Running wires through firewall

[MountainManJoe]

Squiddy I think you need to read and understand posts fully before shouting at people.
First of all, I never said electrical tape was the ONLY protection I would use.
Second, what fumes are you talking about? I don't have any exhaust or fuel leaks. And if there were, I would be sucking on them right now, because that hole was already there out of the factory. Anything I put in the hole, will block it further. Tell you what, just to make you happy, I'm going seal it with silicone after.

Thank you for all the tips. I do appreciate it, and I'll take them into consideration, but I'm going to proceed as planned. I think you are taking this simple task much too seriously and suggesting that only an expert knows how to run a few wires is utter nonsense.

I'll document everything for those interested, and I will report any blown fuses or funny smells here immediately! Cheers.

[JaxSPL]

That hole is perfectly all right for running a wire, AS LONG AS IT'S PROTECTED form shorting out against anything. Silicone or expanding foam can be used to make sure the wire is protected.

This hole may not be the best for running a wire, but it WILL work. It is always best to drill a new hole and plug it with a grommet.

[MountainManJoe]

I took a closer look at the hole today. The hood latch cable was there but pushed aside. The loom you see going through it in the photo goes to the car alarm siren, which must have been installed after. When I was looking at vans at the JY, the hood cable was encased in a rubber fitting which was inserted into the hole. That rubber piece is either pushed in or non existent on mine. There are no signs of abrasion whatsoever on the cable or loom though.

Anyhow, there is a chance the opening may be too small. Where would you suggest making a hole Jax? I need to get close to the fuse block.

[Kidhauler]

Instead of going beside a grommet I have poked a small hole on the side between the exsisting cable and the side. That way it is sealed and protected from rubbing. For 1 wire at a time it works well there is so much junk on the firewall I am always afraid of hitting something.

[v8famvan]

As an automotive expert, I will post my opinions, which you can disagree with if you want.

Like many things in life, things can be done good, better & best (and in contrast - bad, worse & worst).

#1) In my 20 + years in the industry, I have probably only seen a wire chaffed (to the point of shorting) at a uninsulated firewall hole 1 or 2 times out of likely hundreds of instances. The key to avoid the chaffing thru is immobilization of the wire. If it does not move, it will not chaff. I am not saying that I endorse this, just that it does work.

#2) Something that I have done on numerous occasions is what TLB is indicating he might do, go thru an existing rubber passthru grommet. Now, this can be done incorrectly & cause a problem or properly & work good. Utilizing the handy Thexton 436 wire insertion tool you can safely create a hole in the grommet, feed the wire thru the tool, remove the tool & allow the grommet to seal up around it. Works great on suitably sized grommets.

#3) Drilling a hole in a suitable location & installing a grommet to protect the edges can be the best way to install a wire. I say can because even this can be done incorrectly. Ideally, the grommet should be snug on the wire to seal the engine sounds & fumes from entering the passenger compartment, however, this is not usually the case as the wires are usually too small for the grommet.

Here is a pic of the handy wire insertion tool.

[Kidhauler]

Point 2 from James post is what I was talking about. Go thru the grommet not between it and the steel. Also put a fuse 6 inches from the battery to protect the wire just in case it does short. I once ended up in the hospital because some idiot never put fuses in for his alarm and amp. The wiring shorted and lit his whole fuse and relay block on fire as he ran the wires over them. Trust me burning plastic smoke is not good to inhale.

If you can't find a proper grommet to seal the wire drilling a hole and using silicone or hot glue will hold the wire centered and stop all movement.