AC wiring harness question (1 Viewer)

[garfieldthecat]

Hi all,

I was hoping someone could confirm or refute for me whether the AC wiring harness (PN 88605-90A00) plugs into the AC amplifier (PN 88650-60020)? I'm trying to do an AC evaporator housing and cooler retrofit for my 1982 FJ60 that didn't come with factory AC by using parts from an FJ60 that did, and I think I may still need the wiring harness (I have the evaporator housing, radiator, amplifier, and hard lines that attach to the radiator through the firewall). I'm by no means an AC or electrical expert, so any guidance would be appreciated and welcome. Thank you.

 

[2mbb]

Sorry. I can't answer your question but I do have this schematic.

 

[garfieldthecat]

Thank you @2mbb this is very helpful since it shows me the other components that I need to connect the AC wiring properly. The numbered connector images in the schematic are great too for determining the plug type/prong numbers.

 

[Chris Cahill]

Thanks for posting this thread, I too need to retrofit my '84 that did not come with factory A/C. I have been lazy about getting around to it but have collected most of the parts. Please let me know what you figure out. I was hoping all the connections would already be in the factory harness but if there is an additional harness portion I need to source please let me know.

 

[4Cruisers]

@Aloha Jen had a good, detailed thread several years ago. A search will take you there.

 

[Chris Cahill]

I appreciate the heads up. I did search but having trouble finding it. I will send her a PM

 

[garfieldthecat]

Thank you both for your interest in this project. I'll search for @Aloha Jen thread too. I think the schematic diagram @2mbb attached is a good cross reference since it let's us see the plugs, relays, and wiring colors involved. I understand that the AC wiring is a subsystem of the general truck wiring (?) I am still at the stage of figuring out if I have all the physical/mechanical AC components and wiring before I take apart the dash though. I'm assuming my truck doesn't have any of the factory AC stuff in there, since it didn't have the evaporator housing and cooler unit.

 

[Aloha Jen]

The wiring should all be in there, or at least it was on my 60. I believe someone told me that all ac wiring is in place from the factory. The two plugs you attach are by the compressor (or where the compressor should be) and just under the evap box where that wire plugs into the amplifier on the evap box. You will also want to change out all the o-rings everywhere on the system for the right Freon you will be using. Also the AC oil will need to be for the proper Freon you use as well, which may mean you will have to drain your compressor and add the correct oil. The different o-rings and oil is more so if you are converting to r134, we did since you can pick that up at any parts store and is very inexpensive compared to r12 (at least here in Hawaii). I will see if I can find my photos from that project.

 

[Aloha Jen]

Here are some pics of how my retrofit went. Mine is an Hj60 with factory Diesel engine, but other then some wiring, I think it should be very similar if not the same as the fj60. It started with getting an entire system from someone parting out an Hj60 all the way from Canada.

I knew I would be replacing the condenser and the dryer, but needed it to see how it all routed and for any brackets.

If you do not have this short wire harness attached to the evaporator box, you will need to source that. The plugs on top of it are what plug into your main wire harness just above it under the dash. If you take out your glove box, it make it easy to reach the plug.

 

[Aloha Jen]

With the glove box removed it opens up the workspace nicely.

Also, if you don’t have this little blue AC button on your dash controls, you will need to source that as well.

This is also a good time to repair any cracks or busted mounting tabs in the plastic evaporator box (I used JB weld), as well as put in new sponge weatherstripping around the connection points.

 

[Aloha Jen]

I got all new Denso AC parts off of Amazon, prices were pretty inexpensive at the time and quality is good.

when installing the evaporator inside the box, be sure to change out the little o-rings below the little switch and on the ends of the connection tubes. I used a standard o-ring kit that worked good.

make sure that little stick is in there also, it wired in from the evap box wire harness and I think detects if it’s freezing up or something like that.

The completed evap box all cleaned up with new parts and o-rings installed

 

[Aloha Jen]

Condenser bolted right up to existing holes on the front end

hook up your ac lines from compressor to condenser to dryer to fire wall ports of the evap box and your done with installation.

After putting a vacuum on the system to remove moisture and to see if there are any leaks (vacuum should hold pressure if no leaks in the system), then fill with your preferred Freon gas. It’s always good to check for water leaks from the condensation From the evap box that is supposed to drain out a little tube that goes through the fire wall and drains outside. It’s a tight squeeze, but you can get a good look this way!

after that, you can enjoy ice cold ac on the hottest of days. Provides for very enjoyable sweat free cruises when you don’t feel like driving with the widows down. Scientific photographic proof right here!

And one shot of my beautiful Hj60 in its natural habitat. Good luck with your installs!

 

[4Cruisers]

Also, if you don’t have this little blue AC button on your dash controls, you will need to source that as well.
View attachment 2652907
View attachment 2652908

I have a few more of those available.

 

[Chris Cahill]

I was assuming I needed to change the entire dash control - if it's possible to just add the blue button to the existing controls, that would be easier. Thanks so much for re-posting Jen this in super helpful.

 

[4Cruisers]

I can send your the blue lighted AC switch for the cost of shipping, PM me if interested.

 

[Chris Cahill]

Will do, thank you!

 

[garfieldthecat]

@Aloha Jen , just saw your posts and the build photos. Thank you so much for posting these and describing your process. It was super helpful to see all the parts you used. I do have the evaporator housing and will get a new evaporator and all the smaller components listed. I did order a wiring harness when I initially posted, so I think I have that covered but will definitely ask @4Cruisers first next time I need components. Will also get the new Denso AC parts for under the hood. I really appreciate everyone's contributions to this post and for enlightening me on the steps to take next. Looking forward to that AC this summer.