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Installation Manual
For The
System #9040
UNDERHOOD AIR COMPRESSOR
1998½-2001 DODGE
5.9 CUMMINS 24 VALVE DIESEL
(with air conditioning)
TEL: 250-754-6997
FAX: 250-754-6972
TOLL FREE: 800-738-8622
1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3
DOCUMENT 19553
Installation Manual
VR7000 Underhood Air Compressor
System Number 9040a
Application: 1998½-2001 Dodge with the 5.9 Cummins 24 Valve Diesel Engine with Air
Conditioning
Publication Date: October 2000
Publication Number: 19553
Origination Documents: #19553a - introduction
#19554 - compressor and regulator installation
#19555 - oil cooler, air tank and line installation
#19556 - control unit installation
#19557 - throttle controller installation
#19558 - illustrated parts list
#19130 - warranty registration
Registered Trademarks:
VR7000, VMAC and Throttle Commander are registered trademarks of VMAC.
Dodge and Magnum are registered trademarks of Daimler-Chrysler AG.
Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.
Nylok is a registered trademark of Nylok Fastener Corporation.
Copyright 2000
The contents of this manual may not be reproduced in any form without the express written
permission of VMAC
Contents
GENERAL INFORMATION ........................................................................................3
INTRODUCTION ...............................................................................................................5
INSTALLATION NOTES ...................................................................................................... 6
ORDERING PARTS .........................................................................................................7
WARRANTY ................................................................................................................. 7
CHANGES AND IMPROVEMENTS ...........................................................................................7
PART 1: INSTALLING THE COMPRESSOR AND THROTTLE CONTROLLER ... 9
1.1 PREPARING FOR INSTALLATION ................................................................................... 11
1.2 INSTALLING THE BRACKET .........................................................................................13
1.3 INSTALLING THE VR7000 COMPRESSOR AND OTHER COMPONENTS ..........................................15
1.4 INSTALLING THE THROTTLE CONTROLLER ASSEMBLY ..........................................................19
PART 2: INSTALLING THE OIL COOLER, TANK AND LINES ............................21
2.1 INSTALLING THE OIL COOLER ......................................................................................23
2.2 INSTALLING THE TANK MOUNTS ...................................................................................23
2.3 CONNECTING THE LINES ...........................................................................................25
2.4 ADDING OIL TO THE SYSTEM ......................................................................................28
2.5 COMPLETING THE INSTALLATION ..................................................................................29
PART 3: INSTALLING THE CONTROL UNIT ........................................................31
3.1 CONTROL UNIT INSTALLATION ....................................................................................33
3.2 CONNECTING THE WIRING ..........................................................................................34
PART 4: INSTALLING THE THROTTLE CONTROLLER .....................................37
4.1 INSTALLING THE CABLE ............................................................................................39
ILLUSTRATED PARTS LIST ..................................................................................43
WARRANTY REGISTRATION .................................................................................49
1
2
General Information
System #9040
1998½-2001 DODGE
5.9 CUMMINS 24 VALVE DIESEL
(with air conditioning)
UNDERHOOD AIR COMPRESSOR
3
DOCUMENT 19553a
4
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.
General Information
Introduction
This book provides installation instructions for:
VMAC under-hood air compressor installation kit
VMAC Pneumatic Throttle Control
This kit has been designed for:
1998½-2001 Dodge equipped with a Cummins 5.9 24 valve ISB diesel engine with air
conditioning.
Installation steps
The installation procedure in this manual has four main steps:
Part 1: Installing the Compressor
Part 2: Installing the Oil Cooler, Air Tank and Lines
Part 3: Installing the Control Unit
Part 4: Installing the Pneumatic Throttle Control
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)
5
WARNING
!
NOTE
DOCUMENT 19553a
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 re-routed or shifted during installation must be secured
so that they do not contact excessively hot areas or sharp edges. When provided, 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, drilling 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). Always use manufacturers torque
values for OEM fasteners.
The above fastener torque values are applicable when Loctite is used. If the threads are
dry, add 20% to the torque values.
6
DOCUMENT 19553a
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 9 18 35 55 80 110 170 280
STANDARD GRADE 8 NATIONAL FINE THREAD
Size 3/8 7/16 1/2 5/8 3/4
Foot-pounds 40 60 90 180 320
METRIC CLASS 10.9
Size M8 M10 M12 M14 M16
Foot-pounds 19 41 69 104 174
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, Monday through Friday
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 front body support on the passenger side of the vehicle where the
OEM decals are located (Figure 1) . 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.
Figure 1 Location of System Identification Number Plate
Changes and improvements
These products and documents are subject to changes or improvements without notice.
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DOCUMENT 19553a
8
Part 1
Installing
the Mounting Bracket,
Compressor
and Throttle Controller
Mounting Bracket
System #9040
1998½-2001 DODGE
5.9 CUMMINS 24 VALVE DIESEL
(with air conditioning)
UNDERHOOD AIR COMPRESSOR
9
DOCUMENT 19554
10
Part 1: Installing the Compressor
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.
Figure 1.1 Wiring plug beside the battery
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.
11. Remove the coolant return hose from the transmission cooler at the square block tee
connector (Figure 1.2).
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DOCUMENT 19554
12. Loosen the securing clamp which retains the two 1/2” 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 the four (4) hex head cap screws retaining the air conditioning compressor.
19. Carefully move the air conditioning compressor and rest it on the chassis (or slide forward
towards radiator on 2x4 models). Leave the OEM bolts in place in the AC compressor.
Tie or wire the compressor in place so that it does not fall from the chassis and hang by the
air conditioning lines. Do not loosen or disconnect thelines from the compressor.
20. Remove and discard the transmission heat exchanger supply pipe and hose from the front of
the transmission cooler to the cylinder head outlet (Figure 1.3).
21. Remove the T-connector in the bottom hose housing (Figure 1.2).
22. Remove the three (3) 10mm OEM cap screws from lower radiator hose outlet and the
three (3) 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.
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DOCUMENT 19554
Figure 1.2 Location of hoses, fittings and fasteners
Heater
return
hose
Transmission
heat exchanger
return hose
Tee connector Lower radiator hose location
OEM M10 hex
head screws
(2 hidden)
Transmission heat
exchanger supply
pipe
Engine block
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DOCUMENT 19554
Figure 1.3 Location of hoses and fittings
On automatic transmission vehicles,
remove and discard this hose and metal
line, on manual transmission vehicles,
remove the blanking plug from this location
Tee connector with heater coolant return
and transmission heat exchanger return
lines. Disconnect hoses and remove Tee.
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 (Figures 1.4 and 1.5).
ManualTransmission
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 the fitting
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DOCUMENT 19554
Figure 1.5 Hose connections and fittings
2. Connect the supplied 40 x 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.
3. Check the machined surface on the engine block and clean it before attempting to mount
the VR7000 bracket.
4. Remove the belt tensioner, idlers and the lower front AC stub from the VR7000 bracket to
make installation easier.
5. Apply Loctite PST and install the Tee connector (removed earlier) into the rear of the
VR7000 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 (3) OEM M12 hex bolts loosely through the lower section of
the bracket and into the engine.
The roll pins on the VR7000 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 (3) 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. Installthe OEM belt tensioner to the VR7000 bracket using the OEM cap screw. Then
install the VR7000 belt tensioner and both VR7000 idlers removed before fitting the
bracket (Figure 1.7). 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 pointusing the M8 x 20 hex head cap screw. Thread the four (4) A/C cap screws
into place and torque to specifications
10. Install the OEM lower rad hose and clamp. You may have to bend the A/C line slightly to
provide clearance for the belt tensioner.
Cooling line fitting
(note angle)
Socket head cap screw
Heater hose connection
1.3 Installing the cooler hoses and compressor
1. On automatic transmission models, connect the supplied 50 x 5/8 inch heater hose to the
front end fitting on the OEM transmission cooler (located on the side of the engine under the
exhauast manifold). Install a hose clamp and tighten. Route the hose foward 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 Tee and secure it with the
supplied hose clamps Route the hose clear of the exhaust manifold and tie it to the A/C line,
then route it forward and down under the radiator and clear of all hot or moving parts.
Cutting the hose Installing the L-shaped bracket
Figure 1.6
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 2 supplied 8 x 25 mm socket head cap screws
to the front and supplied 10 x 25mm cap screws to the side (Figure 1.6).
4. Apply Loctite and thread the three (3) 8mm studs into the holes in the bottom of the
compressor. Place the compressor on the mounting bracket. Install the three 5/16 flat
washers, apply Loctite, thread the three (3) 8mm nuts on the studs and tighten.
Figure 1.7 Installing the tensioners
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DOCUMENT 19554
Tensioners
Cut this hose
1-10 x 25 SHCS 2-8 x 25 SHCS
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DOCUMENT 19554
OEM Cab Heater
Supply Line From
Manifold
Cut Heater Return
Hose Approximately
1" Before The Bend
Install The Supplied Plastic Tee
Secure Lines
With Ties
Air Conditioning Line
Cab Firewall
Figure 1.8 Connection for manual transmission models
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 VR7000 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 VR7000 pulley to the OEM pulley after cleaning out all dirt and debris using the
OEM bolts.
10. Install the replacement OEM drive belt.
11. Install the VR7000 belt.
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DOCUMENT 19554
Figure 1.9 Compressor and alternator installed on the engine
Alternator
Fan
Crankshaft
Water Pump
Air Conditioning
Compressor
Tensioner
Crankshaft
VR7000 Tensioner
VR7000 Idlers
VR7000 Compressor
Figure 1.10 OEM and VR7000 belt routing
OEM BELT ROUTING
VR7000 BELT ROUTING
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
3 1
15
1
23
4
Cut These Three
Ribs Flush With
The Fan Shroud
1
Remove This
Section Including
The Plastic Bracket
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DOCUMENT 19554
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 VR7000 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 new 11 3/4” long 3/8” hose and two clips
to the expansion tank and radiator.
Figure 1.12 Expansion tank bracket installation
Push The Air Conditioning Fitting Under The Lip Of The Fender
VR7000 Bracket
Fan Shroud Radiator
Coolant Expansion
Bottle
/
