2nd Gen Wiring Overhaul - A slow descent into madness

@deanosaurus Yes that's exactly what I thought that the lengths would need to be different. Thank you for confirming. Once I start the project, I'll post lengths and maybe a few pictures.

 

@deanosaurus got some measurements for the 2.7l. Did a dry run and all the cables will fit and installation will begin once my new terminals arrive.

1. Starting at the top is the Battery Body Ground. I used 12", 0 AWG wire. I changed to this after some further tweaking of the set up.(Not using the 6" cable in the picture below)
2. After some other research, I decided to add a 0 AWG alternator ground to the body. I have an engine to body ground that I updated (not pictured) that this ground will mount with.
3. The battery positive to fuse ended up being the same length as yours. Also used 4 AWG wire as you did.
4. Since the alternator is on the opposite side of the engine compared to the V6, had to measure this a few times. 48" gives plenty of length to snake around and mount to the fuse stud. Again, 0 AWG.
5. Starter positive, same as yours, 36" 0 AWG.
6. Starter ground, same as yours, 48" 0 AWG.
7. Shock Tower ground, 27" 0 AWG

All cables came from https://www.batterycablesusa.com/. These are very nice and high quality. They came crimped with connectors. Definitely recommend checking them out.




So the Big 3 turned into a Big 7, plus the new engine to body ground as well.

I hope this helps.

 

I'm going to link this post in the first post and update the title. Thanks for the update!

 

@deanosaurus sure thing! Thank you too

 

Did the thing today. Got the "Big 3" completed. Overall, not too bad. The most time consuming part was getting the OEM alternator power cable out. Since I have the 4 cyl, it's on the left side of the engine.

I decided to replace the "shock tower" ground as well. Since I didn't mention that in my first post, I got a 24" 0 AWG cable to replace the OEM, I edited that post with the addition of that ground cable.

Some pictures:

Seeing how things lay out with the Headlight Services harness.


KnuKonceptz Bassik Terminals:
Decided to change to these terminals. Having three set screw mounts works better for my set up. They also come with nice, protective covers.


Battery tray rust repair:
Before. Gross.

After some sanding, wire brushing, washing, priming, painting, and clear coating. Not too bad.


Finished product:



I went for a drive after the install, and I noticed a few positive things.
1. Stronger, faster start.
2. Improved fan speed, particularly at setting 4.
3. Faster windows up and down.


I hope this can help other 4 cyl owners!