VW T4 Forum - VW T5 Forum banner

T5 Alternator Charging Problem

12K views 3 replies 4 participants last post by  Edge-Effect  
#1 ·
Hello Forum, this is my first time at posting hope you can help me please,

I have a problem with the charging system on my 2008 T5 2.5 TDI.
Initialy my battery light came on so I checked the voltages at the battery with engine off and when engine running which were 12.5v and 11.8v respectivly.
Knowing what a big job it is to change the alternator I took the van in for Repair at our local Bosch Repair Center where they diagnosed and confirmed no output from the alternator and that a new one was required.

A new alternator was fitted, however after about 250miles the battery light came on again so the van was taken back in for repair again. The Repair Center was very apologetic and said the newly fitted alternator must have devolped a fault and replaced it again with no quibble.
Picked up the van tonight drove home with no battery light on.
When I got home I revved up the van and at around 3000 rpm on came the light! Slowed the engine and out went the light!
I repeated this test several times and without fail on came the battery light at around 3000 to 3500rpm and went out when the engine was slowed.
I have a brand new spare battery which I fitted but this made no difference.
It is now starting to do my head in. Is this normal or have I some other problem? anyone heard of this before?
Any ideas would be gratefully welcomed.

Cheers
 
#3 ·
Sounds like the voltage regulator, which is bolted to the alternator..
The voltage rises with the engine revs as there is no voltage regulation.
If you've got a dc voltmeter and know what you're doing, measure the volts at the battery whilst revving the engine.
The volts shouldn't get above about 14.4v. If they do you need a new voltage regulator
 
#4 ·
I'd also be inclined to check the least expensive things first like battery connections, making sure these are clean and tight. Drive belt, making sure this is in good condition and not slipping, especially at higher revs. Also bad earths can cause all sorts of weird and wonderful things with ignition and exterior lights.