Vmac V900050 Installation guide

Installation Manual

For The

System #V900050

UNDERHOOD AIR COMPRESSOR

2000 FORD E250 - E350

7.3 Power Stroke Diesel with A/C

TEL: 250-740-3200

FAX: 250-740-3201

TOLL FREE: 800-738-8622

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

DOCUMENT 1900679

Installation Manual

VR70 Underhood Air Compressor

System Number V900050

Application: 2000 Ford E250 - E350 with the 7.3 Power Stroke Diesel with A/C

Publication Date: Revised by S. Large, August / 2001

Publication Number: 1900679

Origination Documents: #1900679a - General information

#1900679b - Installing the air tank and lines

#1900679c - Installing the compressor and connecting the lines

#1900679d- Installing the control components

#1900679e - Illustrated parts list

#1900130 - Warranty registration

Registered Trademarks:

VR70, VMAC and Throttle Commander are registered trademarks of VMAC.

Ford, E350, 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 AIR TANK AND LINES ..................................................... 9

1.1 INSTALLING THE BRACKETS AND TANK .............................................................................. 11

1.2 INSTALLING THE TANK .................................................................................................... 12

1.3 INSTALLING THE OIL COOLER ........................................................................................... 14

PART 2: INSTALLING THE CONTROL COMPONENTS ............................................ 15

2.1 PREPARING FOR INSTALLATION ......................................................................................... 17

2.2 INSTALLING THE CONTROL UNIT ....................................................................................... 20

2.3 INSTALLING THE THROTTLE CONTROLLER ......................................................................... 20

2.4 CONNECTING THE WIRING ............................................................................................... 21

2.5 CONNECTING THE BLUE DDC WIRE................................................................................. 23

2.6 CONNECTING THE WHITE WIRE ........................................................................................ 24

2.7 EXTENDING THE AC WIRES ............................................................................................. 25

PART 3: INSTALLING THE COMPRESSOR AND CONNECTING THE LINES ...... 27

3.1 INSTALLING THE VACUUM PUMP ....................................................................................... 29

3.2 INSTALLING THE COMPRESSOR BRACKET ............................................................................ 30

3.3 INSTALLING THE AC COMPRESSOR .................................................................................... 30

3.4 INSTALLING THE VR70 COMPRESSOR ................................................................................ 32

3.5 CONNECTING THE LINES AND COOLER ............................................................................... 33

3.6 INSTALLING COMPONENTS................................................................................................ 34

3.7 INSTALLING THE POWER STEERING PUMP ........................................................................... 36

3.8 CONNECTING THE COOLING LINES .................................................................................... 37

3.9 INSTALLING THE BELTS.................................................................................................... 38

3.10 FILLING THE SYSTEM WITH OIL ........................................................................................ 38

3.11 COMPLETING THE INSTALLATION ..................................................................................... 39

PART 4: ILLUSTRATED PARTS LIST ............................................................................. 41

WARRANTY REGISTRATION.......................................................................................... 47

1

2

General Information

System #V900050

2000 FORD E250-E350

7.3 POWER STROKE DIESEL with A/C

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 1900679

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:

2000 Ford E250-E350 equipped with a 7.3 Power Stroke Diesel

Installation steps

The installation procedure in this manual has three main steps:

Part 1: Installing the air tank and lines

Part 2: Installing the compressor

Part 3: Installing the control system

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

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. Where

possible, follow the routing suggestions 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).

6

Type 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

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 must be attached to the vehicle at the time of

installation. Locate the plate on the front body support on the driver’s side just behind the hood

stop (Figure 1) . Drill the two hole locations using a 7/64” drill bit. Place the plate in position and

fix in place with the two #6 pan head self tapping screws provided.

This plate provides information, which allows VMAC to assist in customer inquiries and

ordering parts. It is important that this 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

NOTE

8

Part 1

Installing the

Air Tank and Lines

System #V900050

2000 FORD E250-E350

7.3 POWER STROKE DIESEL with A/C

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 1900679

10

1.1 Installing the brackets and tank

1. Install the 3/16 and 1/4 inch steel tube

and line assemblies to the fittings on the

back of the tank. Thread the fittings

securely into place but do not tighten

them yet.

2. Fit the C-clamps to the tank as shown

in the photo to the right. Front C-clamp

is fitted 2 inches from the front of the

tank.

The rear C-clamp is 16 inches back

from the rear edge of the front C-

clamp.

3. Tighten pinch bolts enough to just hold

the clamp in position on the tank. This is

to allow levelling tank when installed.

4. Place the tank mount L-brackets on the

C-clamps and install 5/16 x 1/2 inch

hex head cap screws with a flat washer

into the bottom holes on each bracket.

5. Install the two (2) small insulated

double-tube stainless clamps over the

steel tubes so that they can be fastened

to the two top C-clamp bolts

6. Place each of the insulated line clamps

in place over the C-clamp slotted holes

and insert the second 5/16 x 1/2 inch

hex head cap screws and 5/16 washer.

7. Position the L-brackets approximately

half-way in the C-clamp slots and

tighten the top and bottom cap screws

securely.

8. Tighten the line fittings on the back of

the tank.

11

Part 1: Installing the Air Tank and Lines

Back of the tank and the line connections

Insulated double line brackets

12

9. Make sure that the mounting areas on

the driver’s side of the frame are clean,

so that the brackets will fit correctly.

10. Insert each of the tank bracket retaining

cables through the tube on the frame rail

clips.

11. Place the front clip on the top of the

frame rail from the inside, with the cable

over the frame, approximately 12

inches back from the transmission

cross-member.

12. Place the second clip on the top of the

frame in the same manner as the front

clip, approximately 17 inches behind

the front clip.

13. Install the remaining two cable clips on

the bottom of the frame directly below

the top clips.

1.2 Installing the tank

1. Support the tank in approximate

position using floor stands or a suitably

strong support system.

2. Place the tank in position alongside the

vehicle, with the brackets on the tank

facing toward the frame. Make sure

that the tank is in the correct position,

with the “This side up” arrow in the

correct direction and the sight glass

facing forward.

3. Route the 1/4 inch pressure control line

and the 5/16 inch oil scavenge line from

the tank, along the frame, over the body

mount and into the engine compartment.

Tank retaining cables and upper clips

Lower tank clips with cables in place

Tank retaining cables and upper clips

Frame rail

Cable clamps

Top frame

clamps

13

4. Place both cable clamps between the

tank and the frame.

5. Move the tank into position against the

frame, with the bent portion of the L-

bracket on the tank placed over the top

of the frame.

6. Position the front cable so that it fits

into the grooves on the top and bottom

of the mounting bracket on the tank.

7. Insert the threaded end of the cable

clamp into the bottom frame clip.

MAKE SURE THAT THE OEM

EMERGENCY BRAKE CABLE

IS OUTSIDE THE TANK

RETAINING CABLES, NOT

PINCHED AGAINST THE

FRAME.

8. Place a thick 5/16 inch washer over the

threaded end and then install a 5/16

inch nut to hold the assembly in place.

9. Repeat this procedure with the rear

cable clamp.

10. Tighten the nut on the front mount, then

thread a second 5/16 inch nut over the

first to act as a lock nut and tighten it in

place.

11. If necessary, position the frame clips for

the rear mount so they are aligned with

the mount bracket and tighten the nut

on the cable, then install the lock nut.

Tank in position

Outside view of the tank in position

Rear view in position on the frame

14

Cooler mounting location

Cooler mounted in place

Bracket on the frame

12. Remove the four (4) cap screws and

remove the rock guard from the front of

the tank.

1.3 Installing the oil cooler

1. Locate the three (3) mounting hole

locations on the frame, just ahead of the

crossmember.

2. Remove the two hex head cap screws

holding the mounting bracket to the

cooler.

3. Install the mounting bracket to the

frame. Slide the corner of the mounting

bracket under the OEM steel line that

runs over the frame.

4. Install the supplied 5/16 x 1 inch cap

screws through the bracket and into the

frame.

5. Install flat washers and Nylok nuts.

Tighten the fasteners securely.

6. Install the cooler on the bracket, thread

in the two hex head cap screws and

tighten them securely.

Cooler mounting holes

Part 2

Installing the Control

Components

System #V900050

2000 FORD E250-E350

7.3 POWER STROKE DIESEL with A/C

UNDERHOOD AIR COMPRESSOR

15

DOCUMENT 1900679

16

2.1 Installing the control unit

1. Locate a suitable position for the

control unit. A recommended position

is on the side of the driver’s seat base.

2. Remove the step trim from the door

opening on the driver’s side.

3. Place the control unit on the seat base

with the bottom edge of the control unit

flush on the floor below the edge of

the step trim.

4. Using the control unit as a template,

mark the location of the top mounting

holes and drill two 3/16 inch holes.

5. Mount the control unit using the

supplied self-tapping screws.

6. Feed the wire harness with the 7 pins

from the control unit along the channel

under the step trim and up under the

dash.

7. Replace the door trim panel.

2.2 Installing the throttle controller

1. Mount the throttle controller under the

dash, near the steering column using the

OEM fastener.

Mounting the control unit

Mounting the throttle controller

Connectors

from the

throttle

controller

Connecting the cables

17

18

2. Remove the two OEM electrical

connectors from the pedal assembly.

3. Plug the matching connector from the

throttle controller into the pedal

assembly. Make sure that the

connectors are pushed all the way in

with the latches fully engaged.

4. Plug the connectors from the pedal

assembly into the matching connection

at the throttle controller. Make sure

that the connectors are pushed all the

way in and the latches fully engaged.

2.3 Connecting the wiring

1. Install the Drive Disable Circuit under

the dash near the throttle controller.

2. Route the black wire with the piggy-

back connector from the DDC to the

switch on the park brake.

3. Connect the other black wire from the

DDC to the matching black wire at the

throttle controller.

4. Disconnect the OEM wire from the park

brake switch and connect the wire with

the piggy-back from the DDC.

5. Connect the OEM connector to the

piggy-back connector on the switch.

Drive Disable Circuit wiring

Connect to matching yellow

wire from the throttle control

Yellow

Attach OEM park brake wire

Black

Piggy-back

connector

Connect to the OEM

park brake switch

Connect to black park brake wire

from the throttle controller

Connect to the white wire with the

pink tracer from the transmission

park/neutral switch

Blue

Page is loading ...

Vmac V900050 Installation guide

Vmac V900050 Installation guide

Related papers

Other documents