i dont suspose its possible you ran over a plastic bag? i doubt it has to do with the butterfly valve, ive never heard of plastic melting because your exhaust was too hot, due to intake mods, and thats even after market intakes. its possible, but i would def try to get it on a lift and make sure nothing is rubbing. like if your exhaust because loose and its touching anything. i know the engine plastics under the engine tend to fall off because the clips dont hold them too well so you can check and see if there is some plastic cover there too that might have come loose. try to remove the plastic thats on the exhaust so it stops smelling and you can see if anymore is getting onto it. good luck and let us know what happens