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Comments
I hope it goes without saying that a wire that gets hot means TOO MUCH CURRENT. However, there are many reasons why this condition may exist.
The master fusebox above the battery is KNOWN to burn up if the connections get corroded. It is a good idea to slightly loosen and then snug up every nut. (Do this several times for each nut to wipe-clean to fresh metal-to-metal contact)
The battery "+" should be directly connected to the alternator output (thru a fuse.)
Your suggestion of the battery somehow having an internal short thus drawing too much current *may* be valid. However, you are not complaining about the battery going dead so we have to assume there is no short in the electrical system.
My best-guess from your description is that the *sense* for the alternator output is not being measured correctly by the computer hence, the computer is mistakingly telling the alternator to push out WAYYY too much current. (I am assuming you have newer VW with regulator within the computer.)
Older VWs have the regulator bolted to the alternator and are MUCH less expensive than replacing the computer.
Have you used a DVM (Digital VoltMeter) to diagnose? If the output of the alternator is more than 15 volts while engine is running... THIS IS TOO HIGH for a VW. (VW electrical systems are usually around 14.7v)
Here is a link which talks about VW voltage-regulator
http://www.myturbodiesel.com/1000q/multi/alternator-troubleshooting-voltage-regu- lator-repair.htm
it's probably not a short inside the battery, which would be dangerous and can result in an explosion/toxic-chemical-release. (it would make the battery hot - wires would not get so hot - and there wouldn't be much power (if any) available from the battery for accessories/starter.
also i think the reported symptom may be nominal&expected if one is putting an mostly-not-charged battery into a car, with just barely enough power to start it, or also along with jump-starting or roll-starting. a possible way to test that idea is to charge the battery with a trickle-charger overnight. then put it in the car and see if the scalding-wire/too-much-current still occurs.
I can confirm that a 'hunting' idle could indeed be any of the items you mention. (and more)
Have you tried unplugging the electrical connector from the MAF sensor (Mass AirFlow) and then start the engine? This WILL cause the CEL (Check Engine Lite) to come on but can help isolate your issue especially if the idle is now stable.
VagCom http://www.ross-tech.com/vag-com/
I cannot believe this second hose is connected into the engine-block itself....as you surmise, there would be no reason for this.
I am thinking the second hose you describe is likely a warm-air intake. Does this second hose connect near the firewall around the exhaust? Some cars use this to draw in warm air in cold weather.
It is also possible this second hose is the PCV breather. (Positive Crankcase Ventilation)...does it connect into the valvecover?
Finally, are you certain that this second hose is not the INTAKE hose which connects towards the front of the vehicle to draw in cold-air from infront of the radiator? Nearly every fuel-injected car on the road has a cold-air-intake right from the factory. (Waste of $$ to install a CAI kit!!)
Also, you did not mention if a fan is running when the ignition is turned off... this would help to diagnose the situation.
You should have two fans.
1)One of them should run all the time when the AC is engaged. (which includes defrost mode!!)
2)The other fan should only run when the temperature of the antifreeze gets high enough to turn it on.
You need to figure out WHICH of the fans is running.... then we can have a further discussion about the possible routes to correct the situation.
In the meantime, you can test the thermal-switch to see if it is shorted. A shorted thermal-switch is the ONLY way the second fan would run all the time.
In any case, have you tried pulling the fan-relay out.... that should stop the fan from running.
The VWs I have worked on have no belt between the fans and each fan has its own relay.
The voltage was back where it should be & we were back on the road. I had an autozone tech check the alternator & tests indicated it was working fine. (I know, consider the source), but his explanation made sense.
After saying all that, it happened again, but I haven't had a chance to troubleshoot it yet. I haven't charged the battery yet & the car won't start.
Thoughts?
Can the alternator be intermittently faulty?
I didn't know there is a voltage regulator involved.
I agree I need to get a list of ills from the dealer before deciding but I need to get it running 1st.
it's also possible there is nothing wrong: if the car is mostly parked and is used only for short/few-mile trips it is expected that the battery would become discharged. to ensure a full-charge, use a trickle-charger overnight. Or, after starting it via jumper cables, drive at highway speeds for an hour or three.
What size engine is in it? Is it gas or diesel?
The signal lights, blinkers, brake lights and parking lights of my 2011 Jetta is not working. The bulbs, fuse, fuse board and even the CENTRAL ELECTRONIC CONTROL UNIT had been checked but they are all good.
Please can anyone help with a solution to this.
Regards.