EA81 A/C pulley bracket design Q?

dfoyl · Post by **dfoyl** » Tue Oct 30, 2007 10:21 am

This doesn't really fit in any other workshop forum, so I'm posting it here.

I am finishing off the retro-fitting of a 1983/4 EA81 coupe A/C system into my 1989 Brumby and the A/C pulley bracket design has me baffled.

There is a M10 bolt running into the back of the pulley bracket that mounts the bracket to the engine bracket that supports the compressor, alternator, etc - no problem there. There is also a LONG M8 bolt that runs vertically through a short (about an inch square) plate with two holes in it, and goes into a tapped hole in the pulley bracket. The plate has an M10 hole and a M6 hole - the M6 hole has a short M6 bolt going through which mounts to the engine bracket.

The short (1" square) plate is the design I don't understand - it is squared off at the M6 end and rounded off at the M10 end, with stamped in tabs on each side. The design problem I see is (1) the M10 hole size doesn't fit the M8 bolt and allows for play, and (2) the rounded-off end doesn't fit flush with the pulley bracket - it hits the welds, and means the plate ends up sitting on an angle. I know the plate is there to allow for tensioning the A/C belt, but I can't believe the design is correct.

Does anybody here have any close-up photos of their EA81 A/C pulley bracket setup or suggestions as to the layout? I've checked a few cars at wreckers locally and most A/C systems are gone or were not fitted originally and use the much smaller engine bracket (no support for the compressor).

Thanks,

Dean.

YouTube · Post by **El_Freddo** » Tue Oct 30, 2007 12:40 pm

One problem could be that several brackets were used as the MY models progressed, could be a case of finding the right one to suit your brumby.

I'm not sure if this is true, but i've heard a few differences between the MY and later brumby's.

Cheers

Bennie

dfoyl · Post by **dfoyl** » Tue Oct 30, 2007 2:31 pm

You're right on changes during the years (even simple things like the door sensor switch rubber, wiring connections for 2wd/4wd lever, etc) - but in this case it's all off the same car - I changed the entire engine bracket, crank-driven fan, etc - so it should all bolt together cleanly.

Dean.

subybrumby · Post by **subybrumby** » Tue Oct 30, 2007 4:59 pm

Hope this helps..not sure what you;re after..this is an ea81 brumby 91 model with an aircon that was installed from a wreck...works fine..let me know if you need a shot from another angle

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dfoyl · Post by **dfoyl** » Tue Oct 30, 2007 7:07 pm

Thanks, that looks like a MUCH better design. Mine is just nuts, the alternator belt runs *just* under the bracket. Any idea which year your donor A/C system came from ?

I know there are at least 3 different setups because I had the problem with getting the right size belt - mine is the earliest (I think) and longest belt.

The only bits I'm still stuck on is the wiring near the battery (there were two wires - red with white stripe - running to the front left headlight but I don't know which wires go where), and the run from the two connectors out of the dryer unit (two pairs of two) that I believe run around to the relays on the left shock tower - I'm sure there was at least one wire running across the engine bay, clipped to the spare tyre bracket, and then into the relays but I can't find that cable and don't recall the connections. The 1983 FSM isn't much use, I think the donor was a late 83 / 84 and the diagrams don't match the wire colours

Dean.

subybrumby · Post by **subybrumby** » Tue Oct 30, 2007 8:02 pm

Dean, I'll have another look tomorrow in the light...we got the entire unit ($600), brackets pulleys and wiring harness, relays from a wreck in Adelaide and had it shipped to toowoomba (model brumby unknown). When it got here, all we know is that it came out of a brumby that had been rear ended. We just told the wrecker that we wanted the lot. My son installed it but got totally bawlsed up on the wiring and the instalation was completed, wired and gassed by a musician friend who is an autoelectrician/aircon specialist. We basically installed the engine pulley, hardware, compressor etc ourselves and you will find that you lose the mechanical fan and replace it with a second electric fan. I'll see what I can find on the car for you but my knowledge of the electrics is a bit limited because I didn't wire it.

Incidently, I have another brumby (1988 with an EA82T) and the compressor and alternator are the other way around. That is to say that the alternator is on the outside.

Trevor

dfoyl · Post by **dfoyl** » Wed Oct 31, 2007 10:19 am

Sounds good

One more question - where does the fast idle air hose plug into (located in the front left corner of the engine bay) - somewhere on or near the carb / air cleaner I assume but there are so many air hoses on the EA81 carb it's a bugger to find

Dean.

subybrumby · Post by **subybrumby** » Wed Oct 31, 2007 5:02 pm

Ok..see how we go...
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The vacuum idle up is attached to the carby and when the vacuum switch on the turret is activated, a hook brings up the idle up on the carby.

The vacuum on mine is connected into a T piece on the line that runs across the back of the engine (Pictured). It then runs up to the actuator on the relay bracket attached to the drivers side strut turret, and then from there down onto the back of the actuator on the carby.

Because, I didn't wire it up, that's probably as far as I can go without bull..sh...tn to you.

I can tell you that when the gear arrived from the wreckers, there was a harness for the aircon that has the dash switch on one end and comes out into the engine bay and lays under the radiator and ends up at the aircon. My auto elect friend had trouble with the wiring, and I think he threw a lot of it away and just wired it up himself.

My advice:- Install all the hardware yourself if you can, and you must have everything, pulleys, idle up, evaporator, condenser etc etc, then see if someone can wire it for you. Our trouble was trying to get the fans to work together as I remember.

Hope this has helped and good luck...

Trevor

discopotato03 · Post by **discopotato03** » Wed Oct 31, 2007 6:10 pm

If its of any interest I found a wrecked Brumby with an AC bracket that looks like the one in the above pics . Its off the engine as is the compressor , didn't think to look for relays etc .
If in Sydney and interested PM me .

Cheers A .

dfoyl · Post by **dfoyl** » Thu Nov 01, 2007 5:08 pm

Ok, I am up and running

I just need to hook up the idle vacuum, though it'll only be until I fit the SPFI system. Thanks for all the photos, makes it a lot easier. I haven't yet been able to upload photos since the change to Vista

Thanks for the offer on the bracket Adrian, I'll have a bit more of a look around this weekend and if I can't turn one up I'll PM you. I'm not happy with the near-rubbing for the alternator belt...

Dean.

discopotato03 · Post by **discopotato03** » Sat Nov 03, 2007 9:03 pm

Hi all , I now have the MY electric main fan and most of the A/C loom from a dona Brumby . Would anyone have a wiring diagram so I can work out exactly how the two relays on the drivers side strut tower switch things . The wider relay has a 6 spades and a white plug while the other has four pins and a black plug . A

This'll be a bit tedious but those who have been there will understand the MY A/C sub loom , all I'm interested in is the wiring for the MY A/C rad fans .

The relay plugs :

A) Black 4 female spades .

1) Heavy Blue wire with green trace . This has an inline glass fuse so must be the positive power supply , its been ganged to another slightly smaller gauge blue wire leading to the white plug relay plug . I'm not sure where the heavy blue/green wire finds power because its been cut downstream of its inline fuse .

2) Short blue wire/black trace leading to male bullet connector .

3) Blue wire/red trace . This terminates at a "T" shaped two male spade wite plug and I'm guessing its the power supply to the main fan . There is also a black wire to this plug that runs all the way back to the white relay plug and appears to earth everything on this A/C sub loom . It has a joint a couple of inches short the white relay plug to earth some A/C related gadget . Where the female spade fits the white relay plug it is ganged to a short length that terminates in an eye fitting thats bolted to the strut tower (body earth) .

4) Forth wire from the black relay plug is yellow and goes to the white relay plug .

B) White six female spades .

1) Black , A/C sub loom common earth .
2) Yellow and from black relay plug . This is ganged at the white plug fitting and runs back along the loom approx 3 ft and exits to a two male pin 90 deg female white plug . This plug is joined to another similar but male plug with female spades via a ganged yellow and a blue wire . My guess is this may be power to the A/C booster fan that possibly earths through the radiator which has its own short earth wire ?
3) Red wire/black trace . This runs two inches out from the white relay plug the forms half of the two wire section that runs back inside the cabin (along with bonnet latch cable etc) and goes to a pair of bullet connectors (red/black female and black/yellow male) . These then run behind the middle console to the "AC" switch . Back in the loom the black/yellow runs to the fathest end of the A/C sub loom and is one of two wires that plug into the black cylindrical gadget - A/C fluid filter ? The other wire is red/white trace and runs eventually back to the white relay plug . Its curious because halfway back it has a short length of red/silver trace wire in its middle joined by two sets of bullet connectors . It then continues back to the white relay plug as a red/silver trace wire 4) .
5) Blue power wire ganged from black relay plug .
6) Another blue wire that runs to the other end of this A/C sub loom to somewhere near the above mentioned black cylindrical filter and terminates in a female bullet connector .

I hope this makes some sense , its easy for me because I've striped this loom .

Cheers A .