I had a similar prob last summer.
As it turns out the ground wire on the harness leading to the Coil pack went
bad.
All I did was splice a new ground into it and grounded it to the engine.

Mark Reda.

----- Original Message ----- 
From: "Eric Schumacher" <[email protected]>
To: "Chad Rebuck" <[email protected]>; "16v"
<[email protected]>
Sent: Thursday, July 10, 2003 9:44 PM
Subject: Re: [a2-16v-list] ground connections and hot wires


> Hello Chad
>
> Usually VW does both in modern cars, connect both to chassis and run a
> brown wire. Even body grounds can have surprising resistance.  Having the
> wire there makes individual points redundant. Any wire that gets hot
should
> be looked into.  Often it is not the wire but rather the lug/wire
> interface.  The copper wire is quite conductive of heat so it gets hot for
> quite a distance from the lug.  Also, for reasons totally unknown to
> me,  The wire VW uses can sometimes develop a rather high resistance. Best
> thing is to go around with your voltmeter and measure the drops across
> wires, lugs, connector pins, etc and see where the voltage drop
> occurs.  Use a needle or something sharp to access the wire about an inch
> from the lug.  A systemic approach to finding the actual problem then
> replacing the deficient interface will keep the lights bright and the
> blower blowing hard.
>
> Lotsa Luck Eric
> 85 GTI with VR6 Power
>
> At 08:37 AM 7/9/03 -0400, Chad Rebuck wrote:
> >I have replaced the stock battery terminals and run some additional
ground
> >cables to the engine and body.  I've noticed that a ground wire (maybe
8 -
> >10 gauge) is connected directly to the battery, which I think comes from
> >the fuse/relay block ground terminal.  This wire gets hot when the ac fan
> >is on speed 3 or 4.  Why would vw run a separate ground connection
instead
> >of grounding to the chassis or ground point next to the fuse block?  I am
> >suprised the insulation on this wire is still there - maybe it is because
> >more current is flowing through the system with my upgraded connections
at
> >the battery?
> >
> >Chad
> >
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>
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