I've looked through the service manual and parts book and can't seem to identify a cable coming off the alternator (pic below-not mine, a non-melted version). The circled part on mine has melted somehow and it's causing all sorts of issues as I'm sure you can imagine. Anyone able to identify the cable/harness for me so I can get it ordered and replaced? Thanks

 

I think it's the battery cable, but best pics I can find that part is maybe only shown from the underside so can't confirm. This is what connects to terminal B on the alternator.

 

The alternator power wire is part of the positive battery cable harness. I can post a picture if you'd like.

 

Good reminder - should we check this connection and clean and use dielectric grease on this alternator-battery connection?

 

Yes, absolutely. If the nut on that connection is anything less than fully tight this will cause the connection there to overheat and melt the cover. In the worst case scenario the outer covering for the entire output wiring melts/burns off too. There are at least several past threads on here documenting this issue. It potentially could lead to a full-on engine bay fire even.

I think it may be more critical due to the fact that the alternator regulator is internal and fully controlled by the PCM. With a loose connection it may be trying to drive the alternator output higher from not being able to detect the true output.
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It’s also the 67-070 ID number shown on this 6701A diagram for Engine & Transmission Wiring Harnesses

be advised that this harness is different depending on S1 vs S2 and also Manual vs Automatic transmission as well as 4 spd vs 6 spd Automatic transmission type



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Thanks., Is there a torque spec on that connection (other than 'gutentight')?

 

snuggly tight is good enough, but the service manual likely lists a tq spec

imo the issue is most likely somebody maybe tightened the nut down by hand, but then forgot to put a tool to it and tighten it down fully