TD5 dressed bulkhead - retrofit to earlier 4 cyl

[joe1]

Is it feasible to take a fully dressed (ie all ancillaries present, steering column, pedal boxes etc) TD5 bulkhead and drop it on a earlier 4 cyl diesel chassis?

Obviously it is possible to transfer all the bits from an early bulkead to a later one but this is fiddly as there's so many bits to come off (I'm aware of all the small differences that exist between the two bulkheads as in other threads such as saddle widths, wiper holes and loom entry holes).

The main problem with this idea as I see it is mating the TD5 loom to existing wiring, by a series of extensions and 'suitable connectors', but of course identifying all the TD5 bulkhead wires in the first place as the first time you'll probably see it is stripped from the chassis with a lot of loose wires hanging around.

So if anyone's done or attempted this, what are your thoughts about this and wiring identification in particular?

[Guest diesel_jim]

The bulkhead will physically fit onto the chassis, but not much of the wiring will match up.

stuff that should match:

battery connection

front lighting loom (depends... earlier Td5's had the light loom permantly connected to the bulkhead...later ones it's on a plug & socket)

possibly rear lighting loom, but probably not as the Td5 rear loom has the feed for the fuel pump. you could get a Td5 loom and just not use the fuel pump part so enabling the plug& socket to fit under the bonnet

stuff that won't fit:

the Td5 engine loom is nothing like a 4cyl loom. nthing at all.

all the guages work off of the Td5 ECU, so they won't easily work without a lot of hacking around.

Things like heater fan/wiper motor/light switch/horn/indicators/brake lights/dash lights/interior lights should still work as they're "in built" into the Td5 loom.

with some jiggling about you'd be able to identify what cables go where to the ECU, and by shorting out certain ones and adding extra senders (like water temp/oil pressure/alternator charge etc) you should be able to make stuff work.

[joe1]

Hmm thanks for that, sounds like a complete nightmare! Looks like its probably easier to strip all the bits of the early bulkhead and refit them to the later one - at least that doesnt involve too many intelllectual challenges!