Vmac 9041 Installation guide

Installation Manual

For The

System #9041

UNDERHOOD AIR COMPRESSOR

1999-2000 FORD F250-F550

TRITON V10

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

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

DOCUMENT 19392

Installation Manual

VR7000 Underhood Air Compressor

System Number 9041

Application: 1999-2000 Ford F250-F550 with the Triton V10

Publication Date: January 2000

Publication Number: 19392

Origination Documents: #19392a - introduction

#19393 - compressor and oil cooler installation

#19394 - air tank and line installation

#19396 - throttle controller installation

#19395 - control unit installation

#19397 - illustrated parts list

#19130 - warranty registration

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.

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

Contents

GENERAL INFORMATION................................................................................................ 3

INTRODUCTION ........................................................................................................................ 5

INSTALLATION NOTES .............................................................................................................. 6

ORDERING PARTS .................................................................................................................... 7

WARRANTY ............................................................................................................................. 7

CHANGES AND IMPROVEMENTS .................................................................................................. 7

PART 1: INSTALLING THE COMPRESSOR, OIL COOLER AND OIL FILTER ........ 9

1.1 PREPARING FOR INSTALLATION .......................................................................................... 11

1.2 INSTALLING THE BRACKET ................................................................................................ 12

1.3 INSTALLING THE VR7000 COMPRESSOR AND OTHER COMPONENTS ......................................... 14

1.4 INSTALLING THE OIL COOLER AND ADAPTER ....................................................................... 16

1.4 INSTALLING THE REMOTE OIL FILTER ASSEMBLY .................................................................. 20

PART 2: INSTALLING THE AIR TANK AND LINES ................................................... 23

2.1 INSTALLING THE BRACKETS AND TANK ............................................................................... 25

2.2 CONNECTING THE AIR AND OIL LINES ................................................................................ 28

2.3 ADDING OIL TO THE SYSTEM ............................................................................................ 32

2.4 COMPLETING THE INSTALLATION ...................................................................................... 33

PART 3: INSTALLING THE CONTROL UNIT ............................................................... 35

3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 37

3.2 CONNECTING THE WIRING ................................................................................................ 38

PART 4: INSTALLING THE THROTTLE CONTROLLER ........................................... 41

4.1 INSTALLING THE THROTTLE CONTROLLER ASSEMBLY ........................................................... 43

4.2 INSTALLING AND ADJUSTING THE CABLE ............................................................................. 46

ILLUSTRATED PARTS LIST.............................................................................................. 49

WARRANTY REGISTRATION .......................................................................................... 55

1

2

General Information

System #9041

1999-2000 FORD F250-F550

TRITON V10

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 19392A

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 underhood air compressor installation kit

VMAC Pneumatic Throttle Control

This kit has been designed for:

1999-2000 Ford F250-F550 equipped with a Triton V10

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)

NOTE

WARNING

!

5

DOCUMENT 19392A

Installation Notes

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

2. Follow all safety precautions for under-hood 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.

6

T

y

pe 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 19392A

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 Standard 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 front body support on the driver’s side of the vehicle near the hood

stop (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.

7

DOCUMENT 19392A

8

Part 1

Installing

the Compressor,

Oil Cooler and

Oil Filter

System #9041

1999-2000 FORD F250-F550

TRITON V10

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 19393

10

Part 1: Installing the Compressor, Oil Cooler and

Oil Filter

1.1 Preparing for installation

1. Disconnect the batteries.

2. Disconnect the wiring from the alternator. Remove the alternator top support bracket and

the alternator from the engine.

3 Drain the coolant. Remove the top radiator hose.

4. Cut off the OEM locking rings securing the lower radiator hose to the cooler diverter.

Remove the diverter from the cooler hoses, then remove the diverter and the bottom

radiator hose.

5. Remove the coolant expansion tank.

6. Remove the OEM drive belt and the engine cooling fan

7. Remove the OEM oil filler cap and install the supplied replacement.

8. Remove the OEM 10 mm bolt with the 8 mm studded end from the top right location on the

timing cover (Figure 1.2).

9. Make sure that the areas where the VR7000 bracket will mount are clean so that the

bracket will sit flush on the mounting areas. Place the VR7000 bracket in position and

make sure that it does not contact the intake manifold. If necessary, grind off the casting

flashing to provide clearance (Figure 1.1).

11

DOCUMENT 19393

Figure 1.1 Grind off flashing from inlet manifold

Grind area shown within border

12

1.2 Installing the bracket

1. Install the compressor mounting bracket to the engine as shown in Figure 1.3.

Figure 1.3 Installation location for compressor mounting bracket

2. Apply Loctite, then install three (3) 10mm x 35mm socket head cap screws,

two (2) 8mm x 25mm hex head cap screws and one (1) 10mm x 100mm socket head cap

screws as shown in Figure 1.4.

DOCUMENT 19393

Left Bank

Right Bank

Remove This

Studded Hex

Head Cap Screw

OEM Belt Tensioner

OEM Back Idler

Figure 1.2 Location of OEM components

13

Left Bank

Right Bank

Three (3) 10mm x 35 mm

Socket Head Cap Screws

One (1) 10mm x 35 mm

Socket Head Cap Screw

Two (2) 8mm x 25mm Hex Head Cap Screws

Figure 1.4 Location of fasteners for the mounting bracket

VR7000 Belt Tensioner

VR7000 Back Idler

VR7000 Ribbed Idler

Figure 1.5 Location of idlers and tensioners

3. Tighten the fasteners until they are snug and then torque them to specifications

4. Remove the hex head cap screws from the back idler and the ribbed idler (Figure 1.5).

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

5. Torque the Nylok fastener on the VR7000 belt tensioner to specifications.

DOCUMENT 19393

14

5. Clean all dirt and contamination from the inside of the OEM crankshaft pulley.

6. Make sure that the threads in the three (3) 10mm holes are clean.

7. Place the VR7000 crankshaft pulley in place over the OEM pulley. Apply Loctite to the

three (3) 10mm x 60mm hex head cap screws and supplied flat washers and install them

into the holes in the OEM pulley. Torque the fasteners to specifications.

8. Install the VR7000 serpentine belt according to the routing diagram in Figure 1.7.

Crank

Pulley

Water

Pump

Alternator

Power Steering

Air Conditioning

Idler

Tensioner

Figure 1.6 Installation of OEM belt

1.3 Installing the VR7000 compressor and other components

1. Apply Loctite to the studs on the bottom of the compressor, position the compressor in

place on the VR7000 bracket, install the 8 mm nuts and flat washers and torque to

specifications.

2. Install the alternator and connect the wiring. Some readjustment of the wire harness is

necessary.

3. Install the fan spacer, then install the engine cooling fan.

4. Install the OEM serpentine belt according to the routing diagram in Figure 1.6.

DOCUMENT 19393

15

Crank

Pulley

VR7000 Back Idler

VR7000 Compressor

VR7000 Tensioner

VR7000 Ribbed Idler

Figure 1.7 Installation of VR7000 belt

DOCUMENT 19393

9. Install the upper radiator hose.

10. Enlarge the mounting hole in the coolant expansion tank as shown in Figure 1.8, then mount

the expansion tank back in place.

Extend Hole 1/8”

Figure 1.8 Enlarge the mounting hole in the expansion tank

16

1. Remove the nuts on the studs securing the battery ground cable bracket to the lower engine

timing cover (Figure 1.9). Remove the battery ground cable from the stud. Discard the

battery ground cable bracket.

Figure 1.9 Removing the battery ground cable

OEM Battery Bracket And

Ground Strap Locations

2. Install the supplied VR7000 cooler hoses to the OEM diverter as shown in Figure 1.10.

Place hose clamps over the cooler hoses and tighten them.

3. Install the two short 3/4 inch heater hoses to the diverter connections. The longer (9 inch)

hose must be installed on the connection that will be closest to the engine. The short (7-1/2

inch) hose must be installed on the connection that will be closest to the radiator. Place

hose clamps over the connections and tighten them.

4. Slide a hose clamp over each of the short hoses. Insert the supplied barbed connectors,

position the hose clamps and tighten them.

5. Fit the cooler in place under the crankshaft pulley, over the two studded fasteners at the

front of the engine block. Make sure that the transmission cooler lines fit under the

mounting bracket on the oil cooler (Figure 1.10) and that the battery cable is in front of the

mounting bracket.

DOCUMENT 19393

1.4 Installing the oil cooler and adapter

17

Figure 1.10 Mounting the cooler

VR7000 Oil Cooler

4-1/4 x 1-3/4 Coolant Hoses OEM Coolant Diverter

7-1/2 x 3/4 Hose

9 x 3/4 Hose

Barbed Fittings

OEM Transmission Cooler Lines

Install On These Studs

OEM Lower

Radiator Hose

OEM Oil Filter

Cooler Hoses

DOCUMENT 19393

6. Thread the supplied 10 mm Nylok nuts over the studs and torque them to specifications.

7. Slide hose clamps over the lower hose and diverter assembly connections, fit it into place

between the oil cooler and the radiator, position and tighten the hose clamps.

8. Shorten the OEM lower radiator hose as required to provide a good fit between the cooler

and the engine connector. Be careful that the hose is not kinked when installed.

9. Slide hose clamps over the lower radiator hose, install it, position and tighten the clamps.

10. Slide hose clamps over the OEM oil filter cooler hoses, fit them over the barbed fittings,

position and tighten the clamps.

18

11. Secure all hoses with the supplied clips. Use a tie-wrap to secure the OEM transmission

cooler lines and battery cable to the tank bracket.

12. Remove the 3/4 inch heater supply hose from the manifold outlet tube (Figure 1.11) and

remove the tube from the manifold using a puller or by inserting a snug fitting cap screw into

the fitting and using visegrips. Apply sealant to the supplied 5/8 inch core plug and install it

into the manifold.

13. Loosen the cap screw holding the electrical connector to the intake manifold beside the

temperature sensor and rotate it 90 degrees counter clockwise. Tighten the cap

screw.

14 Remove the OEM coolant temperature sending unit at the front of the inlet manifold next to

the thermostat housing. (Figure 1.11).

Remove this

OEM hose

Rotate this

connector

90 degrees

counter clockwise

Remove this

OEM temperature

sensor

Figure 1.11 Removing parts to install the adapter block

DOCUMENT 19393

15. Apply Loctite 592 sealant and install the supplied heater hose adapter block into the port of

the removed OEM coolant temperature transmitter. Tighten the adapter and make sure that

final alignment has the 1/2” hose barb fitting facing the passenger side of the vehicle (Figure

1.12).

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Vmac 9041 Installation guide

Vmac 9041 Installation guide

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