Vmac V900061 Installation guide

Installation Manual

For The

System #V900061

UNDERHOOD AIR COMPRESSOR

2001 GENERAL MOTORS

2500HD - 3500

DURAMAX DIESEL

TEL: 250-740-3200

FAX: 250-740-3201

TOLL FREE: 800-738-8622

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

Document 1900686

Installation Manual 1900686

VR70 Underhood Air Compressor

System Number V900061

Application: 2001 General Motors HD2500 - 3500 with a Duramax diesel engine

Publication Date: Revised by S. Large, August / 2002

Origination Documents: 1900686 - Manual Document

1900686a - General information

1900686b -Preparing for installation

1900686c - Installing the air tank and lines

1900686d -Installing the cooler and main bracket

1900686e - Installing the control unit

1900868f - Illustrated parts list

1900030 - Warranty Registration

Registered Trademarks:

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

HD2500, 3500 and Duramax are registered trademarks of General Motors Corporation.

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 ................................................................................................................ 5

ORDERING PARTS ...................................................................................................................... 6

WARRANTY ............................................................................................................................. 6

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

TOOL REQUIREMENTS ............................................................................................................... 8

PART 1: PREPARING FOR INSTALLATION ................................................................... 9

PART 2: INSTALLING THE TANK AND LINES............................................................ 17

2.1 INSTALLING THE CABLES AND STRAPS ................................................................................ 19

2.2 INSTALLING THE C-CLAMPS .............................................................................................. 20

2.3 INSTALLING THE L-BRACKETS .......................................................................................... 20

2.4 INSTALLING THE P-CLIPS ................................................................................................. 21

2.5 INSTALLING THE TANK .................................................................................................... 22

2.6 ATTACHING LINES TO THE TANK ...................................................................................... 23

PART 3: INSTALLING THE COOLER AND MAIN BRACKET .................................. 25

3.1 INSTALLING THE COOLER ................................................................................................. 27

3.2 INSTALLING THE VR70 CRANK PULLEY ............................................................................ 27

3.3 INSTALLING THE RADIATOR AND HOSES .............................................................................. 28

3.4 INSTALLING THE MAIN BRACKET AND COMPRESSOR ............................................................. 29

3.5 INSTALLING OTHER COMPONENTS ..................................................................................... 31

3.6 CONNECTING THE REMAINING HOSES ................................................................................ 36

3.7 COMPLETING THE INSTALLATION ..................................................................................... 37

PART 4: INSTALLING THE CONTROL COMPONENTS ............................................ 41

4.1 INSTALLING THE CONTROL UNIT ....................................................................................... 44

4.2 INSTALLING THE SWITCHING BOX ...................................................................................... 45

4.3 INSTALLING THE THROTTLE COMMANDER ......................................................................... 45

4.4 CONNECTING DRIVE DISABLE CIRCUIT (DDC) ...................................................................... 47

4.5 CONNECTING THE WIRE HARNESSES .................................................................................. 50

PART 5: ILLUSTRATED PARTS LIST ............................................................................. 53

WARRANTY REGISTRATION.......................................................................................... 59

1

2

General Information

System #V900061

2001 GENERAL MOTORS

2500HD - 3500

DURAMAX DIESEL

UNDERHOOD AIR COMPRESSOR

3

Document 1900686

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 the VR70 Underhood Air Compressor. The

information in this book should be read completely before attempting installation.

Installation steps

The installation procedures are divided into the following main steps:

Part 1: Preparing for installation

Part 2: Installing the tank and lines

Part 3: Installing the cooler and main bracket

Part 4: Installing the control components

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)

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 suggestions in this manual.

5

WARNING

!

NOTE

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.

Ordering parts

To order parts, contact your VMAC dealer.

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 as shown in Figure 1. Drill the two hole locations using a 7/64” drill

bit. Attach the plate with the two supplied #6 pan head self tapping screws.

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

the ordering of parts. It is important that this plate is affixed to the vehicle.

6

NOTE

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

Figure 1 Location of System Identification Number Plate

7

Special installation notes

If you intend to use an auxiliary air receiver with this system you must observe the following

installation procedure (Figure 2) . Failure to observe this procedure will result in damage to the

system.

1. The line from the VR70 tank to the auxiliary air receiver must have a one-way check valve

installed to prevent blowback from the auxiliary tank and to prevent moisture from entering

the VR70 tank.

2. The line to the auxiliary tank must not be installed in the bottom of the tank, but must be

installed as high as possible to prevent water from clogging the line.

Figure 2

VR70 Tank

Auxiliary Receiver

One-way check valve

Install the line as high as

possible, NOT on the

bottom of the tank

Changes and improvements

These products and documents are subject to changes or improvements without notice.

8

Tool Requirements

List of tools required for compressor installation

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

tool (Part # 5900010) .

• VMAC crankshaft pin extraction tool (Part # 5900076) .

•1/2” drive metric socket set.

•1/2” drive SAE socket set.

•Allen key sets – metric and SAE.

•Mechanic’s screwdriver set.

•Nut drivers – 5/16- 3/8 inch.

•1/2-inch drill with assorted bits up to 1/2-inch.

•Hacksaw or zip wheel suitable for cutting metal.

List of tools required for throttle component installation

•Small soldering gun/ Soldering pen.

•Wire cutters.

•Wire strippers.

•Crimping tool.

•Digital multimeter – preferably with a frequency (Hz) setting.

•Very small Jeweler’s screwdriver set for the adjustment of the throttle control.

9

Part 1

Preparing for Installation

System #V900061

2001 GENERAL MOTORS

2500HD - 3500

DURAMAX DIESEL

UNDERHOOD AIR COMPRESSOR

Document 1900686

10

11

1. Disconnect the positive and ground cables

from the batteries.

2. Remove the plastic cowling from the top

of the engine.

3. Drain the coolant into a suitable container.

4. Disconnect the top radiator hose from the

radiator and move out of the way.

5. Remove the bolts holding the upper fan

shroud and remove the engine control

module (ECM) and cover from the

driver’s side of the upper fan shroud

(Figure 2).

Do not disconnect the ECM wire

harness, just move the module over

to one side.

6. Remove the upper fan shroud (Figure 3).

7. Disconnect the hoses from the coolant

tank and the heater return hose which is

attached to the lower radiator hose.

8. Remove the lower radiator hoses.

9. Remove the fan using a pin wrench in the

water pump pulley and a fan clutch nut

wrench (as per manufacturers

instructions).

10. Remove the air duct from air cleaner to

engine (Figure 1).

Figure 1

Figure 2

Figure 3

ECM

NOTE

12

11. Remove the plastic inner fender liner on

the passenger’s side. This is an optional

technique to give greater accessability.

12. Disconnect the MAF sensor wire from the

air cleaner and then remove the air cleaner

assembly.

13. Remove the 6mm OEM bolts locating the

air cleaner base mounting plate, then

remove the two 6mm bolts locating the air

cleaner support bracket to the front

upright (Fig. 4).

14. Disconnect the hoses from the passenger

side intercooler tube and remove the tube

and hoses.

15. Disconnect the level sensor wire and

remove the coolant expansion tank and

radiator bleed hose.

16. Disconnect the wiring plugs from the

crank position sensor and the cam sensor

on the front of the engine (Figure 6).

17. Remove the 8 mm cap screw holding the

sensor wire harness clip to the front lower

engine block.

18. Disconnect the two ground wires (from

the same loom) from the lower engine

block.

19. Remove the engine breather canister and

the hose attached to the lower engine

block.

Figure 4

Figure 5

Figure 6

Fuel bleed valve studs

8mm Bolt for breather tube clamp

CAM Position Sensor

Crank Position Sensor

13

20. Remove the 8mm bolt from the cast

alternator mounting bracket that holds the

breather tube and wire harness (Figure 5).

21. Cut the tie wrap holding the loom and

breather tube together.

22. Remove the two (2) nuts from the fuel

bleed valve (Figure 5).

23. Disconnect both fuel inlet and outlet

banjos from the fuel module (Figure 7).

24. Remove the fuel management module on

the top of the right engine bank and move

it up and out of the way. Keep all the

rubber washers, plastic spacers and

mounting bolts (Figure 7).

25. 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.

26. Disconnect the dipstick tube from the fuel

management module mount bracket, then

remove and discard the complete fuel

module and dipstick mount bracket

(Figure. 7).

27. Remove the alternator wiring and locating

bolts and remove the alternator. Do not

damage the air conditioning line.

Figure 7

Figure 8

Figure 9

14

28. Unclip the top of the wire harness plastic

channel attached to the engine fuel rail,

carefully lift out the wiring and cut the ties

locating module end of the channel. Also

remove the lower plastic wire harness

channel (Figure 8).

29. Remove and discard the metal coolant

tube from the heater to the lower radiator

hose.

30. Remove the OEM 8 rib drive belt.

31. Remove the rock guard from under the

front of the vehicle. Keep the bolts.

32. Remove the 18 mm crank pulley bolt

using the recommended OEM crankshaft

locking tool (Figure 11). GM Part #. J-

44643.

33. Remove the crank pulley

34. Using the VMAC crankshaft pin

extraction tool (part # 5900076), remove

the OEM crankshaft pin. An Illustration

of this tool is shown on page 15. Please

Vmac V900061 Installation guide

Vmac V900061 Installation guide

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