse Box Diagram 2000 Porsche Boxster Engine Diagram Porsche 944 Sunroof 97 Dodge Stratus Fuse Diagram, 97, Free Engine Image For 2001 Pontiac Grand Am Radiowiring Diagram • Wiring Diagram 1999 Lexus Rx300 Fuse Box Diagram, 1999, Free Engine Image 62 Corvette Wiring Diagram 1946 Willys Jeep Wiring Diagram 97 Dodge Stratus Fuse Diagram, 97, Free Engine Image For Automotive Repair Questions : 1999 Ford E-150 has a Volvo L Wiring Diagram Torzone Org. Volvo. Auto Wiring Diagram Honda Civic Engine Wiring Diagram Torzone Org Html 05 Accord Coolant Sensor Location, 05, Free Engine Image Wiring Diagram As Well Mk4 Vw Golf VW Wiper Motor Wiring

Recent Files

toro walk behind manualbmw 2001 service manualyamaha t135 service repair manual downloadecommerce 2014 kenneth laudonpolaroid xs7 manualhyundai crawler mini excavator robex 27z 9 service manualmanual del usuario citroen c3user manual super ka plussample numeracy test for health visitors2005 yamaha yzf600r motorcycle workshop manual pdfsample test for dha dentist2004 yamaha f50 hp outboard service repair manualpreschool teacher evaluation formsamsung mv800 manualmorning meeting first gradekawasaki kx250f 2006 workshop service manual pdfhp photosmart 3210 manualsylvania smpk4230 manualsony xperia z1 manualskuyasa learnership application form 2014whirlpool 6th sense dishwasher manualtoshiba manual supportvauxhall corsa c workshop manualyamaha 40v 50h 40w 50w outboard service repair workshop manual downloadsony ericsson yari manualaeon sporty 125 180 service repair manualhonda accord manual transmission oil change2007 subaru tribeca manualnissan micra manual window winder2010 audi a4 cold air intake manualmitsubishi montero manual transmission philippinesaprilia sr50 ditech 1992 service repair workshop manualsamsung rf4267hawp service manual repair guidek9 mundial 4 manualchampion watch led manualcitroen synergie manual free downloadram manual transmission2002 yamaha v150tlra outboard service repair maintenance manual factoryexemplar memo grade11 june 2014aspire learning resources answerswestward expansion for 2nd gradepro shield hot tub manualnissan titan 2005 factory service repair manual pdfintel reader user manualsony ericsson zylo manual pdfold product manuals on webhauck viper manualgehl 802 compact excavator illustrated master parts list manual instant download beginning serial number ab00473mitsubishi shogun manual bookphilips matchline manualyamaha xj600n manualhtc desire c manual pdfhappy birthday banjo tabaapple legacy manualssuzuki rf900r 1993 1998 repair service manual pdfhonda accord manual transmission fluid checkart scope and sequence planner ausvelsyamaha yzf r7 digital workshop repair manual 1999 onwardsford ranger manual transmission problemsmiami dade public schools calendar 2014 2015clinton manual repair1989 mazda rx 7 service repair manual downloadnikon d5200 manual modehonda goldwing gl1500 aspencase se interstate service repair manual 1994 2000download polaris ranger rzr 2008 atv service repair workshop manualaccounting practice office procedures manual2002 yamaha 8 hp outboard service repair manualopel vauxhall calibra 1990 1998 factory service manual pdfcreative curriculum observation1986 yamaha l150etxj outboard service repair maintenance manual factorymeridian business phone manual2009 kawasaki klx250s klx250sf workshop repair service manualtriumph trophy 900 1200 1990 workshop service repair manualdownload now yamaha yz250f yz 250f 2008 08 4 stroke service repair workshop manualmanual d3200 nikon portuguesblakes topic bank problem solving upper primary2004 2005 honda trx450 sportrax atv repair manual pdfcummins onan dsgaa dsgab dsgac generator set with power command 1 1 controller service repair manual instant downloadfault in our stars discussion questionshitachi projector manual downloadvictory vision motorcycle service repair manual 2008 2010 downloadzaner bloser spelling connections grade 6 answerspolaris outlaw 500 atv digital workshop repair manual 2006 20075th grade articles about early explorers2011 yamaha lz250 hp outboard service repair manualgrade 10 pacesetter physical science 2014active range of motion exercises upper extremityduck dynasty coloring pages1990 mercury topaz service repair manual softwarekobelco sk135sr 1e sk135srlc 1e sk135srlc 1es hydraulic excavators optional attachments parts manual download yy04 06001 yh04 00301 s3yy02003ze01year 1 independent writing activitiescanning spam you ve got mail that you don t want jeremy poteetclark cmp 50 cmp 60 cmp 70 forklift service repair workshop manual downloadprayer for flag disposal ceremonyguess the baby weight sweepstake template2003 2005 honda vt750c vt750ca shadow aero workshop service repair manual download 2003 2004 2005mitsubishi workshop manual freeyamaha f115 jet outboard service repair manual pid range 68v 10474081066653 mfg april 2005 march 31 2006punchline bridge to algebra 42 answer keyonan jb jc engine service repair maintenance overhaul shop manual spec a t 967 07542008 yamaha f150 hp outboard service repair manualuser manual panasonic quintrixtier 1 list of wordscanon online instruction manualsmariner 2 stroke 4hp owner manualdaily grammar practice 6th gradeyamaha manual library computer related operationspro tools boom manualcommon core algebra emathinstruction keysfsson 2015 learnership intakeessential questions houghton mifflin first gradedenon dvm1835 dvd video auto changer service manualmercedes 2006 c230 service manualiveco daily manual 50c18 irisbus3rd grade homework packetseasy touch performance verification manualzenith tv remote manualdatexx user manualaccrual account reconciliation templateharman kardon hk 970 integrated amplifier repair manualmanual asus maximus iv extreme2000 yamaha mountain max 600 snowmobile service repair maintenance overhaul workshop manualyanmar 2v series engine full service repair manualmanual motor gilera smash espa olfe review manual 2014june 2014 explorations in geometry exam answerslg lmv1683st installation manualmanual for cobra microtalk2003 yamaha vz250 hp outboard service repair manualharley davidson duo glide 1961 factory service repair manualhyster spacesaver c187 s40xl s50xl s60xl forklift service repair manual parts manual2002 toyota corolla owners manualsample pageant platform essaysbmw e39 525i owners manualford 5000 tractor manualmacbook pro user manual 2011toyota manual transmission listholt chemistry section 1 energy transfer quizcrt monitor service manualnero express essentials manualblackberry manual instructionuniversity of limpopo application form 2015how to change manual transmission fluid honda civic 2002kohler command model ch745 28hp engine full service repair manualsuzuki boulevard m109r intruder m1800r 2006 to 2010 service repair manual highly detailed fsm pdf previewcraftsman 315175040 manualcat 950g service manual aryamaha yz250f full service repair manual 20062004 yamaha z200 hp outboard service repair manual2006 yamaha f115 hp outboard service repair manualover the rainbow notes piano sheetsparadoxes in mathematics stanley j farlowalpha one outdrive manualcraftsman workshop manualjaguar xk8 workshop manual 1987 yamaha fz600 service repair maintenance manual2011 bmw x3 service repair manual softwarephysical science extended response test questions1993 yamaha c30 hp outboard service repair manualstudy guide mos powerpoint 2013 examnissan car manuals free downloadpanasonic dmp bd60 bd601 bd605 bd80 series service manual repair guidevolvo ec27c compact excavator service repair manual instant downloadvolvo v70 service user manualjvc remote control manualsclymer polaris manualsfactory service manual nissan downloadford mondeo repair manualslexmark c540 series service manualmanual gilera yl 150polaris sportsman 500 6x6 full service repair manual 2003 2004canon xs manualbelarus 1025 factory parts manual2007 yamaha v star 650 custom midnight motorcycle service manualps2 slimline instruction manualkaren kingsbury summerjan 2014 c3 replacement paper2007 toyota corolla s owners manualkonica manual slrdell manual e521kawasaki gpz900r zx900 workshop service repair manual 1984 1990 1 downloadharley davidson touring 2006 service repair manualyamaha outboard 40 hp to stroke owners manualtriumph bonneville 2006 factory service repair manualomc 115 turbojet informationhonda cd125s sl125 digital workshop repair manual 1971 on2003 2012 kawasaki prairie 360 kvf 360 service repair manual instant downloadyamaha virago xv700 xv750 service repair workshop manual 1981 1997year 7 cats test papers ukyamaha vino 50 yj50 scooter 2001 2005 complete workshop repair manualsuzuki hatch with 550cc engine service repair manual 1977 1984 downloadgenesis compound bow manualmichigan pageant resume formford escape hybrid 2009 workshop repair service manual 9734 complete informative for diy repair 9734manual hyundai santa fe 2004yanmar tf50 160 tf series engine full service repair manualducati hypermotard 2013 sp workshop service manualschematic diagram manual jvc ch x550 cd changerkohler magnum model m12 12hp engine full service repair manualkubota b1750hsd tractor illustrated master parts list manualhyosung rx125 rx 125 1997 2009 repair service manual pdfsony kdl50ex645 manualgateway computer manualsgoogle nexus operating manual1985 yamaha 115etlk outboard service repair maintenance manual factorysakai r2 1 service manualbiology b1 gcse revision ocr bookletsummer activities calendar for elementarytransaction banking corporatemcgraw hill 3rd grade comprehensiondownload pro tools manualgeneral motors truck repair manualexcel fy 14 calendar templatecomponent maintenance manualrca tv manuals freemanual ipad 4 portuguesvizio manual va26lhdtv10tderbi gpr 50 r manual2005 kia amanti owners manual pdfaustin 7 haynes manualsanyo tp 1030 turntable service repair manualmy side of the mountainsony manual camera digitalricoh pro907ex manualnonlinear programming solution manuallego instruction manuals online freedownload 1995 2000 honda fourtrax 300 repair manual trx300peavey xr 600e manualcan i change my manual transmission to automatic2007 toyota camry owner manual downloadtouch of crimson sylvia dayfirst alert security keypad manual2007 toyota prius owners manual pdfphysical science physics p1 exemplar 20141991 bmw m5 service and repair manualmercury mariner jet drive 240 efi 2001 2008 workshop manual2005 yamaha f8 hp outboard service repair manualmazda rx7 manual transmission fluidmaytag neptune dryer repair manualbece news in s lyamaha outboards 1984 1996 service manuals parts catalogsrogers htc user manual1994 bmw 530i t service and repair manualchrysler 300 repair manualvauxhall opel astra belmont shop manual 1980 1995