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On 11 Feb 2004 at 22:16, Mike Wodkowski wrote: > > If you wanted to send me the generator I would be happy to look at it, but I > > realize that's not much help from this far away. You might just be better off > > exercising your Bosch warrantee, or has it expired? > > > > If you like, I could send you a good generator first. > > Well, the only problem there is I worry the redundancy of the problem is > caused by something wrong that's eluding me, and that it will take it out on > your good generator. If that's a risk you're willing to take, then I'm game. I accept the risk. I'll look at what I've got and pick a good one to send you. You'll have to remove your pulley (you're probably good at that by now) and reuse it. I just ask that you send me your old, bad one in return. Please don't disassemble it first; I want to be the first to look in there. I'll be happy to let you know what I find. I have your address already. I'll try to get one on the way to you this weekend. > I'm just going to be stymied if this turns out coincidentally to be the 4th > generator of poor quality I got from Bosch, of all places. It's > unfathomable, although the last two WERE carelessly wired... Yes, but right now, that's our best hope. > > Just a guess, but see what you can inspect where the wire runs. > > This is the problem. There's about 8" on either side (gen side or VR side) > to inspect the wires. And from what I can see, they look good. The > connectors are on tight, the insulation is unworn. Not even brittle. > And then it goes inside a harness with a whole bunch of other wires, out of > reach and out of side without destroying the harness. I've seen a car where the body was abused and rusting out. On that car some of the welds had broken and the body was sagging such that one body panel was sliding past another. It just happed that this occurred next to a hole where that harness came out, so that the harness was being sliced thru by the moving body panel. I think that car was a 70, and in 71 VW moved the location of that harness. In the early version that harness runs under the LR fender and comes into the engine compartment from the left, to the left of the pressure sensor. I suspect that location was vulnerable for several reasons, so VW moved it so that in 71- 3 it runs forward under the cargo floor. If you can, just crawl under there sometime and see if there is any evidence that there is anything chewing thru the covering of that harness somewhere. It's pretty well covered, so I think this is unlikely, but you should still check. Check it at every place where it passes thru a hole and also check the metal flaps that fold over it to hold it in place. While you're under there, check the large ground braid that runs from the front of the transmission to the body. Have you ever had trouble with getting the starter to turn? If so, this braid is a suspect. Just make sure it is in good shape. Sometimes it is helpful to loosen the nut holding it, grease the junction to limit corrosion, and retighten it. Another thing you could do would be to check the continuity of the D+ and DF wires, especially the DF wire. Disconnect them at both ends and verify that you have good continuity thru each even while you pull and flex (gently) each one. You're looking for a wire that is actually broken under the insulation. -- Jim Adney jadney@vwtype3.org Madison, WI 53711-3054 USA ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org