Need input on fuse block on top of battery melting again...

[Turbomania]

Fuses blow for a couple of reasons. The first and most common cause is a short circuit that allows too much current to flow in that circuit thus causing the fuse to blow, interrupting that current before it causes any further damage to the wiring. The second is age and vibration with the third being bad fuses to begin with. The two 30 AMP fuses on that battery top fuse container is for the coolant fans, single speed and the ABS system. Now that's for my 99 1.8 T. The fuse arrangements may have changed over the model years so be sure and check it with someone that has personal knowledge of VW's, etc. I don't think that a blown fuse for the cooling fans or ABS would keep your car from starting so it must be something else. Question??? Do you have an after market anti theft device installed in this car? This non-start issue may be caused by the stock anti-theft device also or something else in the starting circuitry. There is also the anti-theft starter lock relay that is located on the relay panel inside under the left dash. It's on the upper auxiliary relay panel, top row, third from the left.#185 This must be checked also. There is a switch for this relay that is located on the upper portion of the clutch pedal that is activated as soon as you depress the clutch allowing for the stater to work. Auto have a park-neutral switch. These switch's may also be bad. It could also be a bad ignition switch. You need a good diagnostician with a VAG-COM scanner like the one that VW uses. Good Luck, JK

[cheer_dad]

...clarification... The fuse itself, never blew, but instead the fuse box melted around it. I have ordered the replacement part which should arrive in a day or two. There may be some other issue, but regardless this "charred" part will have to be replaced. I'm inclined (or at least hopeful) that this is my only problem with the car. The other thing to note the fuse box on the 2001 beetle turbo, has 3 X 30amp fuses. The one closest to the wiring is the one that overheated and melted the area.

If this replacement doesn't do the trick, I'll let you know.

Regards,

cheer_dad

[cheer_dad]

Unfortunately, this replacement did NOT get the Beetle running again. The part had to be replaced as it was really melted, but clearly I have another problem that the VW dealer will have to look into. My guess is starter (which bothers me a bit) since it was replaced about 4 months ago... Also, most enjoyable is the added level of grief that I'm getting from the wife... Ah the joy...

Regards,

cheer_dad

[elandem]

We have a 1998 Turbo

>>>The more I write about this problem, the more I am answering my own questions.<<<< But please read and comment.

Yesterday, my wife was driving and suddenly, the cabin filled with smoke. Not good. When I looked at it, I quickly realized that I have an in-line fuse that had melted and smoked. (A little bit of electrical smoke goes a long way.)

I have attached a picture of the fuse holder. We are not original owners, and the wire is a direct feed from the + terminal. I do not recall the amperage of the fuse, and can't tell now. <<<<Now that I've gone to look at it again, I realize that the in-line fuse holder connected directly to the battery is necessary because one of fuses holder on the the 3-fuse box on the battery was charred. Pic below>>>>>> Read on.

A little history. A few months ago, I was having trouble with the battery running down daily. I replaced the battery and it continued. I took it to my trusted mechanic and they pulled all fuses, but could not locate the cause of the drain. (Charged me nothing). It kept happening. Because that fuse looked out of place (it is on a rather large wire, and attached with electrical tape to a much smaller red wire before it drops behind the battery), I investigated it. I pulled that fuse, and noticed that the fuse holder was rather tight and seemed to compress the fuse from side-to-side (almost making it short on itself). It seemed odd. I pulled it and determined that it is for the A/C somehow. (A/C doesn't work with the fuse out). I put it back in, the A/C started working again, and the battery drain problem stopped completely. I have had no problem with a dead battery for months. Rather odd, but it is working, so I forgot about it.

When I was messing with it today, I found a smaller red wire that comes from a 3-wire junction on top of the battery <<<the one with the charred fuse holder>>>. That wire was just dangling behind the battery, attached to nothing. My assumption is that this little red wire should be connected to what the big red wire with the in-line fuse is attached to. <<Yes, it must be since the fuse holder is melted, and not operational - the in-line fuse holder was added to replace it>>>

Is my assumption correct that the wire in question that used to feed from the box on top of the battery is for the A/C? It must be since the A/C doesn't work now, and didn't work when I pulled the in-line fuse,,,,,,right? Can this assembly be reasonably replaced?