Air-Con Wiring Harness Help

Buddyboy · Post by **Buddyboy** » Thu Jan 05, 2012 9:05 pm

Hi Guys,
Need some help. I have installed an Air-conditioning unit from another Brumby into my 1989 Brumby. Everything is fitted, except the wiring. As I did not remove the unit, I need a little help with the wiring harnes that came with it. I have figured out that the long lead of the harness runs to the Relays, and the other end runs to the Evaporator, the Evaporator connection was in place, so I assume that this is correct. I am at a loss where the other wires go, with exception to the short lead, which comprises of three wires. One Yellow, One Black and One Dark Blue, these apparently go to the Air Con Switch on the dash.
The wires in question are those shown in the photograph taken inside the cab. The other photo is of the short lead to the Air Con Switch.
Regards
Buddyboy
PS maybe I shown include some colours, as the photos do not clearly indicate what they are. Top of upper joiner, one green, one yellow and one red with red loop. Top of second joiner, one yellow/white, one red/white and one black, bottom of joiner, same as top. Green/white and red/white in the background belong to the original blower unit.

YouTube · Post by **El_Freddo** » Thu Jan 05, 2012 9:45 pm

^ Ok, so you've got some cut wires there, any idea where the other end of the wiring from those plugs go, I'm not talking about the cut ones, I'm asking about the ones that are not cut that you can check out.

And is this a lead that came with the kit?

I'm not near Sunnie the Brumby at the moment to pull his dash apart to check out his wiring for you and probably won't be for about a week if I'm lucky.

Hopefully someone will be able to help out in the mean time

Cheers

Bennie

dfoyl · Post by **dfoyl** » Fri Jan 06, 2012 7:22 am

Is it a factory unit or aftermarket ? I can see the sticker on the system, is that just a service sticker ?

If it's factory, I assume you have done all the under-bonnet stuff (change the mount (20 kilogram bracket!), hook up the fast idle, install the small radiator, change from crank mount fan to dual thermofans, mount the relays to the drivers side strut tower, run the cables through into the cabin (right next to where the ID plate is on the firewall), change the glovebox back to the shorter version, change the under-dash unit from a blower to a combined blower & air-con, run the drain pipe (passenger footwell) and then all that's left is to junction in the wiring and cut out the AC button. The junction was where I got stuck, and one of the guys here told me - you just T it in to the control system - unplug the connectors and add the male-to-female cable that controls the AC, then re-connect. This is from memory the cable in the second photo.

It's a bitch of an install with the dash still in place, probably took me 40 hours all up - about 8 hours to dis-assemble from the donor (84 EA81 coupe), and the rest was hooking everything up.

I'll have a look at the yellow/black/dark blue for you.

Buddyboy · Post by **Buddyboy** » Fri Jan 06, 2012 5:27 pm

El Freddo and dfoy,
Thanks for your replys. I found that the yellow/white, red/white and black run to the original fan switch, and what I have shown in the first photo is the connector that joins those wires. Whoever took it out has just cut the wires above and below this original joiner. The yellow wire connected to the second joiner must deliver power to that connector, as I now have a reading on the multimeter at the relays. To answer dfoy's question, I am not sure that it is a genuine Air Con, although it could be. My set up is a lot different to others that I have seen on this site. My control wires run out the same holes as do the pipes, on the passengers side. My relays are also situated on that side towards the front and near the radiator. I figured this out as there are two short leads that run from the relay to the compressor and another to the line filter. I also could not find a drain on the evaporator, so I guess I will find that when I start to run the system.
The other wire (red joined to blue) that comes out of the upper connector, as shown in the photo, is another power lead, so it could have been for a glove box light for all I know. I am taking it to get re gassed on Monday, and he is also an Auto-electrician, so I will see if he give my wiring the thumbs up. The only think that I am short off is the slim line thermo fan. I have an additional standard thermo fan, and I thought that I could modify it to fit, but as most of you will know, it don't fit. So if anyone out there has a slim line fan that they want to sell let me know. I live on the east coast in Queensland. Thanks Buddyboy

Buddyboy · Post by **Buddyboy** » Sat Jan 07, 2012 10:13 am

Guys,
Picked up a slimeline fan from a guy in Coffs Harbour, he is coming to Qld this morning and will drop it off. How's that for luck.
Buddyboy

YouTube · Post by **El_Freddo** » Wed Jan 11, 2012 12:47 pm

How have you gone with the wiring issue, did the auto electrician work it out for a fair price?

Cheers

Bennie

Buddyboy · Post by **Buddyboy** » Thu Jan 12, 2012 12:03 pm

Brumby is still at the autoelectricians, he is working on it in between other jobs, to keep the cost down for me. Will let you all know how it turns out. Will also take some photos of the wiring and do a bit of a write up to assist others in the future.

Buddyboy · Post by **Buddyboy** » Thu Jan 12, 2012 5:19 pm

Well Buddyboy's Brumby is still at the Auto-electricians. Got a call this afternoon that there was something wrong with the compressor. Turns out that the compressor is full of rust and has fine metal shavings. So tried to find another compressor all afternoon, without much luck I might add. The compressor like most of my system is not standard, although it was taken out of a Brumby, or so I was told, prior to purchase. Pipes and wiring fit fine, and the compressor turned with the clutch engaged, prior to fitting. Looks like it may have been left out in the weather after removal from the donor vehicle.
Well, I am now looking for a Sanden SDB705 Model No 7073 compressor, so anyone out there in Subaru Land, has one or knows where I can get one, please let me know. Apparently the SBD705 has been replaced by a SD7B10 model 7073, just to make things a little more confusing. This compressor came standard on a Subaru Fiori, and I believe could also could have come on early Suzuki Vitaras. Other than that, the "Sparky" said that the wiring is fine, and I can pick up the ute in the morning, less the compressor of course. Just had the hottest three days here on the Gold Coast, so I didn't miss the Air Con at all. I am hoping for better luck next week. Special thanks to D_phantom got your e-mail today.

YouTube · Post by **El_Freddo** » Thu Jan 12, 2012 10:22 pm

On the bright side the wiring is all sorted! Did it cost much to fix in the end?

As for the compressor, keep an eye on ebay, I'm not sure if you're after a new one or a secondhand one in unknown condition. It could be a good investment to buy a new one or even look into re-conditioning your current one...

Cheers

Bennie

Matt · Post by **Matt** » Fri Jan 13, 2012 7:37 am

Have you got an email i have a Factory air con wiring diagram and how to fit it. If you want i could take some pics and email it to you? The original are usuable but not the best.

Buddyboy · Post by **Buddyboy** » Fri Jan 13, 2012 8:50 am

Thanks guys, yes I think that a new compressor would be the way to go, one less thing to break down in the future. Matt, thanks for the offer but I have a copy of the installation already. Sorry phantom_D, had your handle around the wrong way, but thanks again for your help. Picked up Buddy the Brumby, hope no one else has that name for their beloved Brumby at the moment. For an actual breakdown of what the air conditioning wiring cost I'm not sure, they replaced two of the relays, provided an additional relay for the thermofan (Air Con), replaced some of the wiring harness and in general just made everything a bit more professional. I also asked them to tidy up the wiring from the ignition switch, previous owners had cut into a number of leads, and then cut wiring off, covering with tape. In total it cost me $230.00. This also included them taking off the compressor and checking it out. Will let you know of what the other costs are when and if we find a new compressor and have it fitted and system gassed.