Vmac V990002 Installation guide

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

1

Installation Manual for VMAC

System V990002

Ford 2005 - 2006 6.0L Power Stroke Diesel

Odin Foam - Without Dual Alternators

General Information..................................................................... 3

Before You Start ..................................................................... 3

Part 1: Preparing for Installation ............................................... 4

1.1 Preparing for Installation ................................................. 4

1.2 Modifying the Passenger Battery Tray ........................... 7

1.3 Mounting the Vacuum Tank ............................................ 9

1.4 Glow Plug Modules .......................................................... 12

1.5 Relocating the ICP Sensor .............................................. 12

1.6 Installing the Crank Pulley .............................................. 12

Part 2: Installing the Tank and Hoses....................................... 13

2.1 Installing the Brackets ..................................................... 13

2.2 Installing the Tank ............................................................ 16

Part 3: Installing the Cooler, Bracket and Compressor .......... 18

3.1 Installing the Oil Cooler ................................................... 18

3.2 Installing the Main Bracket .............................................. 20

3.3 Installing the Compressor ............................................... 23

3.4 Completing the Installation ............................................. 26

3.5 Adding Oil to the System ................................................. 31

Part 4: Installing the Control Components .............................. 32

4.1 Installing the Components .............................................. 33

4.2 Connecting the Under-hood Wiring................................ 34

4.3 Connecting the In-cab Wiring ......................................... 35

4.4 Completing and Testing the Installation ........................ 39

Part 5: Finishing the Installation ................................................ 41

5.1 Before Starting the Engine Checklist ............................. 41

5.2 After Starting the Engine Checklist ................................ 41

5.3 Setup, Performance Testing and Adjustments ............. 42

5.4 System Identification and Warnings .............................. 43

5.5 Auxiliary Air Receiver ...................................................... 44

Accessory Products from VMAC ............................................... 45

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Document #1930091

Installation Manual for VMAC System V990002

Ford 2005 - 2006 6.0L Power Stroke Diesel

Odin Foam – Without Dual Alternators

Changes and Revisions

Version

Revision Details

Revised by/date

Approved

Implemented

00

Original manual

IB 18 Apr 2005

SM 10 May 2005

12 May 2005

a

2005 rear tank bracket

IB 07 Jun 2005

BC 09 Jun 2005

11 Jun 2005

b

2006 revisions

IB 09 Sep 2005

SM 11 Sep 2005

15 Sep 2005

c

2006 revisions

IB 04 Oct 2005

SC 04 Oct 2005

07 Oct 2005

Important Information

The information in this manual is intended for certified VMAC

installers who have been trained in installation procedures and for

people with mechanical trade certification who have the tools and

equipment to properly and safely perform the installation. Do not

attempt this installation if you do not have the appropriate

mechanical training, knowledge and experience.

Follow all safety precautions for underhood mechanical work. Any

grinding, bending or restructuring operations for correct fit in modified

vehicles must follow standard shop practices.

These instructions are a general guide for installing this system on

standard production trucks and do not contain information for

installation on non-standard trucks. This system may not fit special

order models or those which have had other changes without

additional modifications. If you have difficulty with the installation,

contact VMAC.

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.

To order parts, contact your VMAC dealer. Your dealer will ask for

the VMAC serial number, part number, description and quantity. To

locate your nearest dealer, call 1-800-738-8622.

All trademarks used in this manual are the property of the respective copyright holder.

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

written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3.

Printed in Canada

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General Information

Before You Start

Read this manual before attempting installation so that you can

familiarize yourself with the components and how they fit on the

vehicle. Identify variations for different model years and different

situations that are listed in the manual. Open the package, unpack

the components and identify them.

All fasteners must be torqued to specifications. Use manufacturers

torque values for OEM fasteners. Apply Loctite 242 or equivalent on

all engine-mounted fasteners. Torque values are with Loctite applied

unless otherwise specified.

STANDARD GRADE 8 NATIONAL COARSE THREAD

Size

1/4

5/16

3/8

7/16

1/2

9/16

5/8

¾

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

¾

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 (ft-lb)

19

41

69

104

174

Newton meter (N•m)

25

55

93

141

236

Hose Coding

Different frame designations will affect the tank mounting position. If

you have to move the tank, the lines may be too short. Measure the

hose shortfall and order a Hose Extender Kit. The following table

shows the color code used by VMAC to identify hose diameters.

Hose Diameter

Colour-Coded Label

1/4 inch

5/16 inch

1/2 inch

5/8 inch

3/4 inch

1 inch

Yellow

Orange

Blue

Green

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Part 1: Preparing for Installation

1.1 Preparing for Installation

Preparation for installation is very important. Missing an item can

cause problems in the installation or even damage to components.

Check off each item as it is completed so that you do not miss any

preparation steps.

□ Drain the cooling system, remove the upper and lower radiator

hose and disconnect the coolant expansion tank hose from the

top of the radiator.

□ Disconnect the batteries and remove the passenger side battery.

□ Remove the plastic air deflector from the upper section of the fan

shroud. Keep this part if the vehicle is to be returned to stock

condition.

□ Remove the two screws securing the upper section of the fan

shroud to the radiator. There are two options for removing the

fan shroud (you can remove the air cleaner to make this easier):

a. Carefully pry the shroud upward to release the rubber seal

from the groove in the stator. Push the top corner of the

shroud back to clear the upper hose spigot and pull the

shroud out. Be careful not to crack the shroud.

b. Locate the molded lines on the fan shroud, one on each side

about 6 inches (15cm) down from the top (Figure 1.1). Use a

suitable tool to cut the fan shroud between these lines

(Figure 1.1). Do not cut the rubber seal. Remove the upper

shroud section along with the rubber seal, then remove the

lower fan shroud section.

□ Disconnect the fan clutch wiring harness from the fan stator and

the fan clutch wiring plug connector. Remove the fan.

□ Remove the rear fan stator (large plastic section with cooling fins

behind the fan) and store it for future use if the vehicle is to be

returned to stock condition.

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Upper shroud

Lower shroud

Rubber seal

Cut along molded line

Figure 1.1

□ Remove the four bolts from the water pump pulley and replace

them with the supplied low profile head bolts.

□ Remove the OEM serpentine belt.

□ Remove the OEM belt tensioner assembly.

□ Remove the intercooler tube on the passenger side and keep the

2-1/2 inch OEM clamps. Discard the intercooler tube, the

connecting hose from the intercooler and the two larger T-bolt

clamps.

Cover the turbo outlet and the intercooler inlet to

protect the system.

□ Disconnect and remove the glow plug relay module with the

mounting bracket. Detach the module from the mounting bracket,

discard the bracket but keep the nuts.

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□ Unscrew the engine oil fill tube. Plug the oil filler opening to

protect the engine.

□ On automatic transmission models, remove the transmission

dipstick from the passenger side valve cover and install the

supplied bracket (using the OEM nut) with the spacer facing

down and away from the valve cover. Attach the transmission

dipstick to the lower spacer of the bracket using the supplied

fasteners.

□ Remove the wiring harness retainers from the studs at the front

of the valve cover. Cut the tape back far enough so that you can

reroute the harness behind the transmission dipstick tube and

over the valve cover. Most of the wiring and the glow plug

connectors should be behind and below the alternator.

□ Cut off the upper threaded section of the two front valve cover

bolt (just below the alternator) flush with the hex nut.

□ Remove the steel heater return pipe with rubber O-ring. Save the

O-ring and the M6 bolt. Disconnect the steel pipe from the heater

hose and discard the pipe.

Figure 1.2

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□ Install the OEM O-ring onto the replacement heater hose barb

connector and install it into the front of the engine where the

heater hose pipe was removed (Figure 1.2). Cut a short piece of

3/4 inch hose from the supplied 8 inch piece, fit it onto the hose

barb and secure it with a clamp.

□ Insert the long end of the supplied replacement steel heater pipe

into the short 3/4" heater hose and position the short end with

the tab along the alternator, pointing toward the firewall.

□ If equipped, remove the sound proofing from the underside of the

hood.

□ Remove the plastic clips holding the flexible mud deflectors to

the top and bottom of the radiator cross-member.

□ For easier installation of the cooler, remove the bolts from the

small power steering cooler in front of the radiator cross-member

and leave it loose in position. You can also remove the radiator

hold-downs and raise the radiator for better access.

□ Some trucks may have a crossbeam behind the air dam and

under the radiator while others may have a crossbeam that also

retains the tow-hooks. This can be removed to provide easier oil

cooler installation.

1.2 Modifying the Passenger Battery Tray

□ Remove the passenger side battery tray.

□ Turn the battery tray over and cut off the fender bracket along

the bottom crease of the battery tray (Figure 1.3).

□ Install the supplied battery bracket to the inner side of the

passenger fender using the two OEM M8 bolts (Figure 1.4).

□ Install the passenger side battery tray reversed 180 degrees and

fasten it in place with 5/16 x 1 inch bolts with 3/8 inch flat

washers and 5/16 inch lock washers and nuts. The battery tray

hold-down clamp should face to the rear of the vehicle and the

tray should be on a slight angle. Slide the tray as far forward as

possible.

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You may have to trim off some of the plastic web on the

windshield washer bottle to clear the edge of the battery

tray.

Figure 1.3

Battery bracket

Figure 1.4

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□ Drill an 11/32 inch diameter hole through the OEM support

bracket using an existing hole in the battery tray as a guide.

Install a 5/16 x 1 inch bolt with 3/8 inch flat washer and 5/16 inch

lock washer and nut. Tighten all fasteners.

1.3 Mounting the Vacuum Tank

If the truck does not have air conditioning, you must

still relocate the vacuum tank on the plastic fender liner

to clear the compressor but will not have to replace the

short hose or use the mount bracket.

□ Remove the vacuum tank from the passenger side fender and

save the nuts for reinstallation.

□ Disconnect the hoses from the vacuum tank and discard the

short hose from the vacuum pump to the vacuum tank.

□ Remove the three bolts mounting the air conditioning

receiver/dryer from the heater housing.

If necessary, remove the fender liner for better access.

□ Carefully bend the forward facing top larger air conditioning line

out towards the inner fender until parallel to the fender. Twist on

the vertical section while supporting the receiver/dryer canister

and push inwards. This can be accomplished using a long pry

bar protected where it rests between the two vertical sections of

the lines (Figure 1.5).

□ Bend the other line by pulling upward and forward on the

receiver/dryer canister to provide adequate clearance.

□ Remove and discard the plastic shroud from the receiver/dryer.

□ Remove the bolt and clamping components from the supplied

heavy duty clamp and slide the clamp up onto the receiver drier

with the open side towards the front of the vehicle, above the

electrical connection.

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First bend

Support first

bend by pushing

here

Second bend

pull up on the

bottom of the

cannister toward

the front

Position the cannister in front of the wiring plug

Place the clamp above the electrical

connector facing forward

Figure 1.5

□ Install the clamping bolt in the clamp and through the vacuum

tank bracket. Leave the clamp loose enough so that you can

adjust the position (Figure 1.5).

□ Remove the front bolt holding the vacuum pump bracket to the

passenger side fender. Place the supplied vacuum tank bracket

in position over the OEM vacuum pump bracket and install the

OEM bolt.

□ Mount the vacuum tank bracket using the original OEM M6 nuts

with the hose connections at the bottom, angled at approximately

45 degrees (Figure 1.6). If required, bend up OEM vacuum pump

and OEM vacuum pump bracket approximately 20 degrees to

clear the air conditioning condenser (Figure 1.7).

□ Install the supplied 1/8 inch rubber hose between the vacuum

pump and the vacuum tank and connect the other hoses.

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Figure 1.6

Figure 1.7

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1.4 Glow Plug Modules

□ Mount the glow plug module to the supplied bracket using the

two OEM M6 nuts so that the module will face toward the center

of the engine when the bracket is installed.

□ Install the assembly on the passenger side engine valve cover

studs beside the engine oil fill-tube using OEM nuts.

□ Wrap any loose OEM wires with tape and connect the glow plug

relays. Make sure that the wire harness is secured behind the

alternator where it will not touch the compressor or turbocharger.

□ Install the oil fill tube.

1.5 Relocating the ICP Sensor

On trucks after 2004.5, the ICP sensor is located on the passenger

side valve cover.

□ Remove the ICP sensor. Make sure that the sealing O-ring

gasket is on the sensor.

□ Thread the sensor into the supplied banjo fitting and tighten.

□ Install the banjo fitting into the valve cover. Make sure that the

copper sealing gaskets are in good condition and are in place.

Point the ICP sensor toward the rear of the truck and torque the

banjo fitting to 15 ft-lbs.

1.6 Installing the Crank Pulley

□ Clean the face of the OEM pulley, install the VR pulley, align the

bolt holes and ensure that the pulley is sitting flush. Apply

Loctite, install three M10 x 70 mm bolts and flat washers and

torque to specification.

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Part 2: Installing the Tank and

Hoses

2.1 Installing the Brackets

For 2005-2006 F450 and F550 model trucks see the

special installation instructions for the rear tank mount.

□ Remove the bolts, washers and nuts from the tank clamps and

the P-clips from the stand-off brackets.

□ Lay the tank brackets on a flat surface with the wide flanges

away from each other (Figure 2.1). The front and rear brackets

are different and are stamped “Front” and “Rear”.

Upper frame clip

P-clip and

stand-off

bracket

Inner tank clamp

Lower frame clip

Spacer (not used on wide frames)

5/16” x 1/2”

Figure 2.1

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□ Insert the cable straps through the upper frame clips and place

one cable on each tank bracket with the cables in the grooves.

□ Place one inner tank clamp onto the front tank bracket. Place

one stand-off bracket under the top front hole.

□ Apply Loctite to the 5/16 x 1/2 inch hex head bolts (with flat

washers) and attach the inner clamp to the front tank bracket

(the top front bolt also mounts the stand-off bracket). Tighten all

the bolts.

2.1.1 All Trucks Except 2005 - 2006 F450 and F550

□ Place the inner tank clamp on the rear tank bracket with the

stand-off bracket under the top rear hole. Apply Loctite and

attach the clamp to the bracket using 5/16 x 1/2 inch hex head

bolts. Tighten all the bolts.

□ Clean the area on the frame between the two cab mounts on the

passenger side and place the front bracket on the frame in front

of the transmission cross-member and as far forward on the

frame as possible. Place the upper frame clip on the frame rail

and make sure the frame seats in the groove.

□ Wrap the cable under the frame, insert the lower frame clip and

make sure the frame is seated in the clip. Install a spacer (if

necessary) a washer and a nut. Tighten the nut securely (do not

over-tighten) and install a second nut as a lock.

□ Place the rear bracket behind the transmission cross-member

and as far back as possible. Attach in the same manner as the

front bracket.

The tank brackets must be positioned far enough apart

to provide good support for the tank, but must not be

positioned in any location where the tank will not be

level when installed.

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2.1.2 2005 – 2006 F450 and F550

□ Place spacers on the rear tank bracket as shown in Figure 2.2;

1/2 inch spacers on the top and bottom front holes, 5/8 inch

spacer on the top rear hole and a 3/4 inch spacer on the bottom

rear hole.

□ Place the inner tank clamp on the spacers with the stand-off

bracket under the top rear hole.

□ Apply Loctite and install 5/16 x 1 inch bolts with washers through

the two front holes, 1/2 inch spacers and into the bracket.

□ Apply Loctite and install a 5/16 x 1-1/4 inch bolt with washer

through the top rear hole, stand-off bracket, 5/8” spacer and into

the bracket.

□ Apply Loctite and install a 5/16 x 1-1/4 inch bolt with washer

through the bottom rear hole, 3/4 inch spacer and into the

bracket. Tighten all the bolts.

Stand-off bracket

Rear tank bracket

Inner tank clamp

5/8” spacer

1/2” spacers

3/4” spacer

5/16” x 1”

5/16” x 1-1/4”

Figure 2.2

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□ Clean the area on the frame between the two cab mounts on the

passenger side and place the front bracket on the frame as

shown in Figure 2.3. Place the upper frame clip on the frame rail

and make sure the frame seats in the groove.

□ Wrap the cable under the frame, insert the lower frame clip and

make sure the frame is seated in the clip. Install a spacer (if

necessary) a washer and a nut. Tighten the nut securely (do not

over-tighten) and install a second nut as a lock.

□ Place the rear bracket on the frame as shown in Figure 2.3 and

attach in the same manner as the front bracket.

7.5” 4”

Tops will be about

1/4” closer together

Figure 2.3

2.2 Installing the Tank

□ Install the front outer tank clamp with both bolts and washers and

leave the bolts very loose.

□ Lift the tank and slide it into the front clamp.

□ Install the rear outer tank clamp.

□ Position the tank for sufficient clearance at both ends and rotate

the tank until the arrow molded into the rear of the tank is

pointing upward. Tighten the clamp bolts.

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□ Thread the fittings of the 1/4 and 5/16 inch steel tubes into the

matching fittings on the rear of the tank with the flexible hose end

to the front of the truck. (Figure 2.4).

□ Install the P-clips on the two steel lines and fasten them to the

stand off brackets. Adjust the tubes in the P-clips as necessary

and tighten the fittings and P-clip bolts.

Figure 2.4

□ Connect the straight end of the longest 5/8 inch hose to the

matching fitting on the front of the tank. Route this hose along

the frame rail, over and inside the cab mounting bracket and

around the steering idler arm to the front of the vehicle. Do not

tighten the fitting.

□ Connect the straight end of the 1-1/4 inch hose to the matching

fitting on the front of the tank. Route this hose outside the cab

mount, up behind the mud guard and fender liner towards the

rear of the engine and along the passenger side valve cover. Do

not tighten the fitting.

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Part 3: Installing the Cooler,

Bracket and Compressor

3.1 Installing the Oil Cooler

□ Insert M10 x 90 mm bolts into the top of the two mount brackets

(Figure 3.1) and place them over the cross-member that runs

under the radiator, outboard of each power steering mounting

bracket.

M10 x 90 mm bolts

with washers

Spacers

Mount brackets

Figure 3.1

□ Place the cooler in position with the threaded fittings facing to the

rear of the vehicle (Figure 3.2) and thread the top bolts into the

top outermost holes on the cooler mount. Leave the bolts loose

enough so that you can move the cooler on the cross-member.

□ Insert bolts into the lower holes and install the spacers. Thread

them into the outermost lower holes on the cooler mount.

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To engine

To radiator

Cross-member

Coolant

bypass

hose

connection

1/2” hose to compressor 1/2” hose from tank

Figure 3.2

□ Loosen the clamp on the hoses attached to the cooler. Connect

the hose to the lower radiator spigot, adjust for best fit and

tighten the clamps.

On some models, the hose will interfere with the

steering linkage. If necessary, cut some material off the

radiator end of the hose to move the hose forward and

away from the steering linkage.

□ Install the OEM lower hose between the engine spigot and the

cooler and secure it with clamps.

□ Connect one end of the longest supplied heater hose to the

spigot on the side of the cooler and secure it with a clamp. Route

the hose up to the engine.

□ Connect the 90 degree end of the 5/8 inch hose from the VR

tank to the passenger side fitting on the cooler. Do not tighten

the fitting.

□ Connect the 90 degree end of the short 5/8 inch hose to the

cooler and route it up the passenger side of the engine

compartment. Do not tighten the fitting.

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□ Adjust the cooler as required to provide a good fit with all hoses

and tighten the mounting bolts.

3.2 Installing the Main Bracket

Due to vehicle assembly variations, the rear right corner

of the main bracket may interfere with the right hand

rocker cover. Make sure that there is clearance between

the bracket and rocker cover before tightening down the

bracket. If necessary, grind a small amount of material

off the bracket where the interference exists until

adequate clearance is achieved.

□ Remove the idlers, idler mount bracket and tensioner from the

main bracket.

□ Mount the main bracket to the right-hand side of the engine

using three M10 x 55mm flange lock bolts (with Loctite) in the

two upper holes and one in the lower outer-most hole. Check to

make sure that the bracket is not interfering with any OEM parts.

□ Carefully bend the air conditioning lines as necessary to provide

clearance for the bracket and compressor. You may have to

adjust line position again once the compressor is installed.

Do not twist, break or damage the air conditioning lines.

Make sure that the connections at the receiver/drier are

not damaged or cracked while repositioning the lines.

□ Route the A/C compressor wiring harness behind the bracket.

Make sure it is not pinched by the bracket.

□ Install the M10 x 35mm flange head bolt into the lower inner-

most attachment point (Figure 3.3) and torque to specifications.

□ Install the OEM belt tensioner.

□ Install the OEM 8-rib belt (Figure 3.4).

□ Install the idler mount bracket to the main bracket using three

M8 x 25 mm socket head bolts and install the idler (Figure 3.5).

!

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Vmac V990002 Installation guide

Vmac V990002 Installation guide

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