[responding to a very old thread] I was having voltage problems in my 85 westy -- freeway driving with AC and headlights on was causing battery to drain, not charge -- replaced the alternator but that really didn't fix it. Finally took the advice and checked out the power wires from the alternator -- sure enough, inside the wiring box they were totally cooked. Investigated some more, and realize just how crazy the german engineering was. Instead of putting in a single beefy wire from the alternator to the starter, they put in two(!) on a single crimp, then run these from the alternator in a spaghetti like path all the way to the left side where they meet another wire, which then reverses the course and ends up at the alternator. Bently lists the 2 from the alternator as "2.5" which junction with the one returning to the starter which is listed as "6.0". If I'm reading the diagram correctly, the entire electrical system passes through this junction to the rest of the van. I don't know what 2.5 and 6.0 represent -- doesn't seem to be mm, mm squared, gague, or amps. In any case, I'm replacing the two 2.5s with an 8 gauge and soldering the connections, which should help a bit. Anyone know if the existing "6.0" wire from the junction to the starter is indeed what feeds the entire system? Eyeballing it it looks like about an 8 gauge as well. I would also echo mark's recommendation that 85 and earlier owners check the junction box -- it just takes a minute, no tools required. On Aug 6, 2007, at 3:04 PM, Mark Drillock wrote: > If I were you I would first examine very closely the 2 red power wires > from the alternator and also follow them to their other ends. I have > seen more of these cooked than you would think. They are often > cooked at > the ends hidden inside the engine compartment wiring box. VW increased > the current capacity of this circuit by 250% in later years and that > is > what I would do on yours. Run a new 8 gauge wire from the alternator > to > the starter motor, using soldered on wire ends made for 8 gauge wire > and > 5/16 bolt hole. This will likely cure most of your problem but if you > measure the voltages at the starter motor lug first you will know how > much of the drop is there. Test unloaded and loaded, as before. > [...] > Mark |
Please note - During the past 17 years of operation, several gigabytes of
Vanagon mail messages have been archived. Searching the entire collection
will take up to five minutes to complete. Please be patient!
Return to the archives @ gerry.vanagon.com
The vanagon mailing list archives are copyright (c) 1994-2011, and may not be reproduced without the express written permission of the list administrators. Posting messages to this mailing list grants a license to the mailing list administrators to reproduce the message in a compilation, either printed or electronic. All compilations will be not-for-profit, with any excess proceeds going to the Vanagon mailing list.
Any profits from list compilations go exclusively towards the management and operation of the Vanagon mailing list and vanagon mailing list web site.