Vmac V900064 Installation guide

Installation ManualInstallation Manual

Installation Manual

For TheFor The

For The

System #V900064System #V900064

System #V900064

UNDERHOOD AIR COMPRESSORUNDERHOOD AIR COMPRESSOR

UNDERHOOD AIR COMPRESSOR

2001 FORD SUPER DUTY F250-F5502001 FORD SUPER DUTY F250-F550

2001 FORD SUPER DUTY F250-F550

7.3 L POWER STROKE DIESEL7.3 L POWER STROKE DIESEL

7.3 L POWER STROKE DIESEL

TEL: 250-754-6997TEL: 250-754-6997

TEL: 250-754-6997

FF

FAX: 250-754-6972AX: 250-754-6972

AX: 250-754-6972AX: 250-754-6972

AX: 250-754-6972

TT

TOLLOLL

OLLOLL

OLL FREE: 800-738-8622 FREE: 800-738-8622

FREE: 800-738-8622 FREE: 800-738-8622

FREE: 800-738-8622

1333 KIPP ROAD, NANAIMO, B.C. V9X 1R31333 KIPP ROAD, NANAIMO, B.C. V9X 1R3

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

DOCUMENT 1900590

Installation Manual Document 1900590Installation Manual Document 1900590

Installation Manual Document 1900590

VR7000 Underhood Air CompressorVR7000 Underhood Air Compressor

VR7000 Underhood Air Compressor

System Number V900064System Number V900064

System Number V900064

Application:Application:

Application: 2001 Ford Super Duty F250-F550 7.3 L Power Stroke Diesel

Publication Date:Publication Date:

Publication Date: February 2000

Origination Documents:Origination Documents:

Origination Documents: #1900590 - introduction

#1900590a - General information

#1900591 - Installing the compressor and oil cooler

#1900592 - Installing the air tank and lines

#1950593 - Installing the control components

#1900594 - illustrated parts list

#1900130 - warranty registration

Notice:Notice:

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

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

permission of VMACpermission of VMAC

permission of VMAC

RegisterRegister

Registered ed

ed ed

ed TT

TT

Trademarks:rademarks:

rademarks:rademarks:

rademarks:

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.

22

2

44

4

Installation NotesInstallation Notes

Installation Notes

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).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.

66

6

DOCUMENT 1900585aDOCUMENT 1900585a

DOCUMENT 1900585a

WARNING

✁

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

88

8

DOCUMENT 1900585aDOCUMENT 1900585a

DOCUMENT 1900585a

Part 1Part 1

Part 1

InstallingInstalling

Installing

the Compressor and Oilthe Compressor and Oil

the Compressor and Oil

CoolerCooler

Cooler

System #V900064System #V900064

System #V900064

2001 FORD2001 FORD

2001 FORD

SUPER DUTY F250-F550SUPER DUTY F250-F550

SUPER DUTY F250-F550

7.3 L POWER STROKE DIESEL7.3 L POWER STROKE DIESEL

7.3 L POWER STROKE DIESEL

UNDERHOOD AIR COMPRESSORUNDERHOOD AIR COMPRESSOR

UNDERHOOD AIR COMPRESSOR

99

9

DOCUMENT 1900591

1010

10

Part 1: Installing the Compressor and Oil CoolerPart 1: Installing the Compressor and Oil Cooler

Part 1: Installing the Compressor and Oil Cooler

1.1 Preparing for installation1.1 Preparing for installation

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.

1111

11

Figure 1.1Figure 1.1

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 1900591DOCUMENT 1900591

DOCUMENT 1900591

1212

12

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 1.2Figure 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 1900591DOCUMENT 1900591

DOCUMENT 1900591

1313

13

Figure 1.3Figure 1.3

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 1.4Figure 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 1900591DOCUMENT 1900591

DOCUMENT 1900591

1414

14

17. Remove and discard the 12 mm bolt from lower alternator bracket (lower right side of the

engine) and the 12 mm cap screw (lower left side of the engine) which retain the ground

straps (Figure 1.5).

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

Figure 1.5Figure 1.5

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 cooler1.2 Installing the oil cooler

1.2 Installing the oil cooler

1. Install the oil cooler on the engine. Insert the supplied M12 x 30 mm hex head cap screws

and 12 mm serrated washer through the ground strap fittings on the drivers side and fasten

the oil cooler in place. Fit the supplied M12x 80 hex head cap screw with the 7/16 flat

washer through the cooler mount strap and the ground strap on the passengers side. Fit to

the lower alternator bracket where the bolt was removed from previosly, tighten both bolts.

Torque the fasteners to specifications.

Figure 1.6Figure 1.6

Figure 1.6

12 mm bolt securing lower alternator bracket

to the engine and holding ground strap

and transmission cooling lines

12 mm hex head cap screw

holding ground strap

DOCUMENT 1900591DOCUMENT 1900591

DOCUMENT 1900591

M12 x 30 HHCS

M12 x 0 HHCS

To engine block

To radiator

1515

15

2. Place hose clamps on both hoses. Connect the right side cooler hose to the bottom radiator

outlet (Figure 1.7) and the left side hose to the engine block connection. Tighten all the hose

clamps securely.

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

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

Figure 1.7Figure 1.7

Figure 1.7

1.3 Installing and mounting components1.3 Installing and mounting components

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

VR7000VR7000

VR7000

mounting bracket using the four (4) M10 x 30 mm hex head

cap screws. 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.

DOCUMENT 1900591DOCUMENT 1900591

DOCUMENT 1900591

Lower radiator hose

Hose to

engine

block

1/2” oil line fittings

1616

16

Installing the VR7000 componentsInstalling the VR7000 components

Installing the VR7000 components

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 1900591DOCUMENT 1900591

DOCUMENT 1900591

1717

17

1.4 Installing the compressor1.4 Installing the compressor

1.4 Installing the compressor

1. Apply Loctite to the burred-ends of the three (3) 8 mm studs and thread them in the holes

in the bottom of the compressor. Tighten them securely using two (2) jam nuts.

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

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

3. Remove the M12 x 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 specifications.

5. Install the OEM belt. Be sure to use the correct routing.

Figure 1.9Figure 1.9

Figure 1.9

6. Install the

VR7000VR7000

VR7000

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

Figure 1.10Figure 1.10

Figure 1.10

VR7000

Crankshaft

Pulley

VR7000

Tensioner

VR7000 Air

Compressor

VR7000

Idler

VR7000

Drive Belt

DOCUMENT 1900591DOCUMENT 1900591

DOCUMENT 1900591

Crankshaft pulley

Power steering

Water pump

Alternator

Idler

Tensioner

Air conditioning

Belt Idler Pulley

Generator

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.

Installing componentsInstalling components

Installing components

1818

18

DOCUMENT 1900591DOCUMENT 1900591

DOCUMENT 1900591

10. 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 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

Part 2Part 2

Part 2

Installing theInstalling the

Installing the

Air TAir T

Air Tank, Filter and Linesank, Filter and Lines

ank, Filter and Linesank, Filter and Lines

ank, Filter and Lines

System #V900064System #V900064

System #V900064

2001 FORD SUPER DUTY F250-F5502001 FORD SUPER DUTY F250-F550

2001 FORD SUPER DUTY F250-F550

7.3 L POWER STROKE DIESEL7.3 L POWER STROKE DIESEL

7.3 L POWER STROKE DIESEL

WITH DUALWITH DUAL

WITH DUAL

ALAL

ALTERNATERNA

TERNATERNA

TERNATT

TT

TORSORS

ORSORS

ORS

UNDERHOOD AIR COMPRESSORUNDERHOOD AIR COMPRESSOR

UNDERHOOD AIR COMPRESSOR

1919

19

DOCUMENT 1900592DOCUMENT 1900592

DOCUMENT 1900592

2020

20

Part 2: Installing the Part 2: Installing the

Part 2: Installing the Air TAir T

Air TAir T

Air Tank, Filter and Linesank, Filter and Lines

ank, Filter and Linesank, Filter and Lines

ank, Filter and Lines

2.1 Installing the tank brackets and tank2.1 Installing the tank brackets and tank

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.

2121

21

DOCUMENT 1900592DOCUMENT 1900592

DOCUMENT 1900592

Cab Mount

Tank

Crossmember Skidplate

Figure 2.1Figure 2.1

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 2.2Figure 2.2

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.

Backing strap

Spacer

(F250-F350 only)

Wire cable

5/16” nuts

L-bracket

C-clamp

mounting

cap screws

2222

22

DOCUMENT 1900592DOCUMENT 1900592

DOCUMENT 1900592

5. Insert the pinch bolt from the top, then install the washer and nut, but do not tighten.

6. Thread the fittings on the 1/4 and 5/16 inch steel tubes into the matching fittings on the rear

of the tank (1/4 inch in the top fitting). Tighten the fittings slightly by hand, but leave them

loose enough so that the lines can move in the fittings.

7. Place the two small insulated double-tube clips over the lines with the flat side facing away

from the tank and the end with the hole hanging down. Position the 1/4 inch steel tube

above the 5/16 inch tube.

8. Place an L-shaped tank bracket against the one of the C-clamp on the tank with the short

arm of the “L” at the top of the tank, facing away from the tank. Install a 5/16 x 1/2 inch hex

head cap screw with flat washer into the bottom hole on the bracket. Do not tighten.

Installing the L-bracketsInstalling the L-brackets

Installing the L-brackets Attaching the L-brackets to the C-clampsAttaching the L-brackets to the C-clamps

Attaching the L-brackets to the C-clampsAttaching the L-brackets to the C-clamps

Attaching the L-brackets to the C-clamps

9. Fit the second hex head cap screw through one of the small insulated double-tube clips and

install it through the top hole in the C-clamp and into the top hole of the L-bracket. Do not

tighten. Repeat this procedure with the second L-bracket, C-clamp and double-tube clip.

10. Make sure that the tubes are parallel to the tank and fit properly in the clips. The flexible

lines attached to the tubes will be routed into the engine compartment when the tank is

installed on the truck.

Insulated double tube clipInsulated double tube clip

Insulated double tube clip TT

TT

Tubes in placeubes in place

ubes in placeubes in place

ubes in place

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Vmac V900064 Installation guide

Vmac V900064 Installation guide

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