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Very important, the chassis ground is what ties the engine and frame/chassis together, every single component inside the vehicle, all the lights, anything and everything that draws current goes through the chassis ground, if you have one.
Most or all of us do if we're lucky but when you start adding accessories to the vehicle you are increasing current flow through the chassis ground, when that path for electrons to flow through becomes too restricted the accessories and everything else in your vehicle will suffer, if you added a more powerful alternator or lets say electric fan or electric fuel pump or whatever, all this stuff adds to the amount of current that must flow through the chassis ground, freely being the key word, without restriction. If you suspect or think your current chassis ground is not sufficient then just add another one, about $20 for 18" of 2 gauge at Jeg's.. A stronger ground is NEVER a bad thing..
if you added a more powerful alternator ... all this stuff adds to the amount of current that must flow through the chassis ground.
A "more powerful" alternator is simply capable of producing more current if called upon by the regulator. An alternator with an increased current rating does not produce more current simply because it holds a higher rating.
It's not as though a 65-amp alternator continuously produces 65 amps, or a 90-amp alternator continuously produces 90 amps. If the system only draws 20 amps, the regulator will increase the alternator's field current until the alternator produces enough current to maintain constant battery voltage. This current will be the same, whether the alternator is rated for 65 amps, or 90 amps. The rating only makes a difference once the alternator is operated near its limit. That's when heavy loads like off-road lights and fans start to tax the factory system.
Stated another way, the alternator has nothing to do with how much current returns to ground. It's not as though the alternator forces current through the system. Loads draw current; the alternator simply tries to replenish.
True, i was assuming that an increased load was the reason the larger alternator and hence the larger chassis ground but you are correct that the larger capacity alternator does not always mean increased load or current flow..
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