Question: high output alternator installation?

[1gDSM4g63]

I'd like to hear what's the best way to do a high output 200 AMP alternator i.e., upgrade lines and/or fuse. I have heard bad situation if the wire rating and/or fuse is not accordingly and it may catch fire and burn out the ECU.

 

[knochgoon24]

I just installed a 140amp alternator. I ran 2ga wire from the alt to the fuse box.
I also have two 4ga wires from the fuse box to the battery. My battery to starter is 2ga and my grounds are all 2ga or 4ga.

I didn't replace the amp fuse in the fuse box, but if I do, I might look into something a bit larger. I haven't blown it yet.

I did a lot of the rewiring because I also ran a 2ga wire to the back of the car for a battery relocation and it was convenient to do it all at the same time.

 

[jeff24680]

I have a 200A alternator installed.

I have 2ga from the alternator to battery, and I replaced the double 8ga wires from fuse box to battery with a single 2ga. I had to bridge the 60a fusible link with the alternator fusible link in the fuse box with a piece of copper strip. This is how I eliminated the double 8ga wires with a single 2ga wire.

Also I upgraded the alternator fusible link to a 120A fuse, I have not blown it yet. I could not find any fusible links higher than 120A if anyone knows where to get some please let me know.


I have not had any problems burning out anything.

I re did all my grounds using 4ga cable as well

Battery Ground
Starter Ground
TB to Battery Ground
IM to chassis ground
Alternator to chassis ground

 

[knochgoon24]

With cars as old as ours, it's a good idea for everyone to replace their ground cables, even if it's only with some decent 4ga wire. The electrical system on DSMs is junk.

 

[1gDSM4g63]

Great, thanks for all the information!