Update: with a bigger alternator wire (in addition to the OEM one you have to leave connected), the "big 3" upgrade is now complete. Note that you MUST
fuse the new wire with a 150A or 200A fuse (the alternator is rated at 110A or so in the service manual).
Benefit: I now see 14.1V solid when running the engine, sometimes 14.2V. With just the grounding upgrade, I would see 14.0-14.1 bouncing around. OEM wire is maybe 6-8AWG...we've now cut the resistance * 1/3.
- 4 feet of 4 AWG OFC (red).
- DB Link ANLFH2 ANL Fuse Holder
- Install Bay 150A ANL Fuse
- 3 copper washers (2 for the fuse holder terminals, 1 for where the wire attaches to the positive battery terminal).
In order to unbolt the OEM alternator connection (intake limits tool access), I removed the serp belt and unbolted the top alternator mounting bolt (12mm), and loosened the bottom one (14mm). With that, the alternator can pivot down (hinged on the bottom) and the positive terminal nut removed. Use a flathead screwdriver to pry the shroud around the alternator positive terminal off (almost like Honda knew someone would want to add a bigger terminal there), remove the rubber boot completely since it will only get in the way of the new wire. (consult service manual). Route wire...zip tie to radiator housing.
*Disconnect the negative battery terminal!!! I dead shorted my battery by touching the positive wire on the engine bay (shorted through the engine grounding). Instantly melted a tiny bit of the lead positive battery terminal.
Overall view. Note the fuse block next to the battery tray. 6 zipties were used to secure the wire. One is hidden under the intake breather. (The serp belt is now green instead of black in the first post, because it was replaced with a Gates heavy duty belt)
Notice the copper washer. That spec of silver next to the white label is melted lead battery post.
With the shroud on the terminal, you wouldn't be able to see any of the aluminum bit. Also note the copper washer sandwiched between the new terminal and the OEM one to maximize contact surface area.
Alternator post shroud and Rubber Boot