alternator wiring harness on 2004 Volkswagen Jetta TDI

TDI has 70k miles on it. There is a small plastic cover included in the plastic battery cover. The small cover (fuse box cover?) has melted a hole in it and the dealer says I need to replace the alternator wiring harness which is generating excessive heat. The cost is over $600. Why would the wiring harness generate heat, wouldn't there be another underlying issue?

by in Alvin, TX on May 26, 2010
1 answer 3 comments
ANSWER by on July 01, 2010
Had the same thing with the 2004 gas model, they used crappy wiring. It builds up resistance and heats up, hopefully your little 110 amp fuse in that box blew or you may need an alternator and or battery as well.
COMMENT by on July 15, 2010
The alternator wiring harness looks like a beast to get at and remove. Has anyone had any experience doing this themselves?
COMMENT by on October 13, 2010
I have a 03 Jetta 1.8T and I replaced the alternator cable harness and fuse box that sits on top of the battery and I also had to replace the battery to fix this problem... You can certainly do this yourself with a little patience and with help from someone. After doing all this the ABS light came on and stayed on.
COMMENT by on June 02, 2015
Just had mu 04 Jetta wire replaced and yes my abs stays on also. is there a fix?
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