Vmac V900069 Installation guide

System V900069

2003 - 2004 GMC C4500 - 5500

6.6L Duramax Diesel

www.vmacair.com

VR70 UNDERHOOD

AIR COMPRESSOR

INSTALLATION MANUAL

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 1

Installation Manual for VMAC

System V900069

General Motors 2003 – 2004

Duramax Diesel

C4500 - 5500

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

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

Special Installation Notes...................................................... 4

Part 1: Preparing for Installation............................................... 5

1.1 Preparing for Installation................................................. 5

Part 2: Installing the Tank and Hoses....................................... 9

2.1 Installing the Brackets and Tank.................................... 9

Part 3: Installing the Main Bracket and Compressor.............. 11

3.1 Installing the Main Bracket.............................................. 11

3.2 Installing the Cooler......................................................... 14

3.3 Connecting the VR Hoses ............................................... 15

3.4 Mounting the Fuel Module and Hoses ........................... 16

3.5 Completing the Installation............................................. 18

3.6 Adding Oil to the System................................................. 19

Part 4: Installing the Control Components .............................. 20

4.1 Installing the Control Components ................................ 21

4.2 Connecting the In-cab Wiring ......................................... 22

4.3 Connecting the Underhood Wiring................................. 23

4.4 Connecting the Power Supply Wire................................ 25

4.5 Completing and Testing the Installation........................ 25

Part 5: Finishing the Installation................................................ 27

5.1 Before Starting the Engine Checklist............................. 27

5.2 After Starting the Engine Checklist................................ 28

5.3 Setup, Performance Testing and Adjustments............. 29

5.4 System Identification and Warnings .............................. 30

5.5 Auxiliary Air Receiver ...................................................... 31

Accessory Products from VMAC............................................... 32

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Document 1930016

Installation Manual for VMAC System V900069

General Motors 2003 – 2004 Duramax Diesel

C4500 - 5500

Changes and Revisions

Version Revision Details Revised by/date Approved Implemented

00 Original manual IB 16 Nov 2004 SC/SM 25 Jan 2005 27 Jan 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.

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. The following table shows the color code used

by VMAC to define the different 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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Special Installation Notes

The following special tools are required:

• 36 mm 12 point 1/2 inch drive socket for removing the OEM

crankshaft bolt

• crankshaft locking tool (GM #J-44643) or VMAC equivalent

(Part #5900010)

• VMAC crankshaft pin extraction tool (Part #5900076)

The following additional materials are recommended:

• assorted sizes of fireproof protective plastic loom

• assorted lengths of nylon tie-straps

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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.

□ Disconnect the batteries.

□ Drain the coolant.

□ Disconnect the MAF sensor wire from the air cleaner and

remove the complete air intake assembly, complete with rubber

air intake pipe, air ducting and the plastic intake resonator

chamber from the top of the engine.

□ Remove the plastic inner fender liner on the passenger side.

□ Disconnect the hoses from the coolant expansion tank,

disconnect the level sensor connector and remove the tank.

□ Remove the air cleaner base mounting plate and support

bracket.

□ Remove the top radiator hose.

□ Remove the upper fan shroud.

□ Remove the fan using the appropriate fan wrench.

□ Remove the OEM belt.

□ Remove the passenger side intercooler tube and hoses.

□ Remove and discard the metal tube between the heater hose

and the lower radiator hose.

□ Remove the lower radiator hose.

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□ Disconnect the fuel inlet and outlet banjos from the fuel

management module, remove the module and move it out of the

way. Remove the rubber washers, plastic spacers, mounting

bolts and banjo fitting seals so they will not get lost.

□ Remove all wire harness retainers from the OEM alternator

mount bracket.

□ Remove the alternator and keep the bolts.

□ Remove the OEM idlers and tensioner.

□ Remove the breather hose from between the lower engine block

and the check valve in the bottom of the breather chamber

casting (Figure 1.1).

□ Remove the 8 mm bolt from the cast alternator mounting bracket

that holds the breather tube and wire harness (Figure 1.2).

□ Remove the bolt securing the engine breather hose and steel

pipe from the breather chamber in the cast aluminum bracket

and remove the hose and pipe.

Breather check valve

Figure 1.2

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Engine breather chamber

Fuel bleed valve studs

8 mm bolt

for breather

tube clamp

Breather tube

Figure 1.3

□ Cut the tie wrap holding the loom and breather tube together;

remove and discard the steel breather pipe from the end of the

rubber breather hose.

□ Remove the two nuts from the fuel bleed valve studs.

□ Remove the short fuel outlet hose and angled banjo fitting from

the engine-side fuel rail. Remove the banjo from the hose and

discard the hose.

□ Remove the OEM mount bracket from the engine. Remove the

check valve from the bottom of the casting. Keep the OEM cast

mounting bracket if you intend to return the truck to original

condition.

□ Unclip the top of the wire harness plastic channel attached to the

engine fuel rail, carefully lift out the wiring and cut the ties

holding the module-end of the channel.

□ Remove the rock guard from under the front of the truck (if

equipped).

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□ Install a crankshaft locking tool, remove the crank pulley bolt and

remove the crank pulley. If you are using the VMAC tool:

• put the socket on the nut

• put the single-pin end of the tool on the front of the pulley with

the locking tool hanging straight down

• put a short extension and long flex-bar on the socket

• turn the engine until the pin on the tool makes contact and the

tool jams against the protruding center-piece of the cross-

member under the front of the engine.

□ Remove the crankshaft pin using the VMAC extraction tool:

• fit the split end of the tool (on the end of the shaft) over the

crankshaft pin and tap downward with the slide-hammer to

make sure that it is seated correctly

• tighten the pinch bolt securely

• use the hammer action of the slider in an upward motion to

remove the pin from the crankshaft

□ Install the replacement crankshaft/harmonic balancer locating pin

and tap it home using a brass drift and a small hammer. Ensure

that the head of the pin is aligned with the crankshaft by twisting

it into position with a crescent wrench (Figure 1.1).

High-strength

crank pin

Figure 1.1

□ Apply a light wipe of oil to the inside of the OEM crank pulley and

install the pulley back onto the crankshaft.

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Part 2: Installing the Tank and

Hoses

2.1 Installing the Brackets and Tank

The tank will mount under the driver side frame rail behind the step

(Figure 2.1).

1/4” line

5/16” line

3/4” hose fitting

1/2” hose fitting

C-clamp

Tube clamp

Pinch bolt Tank brackets

Oil filter

Figure 2.1

□ Remove the hex head bolts securing the forward side of the

drivers step to the frame rail.

□ Place the front tank bracket on the bushings used to locate the

step, with the tank mounting surface of the bracket facing inward

towards the passenger side of the vehicle (Figure 2.1), install the

OEM bolts and tighten to specifications.

The front and rear tank mounts are different. Make sure

that you use the correct mount in the proper location.

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□ Repeat with the rear step bolts to install the rear tank mount.

□ Remove the oil filter from the front of the tank, fill it with VMAC

compressor oil, cover it and place it out of the way.

□ Place the tank on a work bench with the front (oil filter end) of the

tank to your right.

□ Remove the two 1/4 inch pinch bolts from the C-clamps. Expand

the clamps slightly and slide them over the front of the tank, with

the flats of the clamps on the work bench. Position the front

clamp just behind the weld and the back clamp about 15 inches

from the front clamp.

□ Install the 1/4 inch pinch bolts into the C-clamps from the far side

so that the threaded end of the bolts is on the side nearest you

and install the nuts.

□ Rotate the tank so that the arrow on the back of the tank points

away from you and is parallel with the work bench. Tighten the

front C-clamp pinch bolt but leave the back C-clamp loose

enough so that it can be moved on the tank.

□ Thread the 1/4 and 5/16 inch fittings on the steel lines to the

matching fittings on the back end of the tank, leaving the fittings

loose enough so that the lines can be moved. Route the lines

along the top of the tank across the two C-clamps.

□ Place the two insulated tube clips over the steel lines with the

mounting holes downward and align them with the top C-clamp

mounting holes.

□ Support the tank in position under the truck. Install 3/8 x 1 inch

bolts and flange lock nuts into the upper and lower holes on each

C-clamp. Make sure that the upper bolts also secure the two

insulated tube clips.

□ Tighten the rear C-clamp pinch bolt, tighten the four bolts and

nuts holding the C-clamp to the mount brackets and tighten the

steel line fittings on the back of the tank.

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Part 3: Installing the Main Bracket

and Compressor

3.1 Installing the Main Bracket

□ Remove the belt tensioner assembly from the VR main bracket.

□ Install the OEM check valve into the VR main bracket.

□ Remove the plastic caps from the socket head screws, apply

Loctite and place the bracket in place on the front of the engine.

Thread the screws in just enough to hold the bracket in place

(Figure 3.1). Check the fit of the bracket against the engine to

make sure that it fits flat and has no obstructions, tighten the

bolts evenly, then torque them to 41 ft-lbs (55 N.m).

Install OEM

back idler here

M10 x 85 mm

socket head bolts

(one behind the VR tensioner

)

Install the OEM

tensioner here

Figure 3.1

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□ Apply Loctite and install the VR tensioner, the OEM belt

tensioner and one OEM back idler (Figure 3.1).

□ Install the alternator.

□ Place the VR crank pulley in position with the two roll pins on

both sides of the counter balance weight of the OEM pulley

(Figure 3.2).

Position the roll pins here

Figure 3.2

□ Apply Loctite and thread the M18 x 100 mm center bolt with

OEM washer into the crankshaft. Install an engine-locking tool

and torque the center bolt to 200 ft-lbs (280 N.m).

□ Install the OEM belt (Figure 3.3).

□ Remove the nuts and bolt holding the compressor to the

packaging base.

□ Attach the angled end of the short 1/2 inch hose to the fitting on

the side of the compressor with the hose routed over the top of

the compressor just behind the clutch assembly. Tighten the

fitting.

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OEM ribbed idler

OEM tensioner

Alternator

OEM back idler

A/C

P/S

Fan

OEM crank pulley

Figure 3.3

□ Place the compressor on the mounting bracket, apply Loctite and

install the two nuts and the bolt to the underside of the

compressor. Torque them to 19 ft-lbs (25 N.m).

□ Install the VR drive belt (Figure 3.4).

VR70 Tensioner

VR70 Ribbed idler

VR70 Compressor

VR70 Idler

Crankshaft pulley

Figure 3.4

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3.2 Installing the Cooler

□ Remove the strap and the support bracket from the cooler

assembly (Figure 3.5).

□ Position the cooler on the inside of the U-channel cross-member

where the rock guard was located, insert two 3/8 x 1 inch flange

lock bolts through the rock guard mounting holes into the cooler.

□ Place the cooler support bracket on the two bolts with the center

hole facing toward the front of the vehicle, install flange lock nuts

on the bolts and torque to specifications.

□ Pass the support strap through the hole in the top of the cooler

back plate, around the U-channel frame and through the support

bracket. Install a flat washer and 5/16 inch nut and tighten, then

install a second 5/16 inch nut as a lock.

□ Cut the lower radiator hose to length (Figure 3.6).

□ Install each hose section back to the original positions, between

the radiator and the cooler and the engine and the cooler.

Su

pp

ort bracket

Cooler oil hose fittings

T

o eng

i

ne

To radiator

Cooler

suppor

t

strap

Figure 3.5

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To engine

To Radiator

To coolant

expansion tank

Heater hose

connection

8 1/2”

12”

A

C

1”

D B

2”

Figure 3.6

□ Secure the coolant expansion hose in the OEM clip.

□ Cut the ends off the OEM aluminum heater pipe, leaving

sufficient length to install in the replacement heater hose. On the

lower end of the pipe, cut above the bracket.

□ Connect the heater return line from the lower radiator hose to the

hose at the heater using the aluminum pipe ends and the

replacement hose, cutting the hose as required to fit.

3.3 Connecting the VR Hoses

□ Route the longest 1/2 inch hose along the frame, under the

compressor. Connect the 90 degree end to the driver’s side

fitting on the cooler and the straight end to the tank.

□ Connect the straight end of the 1/2 inch hose from the

compressor to the passenger side fitting on the cooler.

□ Connect the straight end of the 3/4 inch to the tank, route it up to

the compressor and connect the angled end to the matching

fitting on the compressor. Loop it so that it forms a smooth curve

parallel to the middle of the compressor.

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No part of the 3/4 inch hose can be higher than the

compressor. If it is, the system will not function

correctly.

□ Route the 1/4 and 5/16 inch hoses to the compressor and

connect them to the matching fittings.

□ Secure all hoses together and in place using plastic ties at

regular intervals along the frame, other harnesses or the cross-

member so that they do not touch the exhaust or moving parts.

□ Tighten all the hose fittings, adjusting the fitting positioning as

necessary to provide clearance and best fit.

□ Apply a light coat of oil to the filter gasket and install the filter on

the tank. Tighten the filter 1/2 – 3/4 turns after the gasket

contacts the base.

3.4 Mounting the Fuel Module and Hoses

□ Remove three inlet control valve mounting bolts and install the

fuel module mounting bracket (Figure 3.7). Also install the two

small support brackets

Support bracket

Mount bracket

Figure 3.7

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□ Place a hose clip over the central fuel bleed steel line, push on

the supplied length of 5/16 inch bleed hose and install the clamp.

□ Place a hose clamp over the supplied 12 x 1/2 inch fuel line.

Push the hose onto the rearward-facing steel line and tighten the

clamp.

□ Place a hose clamp over the 6 x 1/2 inch fuel line. Push the hose

onto the remaining steel line that points to the passenger side of

the vehicle and tighten the clamp.

□ Using two of the saved rubber mounts and M8 hex head bolts,

install the fuel module to the fuel module bracket (Figure 3.10).

Hand-tighten the bolt.

□ Exchange the hex head bolt from the remaining saved rubber

mount for the supplied M8 x 45 bolt and install the rubber mount

to the fuel module. Insert the supplied M8 x 45 bolt through the

rubber mount then into the fuel bracket and thread it into the end

of the fuel module support bracket. Hand-tighten.

□ Tighten the fuel module support bracket at the cylinder head

end. Tighten the fasteners on the fuel module to specification.

□ Remove both banjo bolts from the old fuel lines.

□ Place a hose clamp onto the installed 6 x 1/2 inch fuel line and

install the straight banjo fitting into the hose. Rotate the banjo so

that it will install against the face of the fuel module without

collapsing the hose.

□ Install the banjo bolt into the forward most port in the fuel

module. Ensure the banjo is fully seated and then back it off so

that it can be used to bleed the fuel system. Position the clamp

and tighten.

□ Place a hose clamp onto the 12 x 1/2 inch fuel line and install the

angled banjo bolt into the hose and onto the remaining port on

the fuel module. The end of the banjo points to the passenger

side and into the fuel module. Position the clamp and tighten.

Tighten the banjo to specification.

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□ Mount the fuel bleed bracket to fuel module bracket using the

OEM M8 x 16 flanged hex head bolts.

□ Mount the bleed valve to the bracket using M8 x 35 bolts and

washers.

□ Pass the 5/16-inch fuel bleed line through the gap between the

bent banjo bolt and the fuel module.

□ Place the saved OEM clip on to the bleed valve, push on the

bleed line and install the clamp.

3.5 Completing the Installation

□ Install the supplied 13 x 5/8 inch hose to the 90 degree fitting on

the main bracket and tighten the clamp.

□ Cut the OEM engine breather hose on the straight section just

after the second bend from the free end. Install the supplied

connector and tighten the clamp.

□ Route the OEM breather hose over the engine and down the

outside of the compressor hoses. Push the connector into the

OEM hose and tighten the clamp.

□ Place an HS10 hose clamp onto the 29 x 5/8 inch oil hose and

install it on the straight outlet on the main bracket. Tighten the

clamp. Route the hose through to the bottom of the engine.

Secure the hose in place with a hose clip in the threaded hole in

the lower part of the engine using an OEM M8 x 10 bolt

□ Install the intercooler tube, making sure that the tube is pushed

in all the way and that the clamps are securely tightened. Do not

apply any lubricant to the metal pipe or rubber connectors.

□ Install the air cleaner/coolant fill tank support bracket and coolant

expansion tank. Connect the coolant level sensor wiring.

□ Mark the aluminum fan clutch and blade assembly to ensure

correct orientation, then separate the fan clutch from the fan

blade assembly.

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Vmac V900069 Installation guide

Vmac V900069 Installation guide

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