1998 Dodge Neon electrical burning smell. Smoke

Tiny
TGALL
  • MEMBER
  • 1998 DODGE NEON
  • 4 CYL
  • FWD
  • AUTOMATIC
  • 177,000 MILES
Electrical smell and smoke from alternator area when car i
driven for 10 15 minutes, replaced alternator, (original) same problem, voltage test on battery ok 12-13 volts not running 13-14 volts running, no warning lights lit on dash, no trouble codes fusible link or pcm? Thx replaced belt also where exactley is fusible link?
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Saturday, March 13th, 2010 AT 1:17 PM

5 Replies

Tiny
CARADIODOC
  • EXPERT
No fusible links if you're referring to the older wired-in fuse wires. They still call them "fusible links" but they're giant fuses in the Power Distribution Center.

Look closely at the heavy output wire bolted to the back of the alternator. In rare occasions, high resistance causes heat to build up which leads to burned connections. This can happen where the wire is crimped to the terminal, under the insulation. Proof would be no smell while running the engine with that wire disconnected.

It would be smart to disconnect at least one of the small field wires too. Otherwise the voltage regulator in the Engine Computer will keep trying to increase alternator output. The voltage could rise high enough to damage the diodes. This isn't a common problem; just a precaution.

Caradiodoc
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Saturday, March 13th, 2010 AT 1:40 PM
Tiny
TGALL
  • MEMBER
Inspected wiring harness at alt area, recrimped alt. Lead, looked ok to me, noticed oil pres. Sensor leads melted together for 4 inches inside, outside of harness cover, rewired sensor, dont know if thats the way its made or not. Runs ok for now
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Monday, March 15th, 2010 AT 12:23 PM
Tiny
CARADIODOC
  • EXPERT
Very intersting. There isn't enough voltage on the oil pressure sending unit to cause it to burn up or melt. Is it possible the wires fell onto hot engine parts? The melting insulation would stink.

Caradiodoc
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Monday, March 15th, 2010 AT 2:55 PM
Tiny
TGALL
  • MEMBER
Runs ok for now 40 45 mins on streets no smells or smoke oil pres leads and electric tape cover very brittle and hard like it was heated up, I also disconnected a AC temp sensor up top on firewall, AC doesnt work due to compresser failure, ac reley pulled, no AC clutch, belt problems. 45 min. Ride tomorrow we will see thx very much
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Monday, March 15th, 2010 AT 6:55 PM
Tiny
2CARPROS LINSEY
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Friday, March 19th, 2010 AT 12:01 PM

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