Access through the firewall

helijohn · Aug 30, 2016

I need to run a wire (or three) from the battery in the engine bay to the cab. Is there a ready made access hole in the three door TD4?

hd3 · Aug 30, 2016

in the auto-box hippo .. there's the hole where the clutch pedal would be
( according to prev. posts )
some run the synergy module dash switch lead via the bonnet latch cable hole ..
so some small gauge wiring should fit ..
i found another potential hole just above the clutch pedal
but it required drilling thru something to find out exactly where the exit would be ..
so left it for now ..
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

hd3 · Aug 30, 2016

( d.post )

helijohn · Aug 30, 2016

hd3 said:
in the auto-box hippo .. there's the hole where the clutch pedal would be

Mine is an auto and I had a feeling it might be the way to go as I have used that approach before.
Thanks

htr · Aug 30, 2016

In the 1.8s there is a hole just behind each bonnet hinge. I push through a length of curtain wire and tape the cable onto that.

gstuart · Aug 31, 2016

when I done my synergy I found a hole where the clutch pedal went , if u look under the bonnet u will see a round insulation mark , better to get a torch ,look under the dash and u will see it, push a screwdriver through , use some sleeving or rubber tubing , I made sure I sealed it both ends after pushing the wires through so that no engine fumes could come into the cabin

there is also a grommet behind the fuse box , but a lot harder to get to ,

been trying to find a pic of when I replaced my dashboard and heater matrix, will keep looking

gstuart · Aug 31, 2016

u can roughly see where the tubing goes through , sorry it's not a better picture, is the second picture , has come out twice , is great fun replacing a heater matrix, put in a new dashboard and carpets at the same time

GrumpyGel · Aug 31, 2016

gstuart said:
View attachment 106471 View attachment 106472 View attachment 106471 View attachment 106471 u can roughly see where the tubing goes through , sorry it's not a better picture, is the second picture , has come out twice , is great fun replacing a heater matrix, put in a new dashboard and carpets at the same time

What a mess, its why I've been so hesitant to investigate changing my heater matrix!

Dartmoor Navigator · Aug 31, 2016

gstuart said:
View attachment 106471 View attachment 106472 View attachment 106471 View attachment 106471 u can roughly see where the tubing goes through , sorry it's not a better picture, is the second picture , has come out twice , is great fun replacing a heater matrix, put in a new dashboard and carpets at the same time

Did you do that for fun?

helijohn · Aug 31, 2016

gstuart said:
put in a new dashboard and carpets at the same time

It is the sort of vision that nightmares are made of. I guess you start and have to just go on. There is an expression I heard on a science fiction TV show/film which goes something like "when you get in to trouble keep going till you get out of it".

Great pics but I am having trouble seeing the wood for the trees though I get the idea. I'll possibly do a pinprick puncture at the unused clutch grommet and pass a wire through; it should be tight enough to seal.
First I have to remove the front bumper.

Oh and do all the grease points on my Pajero!

Dartmoor Navigator · Aug 31, 2016

There are grease points on a Pajero?

helijohn · Aug 31, 2016

Dartmoor Navigator said:
There are grease points on a Pajero?

Yes on mine.......about 10. Basically all the running gear like track rod ends, swivels, idler arm joint, propshaft and so on.

Dartmoor Navigator · Aug 31, 2016

Well I had better get the grease gun out then

gstuart · Aug 31, 2016

it certainally was good fun , sad I know but quite enjoyed taking it all out, the matrix was leaking , there was a big scratch across the dashboard which was driving me nuts and carpet was ruined due to the matrix leaking all over it for ages

also installed a complete oem wiring loom to install spots and fog lights

went for broke and took a week to put everything right , looks so much better

ref the firewall hole, is easier to get a torch and put a screwdriver through the firewall and u will then see where it is under the bonnet

I put rigid tubing through so if I needed to run any more wires through I could just push them through without any hassle, but did seal each end up due to it being a ridged tubing

gstuart · Aug 31, 2016

also cutting in a second radio sized hole for a CB

helijohn · Aug 31, 2016

gstuart said:
ref the firewall hole, is easier to get a torch and put a screwdriver through the firewall and u will then see where it is under the bonnet I put rigid tubing through so if I needed to run any more wires through I could just push them through without any hassle, but did seal each end up due to it being a ridged tubing

You have done well on that dash.
Job's a good 'un - all done. There is a blanking grommet and an interior pad which I assume is removed if a clutch pedal is installed so I partly removed it. There is a removable round patch of sound deadening on the engine side. I found a blanking grommet to match and punched a tiny hole in the centre so it seals against the wire then when done pushed back the interior pad and replaced the sound deadening.

helijohn · Aug 31, 2016

@ Dartmoor Navigator
I grease mine about every 5000 miles. You have to be careful not to pump them up too much. I guess it all helps to increase their life.

gstuart · Aug 31, 2016

helijohn said:
You have done well on that dash.
Job's a good 'un - all done. There is a blanking grommet and an interior pad which I assume is removed if a clutch pedal is installed so I partly removed it. There is a removable round patch of sound deadening on the engine side. I found a blanking grommet to match and punched a tiny hole in the centre so it seals against the wire then when done pushed back the interior pad and replaced the sound deadening.

great u found it ok and got the wire through , is a bit of fun under the dashboard , as I put a larger ridged tube through I just sealed the ends. is fun getting the grommet in ,, being twin skinned ,

yes am pleased that I got everything back, the amount of times I had to take the carpet back out where I hadnt seen a wire hidden underneath , looks alot nicer now with the new dashboard and carpet

Rich in Vancouver · Sep 1, 2016

If there is one thing worse than changing the heater matrix it is paying someone else to do it. Thats a lot of hours!

gstuart · Sep 1, 2016

Rich in Vancouver said:
If there is one thing worse than changing the heater matrix it is paying someone else to do it. Thats a lot of hours!

thks , to be honest I didn't think it would take all the time it did

I dread to think what a garage would have charged

they would have got it done a lot quicker than me but never the less a serious bill

when I got the new dashboard , I put some extra sound insulation on the bulkhead and also stuck on the back of the dashboard , where the vents were I cut some new strips on insulation as I thought would be just my luck in putting it all back and finding they were no good

the sound deadening had a really good self adhesive side, so stuck to anything really well

kicked myself for not noting the colours when removing the wires off the ptc heater , but apart from that wasn't that bad, just time consuming

was quite chuffed with myself, even worse I actually enjoyed doing it , lol

got some great experiance so if maybe someone else wished to tackle the job would be good to pass on the knowledge I gained

Access through the firewall

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