Volkswagen 1994-95 Golf or Jetta: Low or Dead Battery

VW did such a great job of insulating the terminals on 1994-95 Golfs and Jettas that they inadvertently created some low/dead battery problems on these cars. In some cases, the eyelet connector of the wiring harness, which connects to the B+ stud of the alternator, had just enough extra insulation applied to it to keep it from making good contact. This in turn prevents the alternator from charging properly. To prevent a return trip to the battery charger, VW suggests that you disconnect the battery ground, remove the eyelet terminal from the alternator B+ stud, and remove approximately 6 mm of insulation from the terminal. Then, some die electric gel should be applied to the eyelet before re-attaching to the B+ stud with a torque of 13 Nm or 10 ft. lbs. Finally, re-attach the battery ground.

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