Vmac 9037 Installation guide

Installation Manual

For The

System #9037

UNDERHOOD AIR COMPRESSOR

1999-2000 FORD SUPER DUTY F250-F550

7.3 L POWER STROKE DIESEL

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3

DOCUMENT 19351

Installation Manual Document 19351

VR7000 Underhood Air Compressor

System Number 9037

Application: 1999-2000 Ford Super Duty F250-F550 7.3 L Power Stroke Diesel

Publication Date: September 1999

Origination Documents: #19351a - introduction

#19352 - compressor installation

#19353 - air tank and line installation

#19354 - control unit installation

#19355 - throttle commander installation

#19356 - illustrated parts list

#19130 - warranty registration

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

Registered Trademarks:

VR7000, VMAC and Throttle Commander are registered trademarks of VMAC.

Ford, Super Duty, F250-F550, Power Stroke Diesel are registered trademarks of Ford Motor

Company

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

Nylok is a registered trademark of Nylok Fastener Corporation.

General Information

System #9037

1999-2000 FORD

SUPER DUTY F250-F550

7.3 L POWER STROKE DIESEL

UNDERHOOD AIR COMPRESSOR

DOCUMENT 19351a

General Information

Introduction

This book provides installation instructions for:

VMAC underhood air compressor installation kit

VMAC Throttle Commander

This kit has been designed for:

1999-2000 Ford Super Duty F250 - F550 7.3 L Power Stroke Diesel

Installation steps

The installation procedure in this manual has four main steps:

Part 1: Installing the Compressor

Part 2: Installing the Regulator, Filter, Air Tank and Lines

Part 3: Installing the Control Unit

Part 4: Installing the Throttle Commander

Terms and symbols

This manual uses the following terms and symbols:

•OEM - Original Equipment Manufacturer

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

•SHCS - Socket Head Cap Screw (also called an Allen head bolt)

NOTE

WARNING

!

This symbol indicates that there is additional information or special emphasis

on a specific procedure.

This symbol indicates that there is a possibility of personal injury or damage to

the equipment if the indicated warning is not followed.

DOCUMENT 19351a

Installation Notes

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

Refer to the Owner’s Manual before operating the system for the first time.

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 re-routed or shifted during installation must be

secured so that they do not contact excessively hot areas or sharp edges. Where

possible, follow the routing instructions in this manual.

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. Torque specifications are in foot pounds (ft-lb).

8. The possibility exists that the primary installer may be color-blind. Always ensure

that another person confirms the color codes on the wires.

Type Grade 8 plated Class 10.9 unplated

Size In Cast or

Steel

In

Aluminum

In Cast or

Steel

In

Aluminum

3/8 48 45

7/16 77 70

1/2 117 95

M8 25 20

M10 45 40

M12 80 70

M14 145 130

DOCUMENT 19351a

Ordering Parts

To order parts, contact VMAC at:

Telephone 250-754-6997

Facsimile 250-754-6972

Office Hours 8:00 AM to 4:30 PM Pacific Time

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.

The enclosed System Identification Number Plate (S/N) must be attached to the vehicle at the time

of installation.

Locate the S/N plate on the drivers side frame member in front of the battery. Drill the two hole

locations using a 7/64” drill bit. Place the S/N plate in position and fix in place with the two #6 pan

head self tapping screws provided.

IMPORTANT

This S/N plate provides information, which allows VMAC to assist in customer inquiries and/or

ordering of parts. It is important that this S/N plate is affixed to the vehicle.

DOCUMENT 19351a

Changes and improvements

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

DOCUMENT 19351a

Part 1

Installing

the Compressor and Oil

Cooler

System #9037

1999-2000 FORD

SUPER DUTY F250-F550

7.3 L POWER STROKE DIESEL

UNDERHOOD AIR COMPRESSOR

DOCUMENT 19352

Part 1: Installing the Compressor and Oil Cooler

1.1 Preparing for installation

1. Disconnect the batteries and remove the battery from the driver’s side box.

2. Drain the coolant from the radiator.

3. Remove the OEM fasteners from the coolant expansion bottle and move it out of the way.

Do not disconnect the hoses from the bottle (Figure 1.1).

4. Loosen the clamps holding the left intercooler tube at the air intake on the engine and at the

intercooler beside the radiator and remove the intercooler tube.

Figure 1.1

5. Remove and discard the plastic cover and attaching nuts from the center top area of the

engine (Figure 1.1).

6. Remove the OEM belt

7. Remove the cooling fan and the fan shroud.

NOTE

Removing the cooling fan will provide additional clearance for removing and installing

components.

Remove This Cover

Remove Coolant Expansion Tank

DOCUMENT 19352

8. Disconnect the air inlet horn from the front of the air cleaner and battery box. Leave this

part in place. This is optional for ease of removal and installation. Remove the air cleaner

box and the battery box from the driver’s side of the vehicle (Figure 1.2).

Figure 1.2

9. Remove the alternator from its mount and lay it back on top of the engine. Keep the OEM

fasteners for alternator installation.

10. Remove the power steering pump pulley (noting the position of the pulley on the shaft), then

remove the power steering pump from the bracket. Keep the OEM fasteners for the power

steering pump installation. You will require the correct puller to remove the power steering

pump pulley.

11. Remove the power steering return hose from the power steering pump. Remove and

discard the metal portion of the hose.

12. Fasten the pump out of the way or lay it on the frame. Do not allow it to hang from the

pressure hose.

13. Remove and discard the OEM alternator and power steering pump mounting bracket and

the OEM bracket fasteners (Figure 1.3).

14. Peen the edge of the valve cover flat against the cylinder head in the area where the

compressor mounting bracket will attach. This allows the compressor mounting bracket to

sit flush with the cylinder head surface (Figure 1.3).

15. Remove and discard the upper and lower radiator hoses.

Remove The Air Cleaner And Battery Boxes

DOCUMENT 19352

Figure 1.3

16. Exchange the forward right bolt and rear left stud on the aluminum cover at the top front of

the engine (Figure 1.4).

Figure 1.4

Exchange these two fasteners

Front

OEM Alternator And

Power Steering Pump

Mounting BracketOEM

Fasteners

Cylinder Head

Mounting Area

Engine Block Mount

FRONT

LEFT SIDE

OF ENGINE

Peen Back This Area Of The Cover

DOCUMENT 19352

17. Remove and discard the two (2) battery 12 mm studs and nuts which retain the ground

straps on the lower left and right sides of the engine block (Figure 1.5).

18. Remove and discard the positive battery cable locating bracket from the same area.

Figure 1.5

19. Clean the front of the engine block thoroughly to ensure that there is no contamination in the

areas where the cooling tank and mounting bracket will fit. If the mounting area is dirty, the

bracket will not mount flush, resulting in fouling of the pulley or belt.

1.2 Installing the oil cooler

1. Install the cooler (complete with attached hoses) and slide the short hose on the cooler over

the water pump tube. Install the battery ground straps. Use the two (2) supplied M12 x

30 mm hex head cap screws (Figure 1.6) and 12 mm serrated washers. Torque the

fasteners to specifications.

Figure 1.6

OEM Ground Strap

Locations On Engine

M12 x 30 HHCS

Oil Cooler

OEM Transmission Cooler Lines

(automatic transmission only)

DOCUMENT 19352

2. Connect the lower cooler hose to the bottom radiator outlet (Figure 1.7). Tighten all the

hose clamps securely.

3. Fit two (2) 4” lengths of 1/2” rubber hose around the transmission line where they pass the

cooler bracket. Use ties to hold the rubber in position on the lines

Figure 1.7

1.3 Installing and mounting components

1. Install the crankshaft pulley using three (3) supplied M10 x 20 mm socket head cap screws.

Torque them to specifications.

2. Install four (4) 3/8” flat washers on the four (4) supplied M10 x 30 mm hex head cap

screws for the compressor mounting bracket. Apply Loctite to the fasteners.

3. Install the supplied VR7000 mounting bracket using the four (4) M10 x 30 mm hex head

cap screws (Figure 1.8). Torque them to specifications.

4. Install the power steering pump to the compressor mounting brackets using the OEM

fasteners.

5. Install the power steering pump pulley. The outer edge of the power steering pump pulley

must be flush with the end of the pump shaft.

HS28 Clamps

To Lower Radiator Outlet

To Engine Block

Connection

Bottom Radiator Hose

DOCUMENT 19352

Figure 1.8

6. Install the alternator onto the compressor mounting bracket using the OEM fasteners.

NOTE

7. Insert the supplied hose barb into the power steering rubber return hose which is attached

to the brake booster.

8. Install the supplied 3/8” x 11” power steering return hose on the other end of the hose barb.

9. Install one of the OEM hose clamps on the end which will attach to the power steering

pump fitting. Install the hose on the pump.

10. Re-align the power steering hoses to clear the steering column.

The alternator must be mounted 180 degrees (upside-down) from the original mounting

position. Rotate the alternator 180 degrees in a counterclockwise direction.

Four (4) M10 x 30

Hex Head Cap Screws

DOCUMENT 19352

1.4 Installing the compressor

1. Apply Loctite to the three (3) 8 mm studs and install them in the bottom of the compressor.

2. Install the compressor to the mounting bracket using three (3) supplied 8 mm nuts and 5/16”

flat washers. Use Loctite on these fasteners and torque them to specifications.

3. Remove the M12 × 80 mm hex head cap screw which retains the compressor belt

tensioner. Apply Loctite, install the fastener and torque it to specifications.

4. Remove the 1/2” x 1-1/4” NC hex head cap screw which retains the idler. Apply Loctite,

install the fastener and torque it to 117 ft-lb.

5. Install the OEM belt. Be sure to use the correct routing. (Figure 1.9).

Figure 1.9

6. Install the VR7000 belt. Be sure to use the correct routing (Figure 1.10).

Crankshaft

Pulley

Water Pump

Power

Steering

Alternator

Idler

Air Conditioning

Compressor

Idler

Tensioner

Figure 1.10

VR7000

Crankshaft

Pulley

VR7000

Te ns io n er

VR7000 Air

Compressor

VR7000

Idler

VR7000

Drive Belt

(part # 16231)

DOCUMENT 19352

7. Install the fan and the fan shroud.

8. Install clamps on the supplied upper radiator hose and fit it on the engine and radiator

fittings.

9. Rotate the hose on the thermostat housing and radiator fitting until the hose clears both the

compressor belt and the fan shroud. Tighten the clamps.

Figure 1.11 - After December 1998

NOTE

Figures 1.11 and 1.12 show the compressor installed on the engine, including the inter-

cooler tube. Figure 1.11 is for trucks manufactured after December 1998. Figure 1.12 is

for trucks manufactured before December 1998.

DOCUMENT 19352

Reverse This Intercooler Tube On Installation

Figure 1.12 - Before December 1998

9. Install the intercooler tube and tighten the clamps. Be sure that the tube clears the back of

the compressor and power steering pump and the bead inside the rubber OEM bellows sits

in the groove properly before tightening the clamps.

If your vehicle was manufactured before December 7, 1998, use the original intercooler

tube, but reverse direction, installing the end which was removed from the radiator in the

intake. Make sure that the tube is firmly installed and that the flexible fitting is completely on

the tube before tightening the clamps.

If your vehicle was manufactured after December 7, 1998, use the supplied intercooler

tube. Make sure that the tube is firmly installed and that the flexible fitting is completely on

the tube before tightening the clamps.

If the locating rib on the inside of the flexible tube does not seat correctly in the groove on

the intercooler tube, it is possible that the connection will come undone, allowing unfiltered

air into the engine. This can result in engine damage.

NOTE

DOCUMENT 19352

Part 2

Installing the

Air Tank, Filter and Lines

System #9037

1999-2000 FORD SUPER DUTY F250-F550

7.3 L POWER STROKE DIESEL

UNDERHOOD AIR COMPRESSOR

DOCUMENT 19353

Part 2: Installing the Air Tank, Filter and Lines

2.1 Installing the tank brackets and tank

1. The tank is mounted on the frame on the driver’s side of the vehicle, positioned so that it will

clear the body mounts, as shown in Figure 2.1. Figure 2.2 provides tank mount component

identification.

DOCUMENT 19353

Cab Mount

Ta n k

Crossmember Skidplate

Figure 2.1

When positioning the tank brackets on the frame, make sure that they will not pinch or

damage any wiring harnesses, lines or hoses.

NOTE

Figure 2.2

2. Clean the area on the frame between the two body mounts so that the brackets will mount

correctly.

3. Connect the 5/16” x 81” oil scavenge line and the 1/4” x 89” pressure control line to the

fittings on the top of the tank (Figure 2.5) before installing the tank.

4. Install the two C-clamps onto the tank, inserting the pinch bolt from the top to clear the

emergency brake cable. Install the washer and nut, but do not tighten.

Wire rope securing cable

Cable guide

Tank C-Clamp

L-bracket

Backing strap

Insert this bolt from the top

to clear the emergency brake cable

Spacer (F250-350 only)

DOCUMENT 19353

5. Install the two L-shaped tank brackets to the C-clamps on the tank. The short arm of the L

should be at the top of the tank, facing away from the tank. Install the four (4) 5/16” x 1/2”

hex head cap screws loosely with flat washers under each cap screw.

6. Locate the correct application in Figure 2.3 which corresponds to the model of truck on

which you are installing this system. Check the measurements to make sure that the location

of the clamps and brackets on your tank match those in Figure 2.3. Adjust the C-clamps to

match your application. Make sure that when the tank is mounted, the drain plug is at the

lowest location and that the tank orientation is as shown in Figure 2.5.

7. Insert the wire rope securing cables through the top slotted holes in the backing straps, then

pass the cable between the cab body and the frame from the inside, behind the transmission

cross member, with the backing straps on the inside of the frame.

On F250 & F350 trucks (all models) use the 10” backing straps that are

attached to the cable assembly.

On F450 & 550 trucks (all models) replace the front 10” backing strap with the

7-1/2“ backing strap that is packed separately.

8. Support the tank and L-bracket assembly in place on the outside of the frame, with the

short part of the L-bracket positioned over the top of the frame and pass each wire rope

securing cable around the L-bracket, between the bracket and the tank. Make sure that the

cable rests between the guide and the C-clamp.

9. Insert the threaded end of the securing cable through the bottom hole on the backing strap.

On F250 & F350 trucks (all models) install the 1/8” thick 5/16” x 3/4” washers,

the 1/2” x 2” spacer and the 5/16” nuts.

On F450 & F550 trucks (all models) install the 1/8” thick 5/16” x 3/4” washers

and the 5/16” nuts. Discard the 1/2” x 2” spacer.

10. Refer to Figure 2.3 to ensure that the positioning dimensions are correct for your model.

On the F450 & F550 standard cab models (2x4 and 4x4) position the rear tank

bracket so that the front edge of the backing strap is approximately 1-1/4” back

from the forward edge of the cut-out for the transfer case. Make sure that the

threaded end of the securing cable is not positioned next to the transfer case

housing, as torque movement will cause the transfer case housing to strike the

threaded end of the securing cable.

11. When the tank is correctly positioned, tighten the securing cable retaining nuts until the

cables pull tight and snug around the frame. Do not overtighten the nuts.

12. Install a second 5/16” nut and tighten it securely against the first to act as a locknut.

Figure 2.4 shows various views of the installation on different models.

NOTE

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Vmac 9037 Installation guide

Vmac 9037 Installation guide

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