Thanks for taking the time once again to clarify everything.
#1 - good, thank you.
#2 - I'm struggling a little bit on where the attachment point of this cable is. Do I run it all the way to where the original very thin ground wire goes - which is to the passenger side mount right behind the bumper?
#3 - I need to spend a few minutes finding this location.
#4 - good, thank you.
#2 - Battery to frame is what I did. I put it under one of the three strut nuts. Removed the nut, wire brushed the metal clean, put the lug over the stud, reinstalled the nut with an extra ugga-dugga. That small ground that I think you're referring to is for the core support electrics, like the cooling fans. The factory battery ground is the 4 gauge that runs from the negative post on the battery to the stud on the front of the passenger side cylinder head. The ignition coil pack and core support grounds also terminate here.
#3 - It was another frame ground using the strut stud. The nearest bolt going into the engine block was that one behind the power steering pump that secures the bracket to the engine block.
So, I have the entire heating/cooling system apart as we've been discussing and have a lot of easy access around. Are there any other parts that I should be proactively replacing? For example, should I replace or upgrade the alternator or any other parts?
Thanks again!
Are you doing all this wiring upgrade stuff as part of your pre-trip maintenance? If your time is limited, I wouldn't worry about it until afterward when things calm down. There are much more pressing to-dos than the Big 3/Big 4. If the alternator isn't giving you any issues, leave it. If it does so happen to fail on the trip, it's super easy to replace in a parking lot. I think it's one of those items in the "may as well just replace the engine, trans, A/C evaporator, heater core, vehicle wiring harness, all switches and electronics just to be sure..." territory. Also, new does not mean fail-proof. Your alternator is working fine- it's tried and true, the devil you know. A new one could have a defect that is sure to show only during a road trip.
It seems you have a full plate with the cooling system refresh and normal pre-trip inspections and maintenance. Save the electrical upgrades for later tinkering.