Vmac V900040 Installation guide

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Document #1930010

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Installation Manual – Document Number: 1930010

VR70 Underhood Air Compressor:

System Number V900040

Application: DODGE 1998.5 - 2002, 5.9L Cummins 24 Valve Diesel, with Air Conditioning)

Publication Date:

Revised by T. W. Mitchner, 17 July 2003

Previous Document Number 1900675

Previous Document Number 1900660

Registered Trademarks:

V70 and VMAC are registered trademarks of VMAC.

Dodge is a registered trademarks of Daimler-Chrysler AG.

Cummins is a registered trademarks of Cummins Inc.

Loctite, Kleen N’ Prime, 242 and PST are registered trademarks of Loctite Corporation.

Nylok is a registered trademark of Nylok Fastener Corporation.

Notice: Manuals and products are subject to change without notice.

The contents of this manual may not be reproduced in any form without the express written permission of

VMAC

Printed in Canada

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CONTENTS

GENERAL INFORMATION............................................................................................5

INTRODUCTION .....................................................................................................................................7

INSTALLATION STEPS .............................................................................................................................7

TERMS AND SYMBOLS ...........................................................................................................................7

INSTALLATION NOTES ............................................................................................................................ 7

ORDERING PARTS ................................................................................................................................9

WARRANTY .........................................................................................................................................9

SYSTEM IDENTIFICATION PLATE ...............................................................................................................9

SPECIAL INSTALLATION NOTES ..............................................................................................................10

CHANGES AND IMPROVEMENTS..............................................................................................................10

PART 1: PREPARING FOR INSTALLATION............................................................................. 11

1.1 PREPARING FOR INSTALLATION...................................................................................................... 13

1.2 INSTALLING THE BRACKET ............................................................................................................15

1.3 INSTALLING THE COOLER HOSES AND COMPRESSOR ........................................................................ 17

1.4 INSTALLING THE THROTTLE CONTROLER ASSEMBLY .......................................................................... 21

PART 2: INSTALLING THE OIL COOLER, AIR TANK AND LINES .........................................23

2.1 INSTALLING THE OIL COOLER .......................................................................................................25

2.2 INSTALLING THE TANK MOUNTS ....................................................................................................25

2.3 CONNECTING THE LINES..............................................................................................................28

PART 3: INSTALLING THE CONTROL UNIT............................................................................ 33

3.1 INSTALLING THE CONTROL UNIT....................................................................................................34

3.2 CONNECTING THE WIRING HARNESS ............................................................................................. 35

3.2.1 2003 MANUAL TRANSMISSION ...................................................................................... 35

3.2.2 2002 AUTOMATIC TRANSMISSION .................................................................................. 36

3.2.2.1 TESTING THE DRIVE DISABLE CIRCUIT (DDC) ................................................. 37

APPENDIX A..............................................................................................................................38

PART 4: INSTALLING THE THROTTLE CONTROLLER..........................................................45

4.1 INSTALLING THE CABLE ............................................................................................................... 43

4.2 ADDING OIL TO THE SYSTEM .......................................................................................................46

4.3 COMPLETING THE INSTALLATION ....................................................................................................47

PART 5: ILLUSTRATED PARTS LIST....................................................................................... 49

MAIN BRACKET ASSEMBLY ..........................................................................................................51

COMPRESSOR ASSEMBLY ............................................................................................................ 51

TANK ASSEMBLY ........................................................................................................................ 52

HOSE KIT................................................................................................................................. 52

THROTTLE CONTROL ASSEMBLY ................................................................................................... 52

TANK BRACKET ASSEMBLY ..........................................................................................................53

OIL COOLER ASSEMBLY ..............................................................................................................53

ELECTRICAL ASSEMBLY ...............................................................................................................53

MISCELLANEOUS ........................................................................................................................53

WARRANTY REGISTRATION

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Document #1930010

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System # V900040

DODGE 1998.5 - 2002

5.9L CUMMINS 24 VALVE DIESEL

with Air Conditioning

UNDERHOOD AIR COMPRESSOR

TM

General Information

Document #1930010

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Document #1930010

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GENERAL INFORMATION

Introduction

This book provides installation instructions for the VR70 Underhood Air Compressor. The

information in this book should be read completely before attempting installation.

Installation Steps

The installation procedures are divided into the following main steps:

Part 1: Preparing for installation

Part 2: Installing the tank and lines

Part 3: Installing the cooler and main bracket

Part 4: Installing the throttle controller

Part 5: Installing the control components

Part 6: Illustrated parts list

Terms and Symbols

This manual uses the following terms and symbols:

· ft.-lbs - Foot Pounds (torque)

· HHCS - Hex Head Cap Screw (also called a hex bolt)

· N•m - Newton Meters (metric torque)

· OEM - Original Equipment Manufacturer

· SHCS - Socket Head Cap Screw (also called an allen head bolt)

· Hex - Hexagon (six sided)

This symbol indicates that there is a possibility of personal injury if the

indicated warning is not followed.

This symbol indicates that there is a possibility of damage to the

equipment if the warning is not followed.

This symbol indicates that there is additional information or special

emphasis on a specific procedure.

Installation Notes

1. It is important that you complete all the installation steps before operating the system.

2. Follow all safety precautions for underhood mechanical work.

3. Use Loctite 242 or equivalent on all engine-mounted fasteners.

4. All hoses, tubes and wires which are rerouted or moved during installation must be secured so

that they do not contact excessively hot areas or sharp edges. Where possible, follow the

routing suggestions in this manual.

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5. These installation instructions are intended as a general guide. In some instances, due to

variations in vehicle manufacture or if prior modifications have been made to the vehicle, it

may be necessary to carry out grinding, bending or rearranging operations for correct fit.

These operations MUST follow sound, standard shop practices.

6. Left and right definitions in this manual are determined when sitting in the driver’s seat, facing

forward.

7. All fasteners must be of the correct size and torqued according to the specifications shown

below. Always use manufacturers torque values for OEM fasteners.

8. Different frame designations will affect the tank mounting position. You may have to move

the tank rearward from the standard position on your application. If you must move the tank,

the lines may be too short. If this is the case, measure the hose shortfall and order a Hose

Extender Kit, P/N (A410XXX)*

* The last three digits in the P/N indicate the length of the extension.

Example: A410055 is a 55 inch hose extender kit.

Hose Diameter Colour Coded Label Part Number Prefix

1/4 inch Yellow 173

5/16 inch Orange 174

1/2 inch Blue 175

5/8 inch Blue 176

3/4 inch Green 177

Table 2 - Above illustrates the colour code used by VMAC to define the different hose diameters.

Torque Specifications

STANDARD GRADE 8 NATIONAL COARSE THREAD

Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4

Foot-pounds (ft-lb) 9 18 35 55 80 110 170 280

Newton meter (N•m) 12 24 47 74 108 149 230 379

STANDARD GRADE 8 NATIONAL FINE THREAD

Size 3/8 7/16 1/2 5/8 3/4

Foot-pounds (ft-lb) 40 60 90 180 320

Newton meter (N•m) 54 81 122 244 434

METRIC CLASS 10.9

Size M8 M10 M12 M14 M16

Foot-pounds 19 41 69 104 174

Newton meter 25 55 93 141 236

Table 1 – The fastener values are applicable when Loctite is applied unless otherwise specified.

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Ordering parts

To order parts, contact your VMAC dealer

Please quote the VMAC part number, the description and the quantity.

Warranty

The VMAC warranty form is located at the back of this manual. This warranty form must be

completed and mailed or faxed to VMAC at the time of installation for any subsequent warranty

claim to be considered valid.

System Identification Number Plate

The enclosed System Identification Number Plate must be attached to the vehicle at the time of

installation. Locate the plate as shown in Figure A. Drill the two hole locations using a 7/64 inch

drill bit. Attach the plate with the two supplied #6 pan head self tapping screws.

Figure A

This plate provides information, which allows VMAC to assist in customer

inquiries and the ordering of parts. It is important that this plate is affixed to

the vehicle.

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Document #1930010

Special Installation Notes

If you intend to use an auxiliary air receiver with this system you must observe the following

installation procedure (Figure B). Failure to observe this procedure will result in damage to the

system.

1. The line from the VR70 tank to the auxiliary air receiver must have a one-way check valve

installed to prevent blow back from the auxiliary tank to stop moisture from entering the VR70

tank.

2. The line to the auxiliary tank must not be installed in the bottom of the tank, but must be

installed as high as possible to prevent water from entering the line.

Figure B

Changes and Improvements

These products and documents are subject to changes or improvements without notice.

11

System # V900040

DODGE 1998.5 - 2002

5.9L CUMMINS 24 VALVE DIESEL

with Air Conditioning

UNDERHOOD AIR COMPRESSOR

TM

PART 1

Preparing for Installation

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1 Preparing for installation

1.1 Preparing for installation

1. Disconnect the batteries.

2. Remove the air cleaner to turbo inlet ducting and immediately cover the inlet to the

turbocharger.

3. Remove the OEM drive belt.

4. Disconnect the wiring from the alternator. Also disconnect the wiring plug beside the

passenger-side battery (Figure 1.1) and remove the retaining clip from the battery tray.

5. Remove the alternator top support bracket, the alternator and the alternator tie mount from the

engine.

6. Remove the battery positive cable from the top of the radiator.

7. Drain the coolant.

8. Remove the top radiator hose.

9. Remove the coolant expansion tank and the windshield washer reservoir from the fan shroud.

10. Remove the lower radiator hose.

Figure 1.1 Wiring plug beside the battery

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11. Remove the coolant return hose from the transmission cooler at the square block tee

connector (Figure 1.2).

12. Loosen the securing clamp which retains the two 1/2 inch steel coolant lines near the exhaust

manifold.

13. Remove the heater return hose from the square block tee connector.

14. Remove the fan belt tensioner, the engine cooling fan and the fan shroud.

15. Remove and discard the lifting lug from the engine.

16. Remove the electric horns from the top-side of the fender panel.

17. Remove the hex head cap screws from the OEM crankshaft pulley.

18. Remove and discard the transmission heat exchanger supply pipe and hose from the front of

the transmission cooler to the cylinder head outlet (Figure1.3) labelled “E” in Figure 1.4.

19. Remove the T-connector in the bottom hose housing (Figure 1.2).

20. Remove the three M12 hex head cap screws and the three M10 hex head cap screws retaining

the OEM mounting unit to the engine block.

21. Remove and discard the entire assembly from the engine block (Figure 1.3).

22. Remove the three M10 OEM cap screws from lower radiator hose outlet and the three M12

hex head cap screws retaining the air conditioning mount to the engine block.

23. Remove and discard the entire assembly from the engine block.

Figure 1.2 Location of hoses, fittings and fasteners

Transmission heat

exchanger return pipe

Transmission heat

exchanger supply pipe

Heater return hose

Engine Block

OEM M10 hex head

bolts two hidden

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Figure 1.3 Location of hoses and fittings

1.2 Installing the bracket

1. Automatic Transmission

Remove the OEM hose barb fitting from the cylinder head which held the OEM

steel coolant line for the transmission cooler. This may have an internal hex.

Apply Loctite PST to the supplied 1/2 NPT 5/8 inch hose barb and thread it into the

supplied brass 45 degree elbow, then thread the assembly into the OEM hose barb

location in the cylinder head. Angle it downwards about 20 degrees (Figure 1.4).

Manual Transmission

Remove the plug in the side of cylinder head just below the front lifting lug

location, then install the supplied 45 degree brass fitting and hose as for the

automatic transmission.

Figure 1.4 Angle of fitting

T-connector with heater coolant return and

transmission heat exchanger return lines

On automatic transmission vehicles, remove

and discard this hose and metal line.

On manual transmission vehicles, remove the

blanking plug from this location.

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2. Connect the supplied 40 × 5/8 inch heater hose to the 45 degree fitting in the cylinder

head, install the supplied hose clamp and tighten. Route this hose down behind the

engine oil filter.

Figure 1.5 Hose connections and fittings

3. Check the machined surface on the engine block and clean it before attempting to mount the

VR70 bracket.

4. Remove the belt tensioner, idlers and the lower front AC stub from the VR70 bracket to make

installation easier.

5. Apply Loctite PST and install the T-connector (removed earlier) into the rear of the VR70

bracket in the OEM orientation.

6. Insert the OEM rubber seal into the groove on the side of the engine. Lift the bracket into

position and install the three OEM M12 hex bolts loosely through the lower section of the

bracket and into the engine.

The roll pins on the VR70 bracket are used to align the bracket with the front

edge of the engine block. They do not fit into any holes.

7. Install the three M10 socket head screws into the holes around the radiator hose fitting. Make

sure that the rubber seal is still in position, then torque all fasteners to specifications.

8. Install the OEM belt tensioner to the VR70 bracket using the OEM cap screw. Then install

the VR70 belt tensioner and both VR70 idlers removed before fitting the bracket (Figure 1.6).

Use Loctite and torque both fasteners to specifications.

9. Place the OEM A/C compressor in position and install the small stub to the lower front

mounting point using the M8 × 20 hex head bolt. Thread the four A/C cap screws into place

and torque to specifications

10. Install the OEM lower rad hose and clamp. You may have to bend it slightly to provide

clearance for the belt tensioner.

Cooling line fitting (note angle)

Socket head bolt

Heater hose connection

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Figure 1.6 Installing the tensioners

1.3 Installing the cooler hoses and compressor

1. On automatic transmission models, connect the supplied 5/8 × 50 inch heater hose to the front

end fitting on the OEM transmission cooler (located on the side of the engine under the

exhaust manifold). Install a hose clamp and tighten. Route the hose forward and down

beside the engine oil filter.

2. On manual transmission models (Figure 1.8), cut the OEM heater return hose approximately 1

inch before the bend. Insert the supplied plastic ‘T’ and secure it with the supplied hose

clamps. Route the hose clear of the exhaust manifold and tie it to the air conditioning line,

then route it forward and down under the radiator and clear of all hot or moving parts.

Tensioners

Figure 1.7

3. Place the L-shaped bracket for the upper alternator support on the side and front of the cylinder

head. Apply Loctite and install the two supplied M8 x 25mm socket head bolts to the front

and supplied M10 x 25mm bolts to the side (Figure 1.7).

Cutting the hose Installing the L-shaped bracket

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4. Place the compressor on the mounting bracket. Apply Loctite, thread the two M8 nuts with

washers on the two front studs and tighten. Apply Loctite and thread the supplied M8 bolt

with washer into the remaining hole at the rear of the compressor.

5. Attach the shortest 1/2 inch braided oil return line to the 90 degree fitting on the engine side of

the compressor and tighten the fitting.

6. Fit the alternator to the boss welded on top of the VR70 mounting bracket using the OEM bolt

and nut.

7. Refit the OEM upper support bracket for the alternator to the installed L bracket using OEM

bolts. Tighten all bolts.

8. Reconnect the wiring to the alternator.

9. Install the VR70 pulley to the OEM pulley after cleaning out all dirt and debris using the OEM

bolts.

10. Install the replacement OEM drive belt (Figure 1.10).

11. Install the VR70 belt (Figure 1.10).

Figure 1.8 Connection for manual transmission models

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Figure 1.10 OEM and VR70 belt routing

Figure 1.9 Compressor and alternator installed on the engine

VR70 belt routing OEM belt routing

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12. Modify the fan shroud as shown in Figure 1.11 Use an angle grinder or similar tool. Cut away

the three ribs and the angled section on the passenger side of the shroud.

Figure 1.11 Fan shroud modifications

13. On 2000 models, install and tighten the supplied fan spacer. Lower the fan shroud and fan

into place together. Fit the fan and tighten.

14. Push the air conditioning line on the passenger side of the vehicle so that it tucks up under

the lip of the inner fender (Figure 1.12). Install the VR70 replacement bracket for the

coolant expansion tank to the two fan shroud retaining cap screws on the passenger side of

the vehicle, then install the expansion tank. Fit the 3/8 × 11-3/4 inch long hose and two

clips to the expansion tank and radiator.

Figure 1.12 Expansion tank bracket installation

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Vmac V900040 Installation guide

Vmac V900040 Installation guide

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