Alternator arcs to earth when I reconnect the intercooler - Disco 4 SDV6

[Chris D]

Has anyone had a problem reconnecting everything after installing a new Disco 4 alternator? My problem is the intercooler pipe (steel) shorts out every time I try to reconnect it. I can't see any problems with the connections at the rear of the alternator and there doesn’t appear to be any arcing or discolouration showing up on the positive terminal. Weird.
Has anyone else experienced this?

Bingo. Problem solved. It turns out the blind side of the intercooler bracket that holds the intercooler pipe clear of the alternator has a redundant (and very sharp) tab that traps the positive lead of the alternator. Given time the tab pierces the cable causing a massive short circuit - which explains the burning smell before the alternator went. Looks like I wasted my money on a new alternator. The bracket design is hopeless, surely this problem could be seen during the assembly of the car originally? 20220928_100353.jpg