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Lost foam casting cost SAAB many engine replacements due to lost coolant with no external leaks visible. I asked TAC once how to prove that a block was faulty so that I could prove it and they told me to buy a couple million dollars of X-ray technology. Thanks TAC (GM technical assistance).
The key to your problem lies in the "idiot" light for the charging system. You can have a perfectly good alternator and still drop many volts across an overheated battery cable terminal. I would look for burnt looking or black terminals at the positive cable connections. A loose positive cable at the alternator can cause arcing and an intermittent concern.
posted by 68.3.18...
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