The vehicle is a 1995 Passat GLX VR6. I just replaced the alternator on it. The old alternator was ok except that I cracked one of its mounts when I was trying to remove a spacer from it--dumb move on my part. Anyways, I just went ahead and bought a new rebuilt alternator.

Car starts fine but the new alternator heats up rapidly, within a few minutes to the point were its to hot to touch, smells like its burning, and I started to see smoke. I immediately shut everything down and began to troubleshoot.

This is my process so far:

Battery was charged before new alternator installed.

Did load test on battery--while its not perfect it was just a hair under ok om the load tester meter.

I checked all battery connections then did a voltage drop test, batt positive to B+ terminal voltage drop was .11v and negative alternator to negative on battery was .05 volt. So passed voltage drop test.

Battery Voltage 12.7V, Battery Charging Voltage with car running about 12.5 to 12.7 per vag-com--this is not right should be 13.5V to 14V I think.

Next step if I had the tool would be an amperage test to check the current output from the alternator.

Anyone have an other thoughts? I am thinking I might have to remove the alternator and have it bench tested.

Tim