Charging system issues

Hi,

It sounds like the alternator is over charging. Do me a favor. Follow this link for testing an alternator. Let me know what voltages are found with the engine running.

https://www.2carpros.com/articles/how-to-check-a-car-alternator

The voltage regulator is integral in the alternator. Let me know what is found. Also, I need to know if the battery was going dead after sitting.

Let me know.
JOe

What was the voltage with the engine running? Also, are you certain all connections are tight? I know that sounds crazy, but a loose connection can cause an arc which causes heat.

Joe

Okay. If your connection was tight, then I have to expect something internal in the alternator was causing the arc. Make certain that the alternator they are providing it the correct one for your vehicle.

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Here are the directions specific to your vehicle. Just adding them so you can confirm nothing was done differently.

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Generator (GEN) - 4-cylinder gasoline engine, removing and installing

CAUTION:

Before beginning repairs on the electrical system:
- Obtain the anti-theft radio security code.
- Switch off all electrical consumers.
- Switch off ignition and remove ignition key.
- Disconnect negative ( -) battery terminal.
- When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks.

Special tools, testers and auxiliary items needed

pic 1

- VAG 1331 Torque wrench (or equivalent 5 - 50 Nm)

REMOVING

1. Disconnect battery.
2. Remove ribbed belt.
3. Remove ribbed belt tensioner.
Tightening torque. 25 Nm (18 lb ft)

pic 2

4. Remove nut from terminal 30/B+ connection
Tightening torque. 15 Nm ± 1 Nm

5. Disconnect electrical connector -2-.
6. Remove harness retainer -3-.
7. Remove M8 hex bolts (generator to bracket)
Tightening torque. 25 Nm (18 lb ft)

8. Lift generator out from engine compartment.

INSTALLING

Install in reverse order of removal, noting the following:

pic 3

- Where applicable, drive threaded sleeves -A- approx. 4 mm in direction of -arrow.

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Again, it's even possible the wrong alternator is being use that doesn't provide enough amperage.

Let me know.
Joe

I have been doing more research on your vehicle and came across this. It indicates the importance of the torque of the wire you are having trouble with.

Take a look through this and the attached pic.

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2002 Volkswagen New Beetle GL (1C1) L4-2.0L (AVH)
Mechanical (including Torque)
Vehicle Starting and Charging Charging System Alternator Specifications Mechanical (including Torque)
MECHANICAL (INCLUDING TORQUE)
Generator, B+ connection

pic 1

Securing B+ wire to generator

CAUTION!
If the B+ wire terminal nut is not torqued as specified, the following may result:
- Battery will not be completely charged
- Vehicle electrical system malfunctions
- Danger of sparking
- Damage to electronic components and control modules due to voltage spikes

The tightening torque for the B+ wire (arrow) securing nut is 15 Nm (11 ft lb).

Let me know if this helps.
Joe

See pic 1 for the two primary from the battery. Pic 2 shows that the alternator is grounded through its mount to the engine.

Let me know if this is what you needed.

Joe