I have a 1992 pickup 3VZ-E 4x4. I had issues where the brake light and battery light came on. Check the forums and figured it was the alternator brushes. I replaced the brush pack and put it all back together. Jumped the engine and ran it for a while. It seemed to be ok. Battery was charging and it was running fine. There was some smoke coming off near the alternator. After inspecting it, the plastic cap that covers the terminal wire on the alternator was melting/burning. I have no idea why that wire is getting so hot. Any ideas on why this is happening?

On the terminal, the order of reassembly was the terminal insulator, thin nut, install alternator in vehicle, place wire end over terminal, thicker nut, plastic protector cap.

 

You need to check it with a meter to make sure it is charging properly. Check it at idle and rev it up. Also a loose connection can cause a lot of heat, loose at the alt or a ground.

 

Did you not get the nut on the B terminal tight enough??both on the inside and out?

Is the wire coming off the B terminal of the alternator that goes to the fuse block burnt and corroded that might also cause it to heat up:jessica: