Vmac V90G120 Installation guide

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VEHICLE MOUNTED AIR COMPRESSORS

System V90G120

2016-2011 Ford F250-F550 6.7L Diesel

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Installation Manual for VMAC 
System V90G120 
 
2016-2011 Ford F250-F550 6.7L Diesel 
 
 
General Information..................................................................... 4 
Before You Start ....................................................................... 4 
Additional Requirements .......................................................... 4 
Part 1: Warranty and System ID ................................................. 5 
Part 2:  Preparing for Installation ............................................... 8 
Part 3:  Installing the Cooler, Bracket and Compressor .......... 14 
3.1 Installing the Oil Cooler ...................................................... 14 
3.2 Routing Battery Cables ...................................................... 15 
3.3 Continuing Oil Cooler Installation ....................................... 17 
3.4 Installing Main Bracket ....................................................... 19 
3.5 Battery Cable and Relocated Battery Box .......................... 31 
3.6 Washer Bottle ..................................................................... 36 
3.7 Air Filter Box ....................................................................... 39 
Part 4:  Installing the Tank and Hoses....................................... 51 
4.1 Installing the Tank and Brackets ........................................ 51 
4.2 Installing the Hoses ............................................................ 53 
4.3 Adding Oil to the System .................................................... 54 
Part 5:  Installing the Control Components .............................. 55 
5.1 Routing the Wiring .............................................................. 56 
5.2 Installing the components ................................................... 57 
5.3 Connecting the In-cab Wiring ............................................. 61 
5.4 Completing and Testing the Installation ............................. 64 
Part 6: Finishing the Installation ................................................ 66 
6.1 Before Starting the Engine Checklist.................................. 66 
6.2 Safety Test ......................................................................... 66 
6.3 Setup, Performance Testing and Adjustments ................... 69 
6.4 Auxiliary Air Receiver ......................................................... 70 
Accessory Products from VMAC ............................................... 71 

VMAC – Vehicle Mounted Air Compressors

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Document #1930190

Installation Manual for VMAC System V90G120

2016-2011 Ford F250-F550 6.7L Diesel

Changes and Revisions

Version

Revision Details

Revised by/date

Checked by/date

Reviewed by/date

Implemented

E

ECN 13-013, ECN 14-018

JR 30 Apr 2014

MH 06 May 2014

RD 06 May 2014

12 May 2014

F

ECN 14-047

JR 14 Nov 2014

MH 20 Nov 2014

DB 19 Nov 2014

20 Nov 2014

G

ECN 18-135 Washer Btl

MSP 11 June 2018

KM/GB 12 Jun 2018

AWG 12 Jun 2018

13 June 2018

Important Information

This symbol is used to call your attention to instructions

concerning your personal safety. Watch for this symbol; it

points out important safety precautions, it means “attention,

become alert! Your personal safety is involved. Read the

message that follows and be alert to the possibility of personal

injury or death. Be alert; your safety is involved. While it is

impossible to warn about every conceivable hazard, let good

common sense be your guide.

This symbol is used to call your attention to additional

instructions or special emphasis on a specific procedure.

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 under hood mechanical work. Any

grinding, bending or restructuring operations for correct fit in modified

trucks must follow standard shop practices.

All hoses, tubes, and wires that are rerouted or shifted

during installation must be secure so that they do not

contact excessively hot areas or sharp edges. Where

possible, use rubber coated P-clips. Follow the routing

suggestions in this manual and cover all hoses with the

supplied plastic loom.

!

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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 1-888-241-2289.

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

truck. 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

Additional Requirements

Special Tools

Pneumatic fan wrench removal set (such as Lisle 43300) or a

manual fan pulley holder (such as KD3900)

OEM flywheel locking tool part number J42386.

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!

Hose Information

Depending on other installed equipment, it might be

necessary to move the air/oil separation tank from its

intended location. The hoses used in VMAC compressor

systems have a specific inner liner that is compatible with

our compressor oil. Use of hoses other than those supplied

or recommended by VMAC may cause compressor damage

and may void your warranty. Please contact VMAC for

replacement hoses and further information.

Part 1: Warranty and System ID

□ Complete the warranty form. 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.

System Identification and Operating Instructions

The System Identification Number Plate must be attached to the

vehicle at the time of installation. This plate provides information that

allows VMAC to assist in customer inquiries and the ordering of

parts.

□ Mark and drill two 7/64” holes in the top of the cross member in

front of the OEM air filter box. Secure the plate with supplied

self-tapping screws

□ Clean cross member beside the number plate and stick the

VMAC belt routing diagram to the cross member.

□ Apply battery warning label to driver side of primary cooling

reservoir.

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□ As part of the installation process, ensure that the safety and

operational instruction decal is affixed in an obvious location so

that it can be seen by vehicle operators. A good spot for this is

usually on the inside of the door or on the panel underneath the

steering wheel. (Figure 1.1).

Figure 1.1

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□ To alert any technicians that may service the vehicle, affix the

servicing caution/contact label in the engine compartment near

the hood latch in a visible location. Thoroughly clean the

selected area before affixing the label (figure 1.2)

Figure 1.2

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Part 2: 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.

Ensure that you have filled out the VMAC Warranty

Registration. Install the System Identification Number Plate

and Operational Instruction Decal. (Please see Part 1 for

details).

□ Locate the blunt-cut OEM SEIC wire harness, on the driver’s

side just below the OBDII port. You will need to find the

transmission park signal (blue with grey stripe wire).

□ Use a multi-meter to verify the transmission park signal. Turn the

key to the RUN position (do not start the truck), as to supply

power to the dash display. The resistance should read close to

0-ohms in park and open circuit in all other gears. If this is

correct, put the car in park and turn the key to the off position.

There are multiple blue wires with various coloured stripes.

The transmission park signal needs to be electrically

verified with a multi-meter to ensure the correct wire is read.

□ Mark transmission park signal wire for connection later in Part 5:

Installing the Control

Components.

□ Disconnect batteries (both driver and passenger side).

□ Drain coolant from both the primary and secondary radiators

(drain for primary coolant is on driver’s side, secondary coolant is

on passenger side). Start with the secondary radiator. Save

coolant to be reused later. Close drain caps when coolant has

been drained.

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□ Remove passenger side battery bracket and battery.

□ Disconnect the mass air flow sensor from the top of the filter box.

□ Remove filter box (both upper and lower sections).

□ Remove tube and resonator that connects the filter box to the

turbo intake.

□ Cover turbo intake.

□ Remove passenger side hood strut and hood strut ball stud from

the hood, (save for later use).

□ Remove lower hood strut ball stud from inner fender.

□ Remove positive terminal block and wiring connector panel from

passenger side battery box. To remove wiring panel pry up.

Positive terminal block has one clip and slides up to remove.

□ Disconnect windshield washer tube from joint above passenger

side battery box on top of firewall.

□ Unplug wiring harness from windshield washer pump and

remove wiring from front lower passenger side battery box.

□ Unplug glow plug module connectors from bottom of passenger

side battery box (3 connectors).

□ Remove the bolt from wheel well that secures inner fender to

battery box.

□ Remove passenger side battery box (save bolts for later use).

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□ Remove glow plug module from bottom of passenger side

battery box (Torx T30 bolts) (save module for later use).

□ Disconnect hoses from secondary coolant reservoir (attached to

passenger side of fan shroud) and remove reservoir from fan

shroud.

□ Remove upper secondary coolant hose (top hose going to water

pump on passenger side of engine).

□ Cut plastic cuff securing hose on secondary rad hose carefully to

preserve fitting (discard band and hose) (Figure 2.01).

Cut Plastic Cuff To

Remove Connector

Upper Secondary

Radiator Hose

Figure 2.1

□ Install supplied hose back on connector and secure with supplied

hose clamp (Figure 2.2).

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Supplied Hose

OEM Quick

Connect

Supplied Hose

Clamp

Figure 2.2

□ Install hose coupling and flexible hose to open end of modified

secondary coolant hose. Leave about 1” gap between hoses

and secure with supplied hose clamps.

□ Remove plastic wire guide from front of EGR on passenger side

of engine (two bolts securing to EGR and plastic ties securing to

wire). Save bolts for attaching the inlet valve brace later and

discard plastic. (Figure 2.3).

Figure 2.3

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□ Using knife cut insulated heat shield if required to clear hose.

Install modified hose back on secondary water pump. Ensure

notches on OEM quick connector align with notches on

secondary water pump. Point elbow towards rear of truck

(opposite to the original direction). Ensure hose is not kinked,

(rotate the hose on the OEM quick connect, if required, to

remove any kinks). Hose must run underneath the injector wiring

harness.

□ Ensure OEM locking clip is engaged on plastic elbow. Loop hose

towards front of truck.

□ Remove bolt securing power steering reservoir to upper fan

shroud. DO NOT remove hose from reservoir. Slide reservoir up

out of clip securing it to the upper fan shroud.

□ Remove 5 bolts (3 on driver’s side and 2 on passenger side) and

wire clips securing upper fan shroud and remove upper fan

shroud from truck.

□ Unplug fan wire (unplug connector closer to the engine, not the

one right on the hub of the fan). Remove long bolt securing fan

wiring harness to engine and discard.

□ Remove the fan (right-hand thread) and pull it out of the engine

bay.

For ease of fan removal and installation, it is recommended

that a pneumatic fan wrench removal set (such as Lisle

43300) or a manual fan pulley holder (such as KD3900) is

used.

□ Remove fan stator (the lower shroud can be left in place if the

stator is rotated to clear the lower lip).

□ Remove upper passenger side fan stator mount and save for use

later.

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□ Release tension on OEM belt (leave belt routed correctly on

passenger side of engine).

□ Remove 2 bolts from secondary water pump (Figure 2.4).

Remove OEM Bolts From

Secondary Water Pump

Figure 2.4

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Part 3: Installing the Cooler,

Bracket and Compressor

3.1 Installing the Oil Cooler

□ Remove lower primary coolant hose (attached to the primary

cooler and engine) (Figure 3.1).

To

Engine

From

Radiator

Figure 3.1

□ Cut the plastic cuff securing the OEM quick connect to engine

side coolant hose (discard OEM quick connect) (Figure 3.2).

Cut Cuff

OEM Quick

Connect

Figure 3.2

□ Cut the radiator side coolant hose 8” from the OEM quick

connect (discard short section of hose with OEM quick connect)

(Figure 3.3).

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OEM Quick

Connect

Discard This

Section

8”

Figure 3.3

3.2 Routing Battery Cables

□ Apply loom to supplied battery cable extensions.

Note: The red and the black battery cables will follow the

same route!

□ Route the supplied positive/red battery cable between the frame

and body from the re-located battery location that will be under

the driver side. Leave 20” of cable to the rear of the body mount

hanging under driver side door.

□ Continue routing the cable above the truck electrical harness and

below the two metal power steering lines.

□ Continue routing, careful to avoid the steering column, around

front of the steering box until the cable reaches the electrical

harness under/beside the fan shroud.

□ Feed cable along fan shroud following other truck wiring

harness.

□ Continue following truck wiring harness under the air intake and

metal bracket. Route along the inner fender plastic wire guide

tray under fender and follow OEM positive cable wire harness to

relocated battery positive terminal.

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□ Route the negative battery cable from the relocated battery

location and follow the positive battery cable. Continue routing

until under the fan shroud and in such a way it will remain clear

of the crank pulley and any other sharp or moving objects.

□ Remove the OEM negative battery block bolt attaching the OEM

negative battery cable located beside the engine side coolant

OEM quick connect (Figure 3.4).

For ease of removal the OEM negative battery block bolt

should be removed with the engine side coolant hose

disconnected. Figure 3.4 shown with coolant hose

connected to illustrate the OEM negative battery bolt

location.

OEM Negative

Battery Engine

Block Bolt

Engine Side

Coolant Hose

Front of

Engine

Figure 3.4

□ Install the supplied negative battery cable lug on top of the

existing OEM negative battery cable lug. Orientate the cable so

that it travels down and under the existing vehicle battery tray

facing the front of the vehicle towards the fan shroud. Reuse the

existing OEM negative battery bolt.

□ Secure battery cables with tie-straps as required as to clear the

crank pulley and other moving parts.

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3.3 Continuing Oil Cooler Installation

Do not strike the impact sensor as this could cause the

airbags to actuate. (Figure 3.5)

□ Position the cooler in the center of the cross-member so that it is

just above the sway bar with the oil ports facing up (Figure 3.5).

Fog Light Connector

Location

Impact Sensor

Location

Cross Member

Figure 3.5

□ Apply Loctite then install bolts through the flat mounting strap

and place them on the front of the cross member on each side of

the impact sensor. Note the impact sensor is located in the

center of the cross-member; the driver side wire connection is for

the fog lights if equipped (Figure 3.5).

□ Thread the bolts into the matching holes on the cooler mounts

hand tight only, this will allow the cooler to be repositioned if

necessary after the coolant hoses have been attached (Figure

3.5).

□ Install the radiator side coolant hose and secure with supplied

hose clamp (Figure 3.6).

!

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Figure 3.6

□ With the radiator side coolant hose secured tighten the cooler

mount bolts to specification.

□ Install the engine side coolant hose and secure with supplied

hose clamp (Figure 3.6). Note, it may be necessary to trim the

cooler end of the coolant hose, do so as required if any kinking

of the hose occurs.

□ Apply hose protection to 1/2" oil hoses.

□ Connect the shortest 1/2" hose to the passenger side of the

cooler and orientate as shown (Figure 3.7).

□ Connect the longest 1/2" hose to the driver side of the cooler and

orientate as show (Figure 3.7). (Note the cooler hoses must be

installed before the fan shroud is installed).

Figure 3.7

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Vmac V90G120 Installation guide

Vmac V90G120 Installation guide

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