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Thread: FYI: Electrical System Issue

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  1. FYI: Electrical System Issue 
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    Audi A3 8L chassis, Golf 4 & Seat models based on VWAG A4 chassis (Golf 4) require inspection of (1) the two earth / ground points located under the engine compartment mounted battery and (2) the positive (+) primary battery circuit located at battery and primary fuse panel mounted directly on top of battery (located in engine compartment)

    the issue is corrosion of copper conductors / leading to high resistance / reduction of conductor cross section area / rapid heating / potential fire hazard

    (internal) service bulletin directs technician to inspect primary positive circuit, remove battery and inspect earth/ground threaded stud points beneath battery molded resin support tray

    clean all earth/ground brass cable/wire terminations using fine emory or production paper (280-400 grit) and if NO broken conductors or obvious green corrosion within conductors, to spray with suitable contact cleaner/preservative spray and re-install. do not over-tighten relevent stud nuts or resin tray bolts

    of particular important is condition of (1) earth/ground cable between battery post - center heavy lug - starter solenoid post

    the center lug can become badly corroded by battery acid fumes / road salt / dampness resulting in the fine multiwire core breaking down with loss of current capacity - seriously overheating...

    also of importance is primary fuse distribution panel above battery - must be free of corrosion damage - loosen fuse nuts and apply contact spray and re-tighten with care - do not over-tighten!!! - DO NOT sand tinned surfaces!

    always disconnect battery before inspecting/re-tightening primary fuses

    yes you must scan for fault codes and clear afterwards

    I am only posting because with care, diy is possible, but carelessness can easily result in expensive damage to your car...
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  2. Re: FYI: Electrical System Issue 
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    note: if there is any question as to service suitability of earth/ground cable (battery post cable) or primary fuse distribution panel - one or both components must be replaced

    DO NOT attempt to solder heavy center earth/ground lug on heavy cable if corroded or broken conductors present
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  3. Re: FYI: Electrical System Issue 
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    I do not want to do multiple posts

    would moderator please add to relevent audi tt and seat and golf 4 threads

    thanks
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