Alternator Wires Melted, What did I do Wrong? Options

[newto914s]

We, my father and I, were in the process of changing the alternator (the old one froze) http://www.914world.com/bbs2/index.php?act...81&hl=newto914s

We got a rebuilt from autozone, but after putting it in we figured out it had a bad diode(never go to autozone). I ordered another one from a place online I get a lot of parts for my old Benz from. It was cheap. $80 for a bosch rebuild + 20 core charge, they have free shipping, and I usually receive my order the day after I place it(crazy fast).
Now I wasn’t there for this, but after my Dad reinstalled the alternator when reconnected the Battery cables the wire harness on the altenator started to fried. By the time he got the wire off the battery again it had completely melted the wire going from the Alt. to the starter, and singed the wires going to the relay board.
What might have caused this? I already ordered a new harness from Jeff, but after I change it I don’t want to melt another one.
Could it be the wrong amp Alt. It’s a 55 amp
Oh, 1.8 block with D-jet
Thanks guys
Samson

[dmenche914]

Right, look for the burn mark, you should see the effect of the electric arc, ah la arc welding. Should be melted metal on the wire, and short location. However you will not find any melted metal is it was not a dead short to ground on your harness. An internal short in the alternator wiould melt the insulation down the wire, but the arc would be inside the alternator.

If the alternator insides (look thru the slots) are burnt, and smell burnt, it is likely the fault is with the alternator, If the case is that, have the alternator company buy you a new harness, refund your money, buy from someone else, and tell us on the list who it is so we can avoid them.