Vmac 9039 Installation guide

Installation Manual

For The

System #9039

UNDERHOOD AIR COMPRESSOR

1996-2000 GMC C2500 & C3500

5.0L (305) & 5.7L (350)

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

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

DOCUMENT 19622

Installation Manual

VR7000 Underhood Air Compressor

System Number 9039

Application: 1996-1999 GMC C2500 & C3500 5.0L (305) & 5.7L (350)

Revision Date: February 2001

Publication Number: 19620

Origination Documents: #19620a - introduction

#19620b - compressor and oil cooler installation

#19620c - air tank and line installation

#19620d - throttle controller installation

#19620e - control unit installation

#19621 - illustrated parts list

#19130 - warranty registration

Registered Trademarks:

VR7000, VMAC and Throttle Commander are registered trademarks of VMAC.

GMC, C2500 and C3500 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 .............................................................................................................. 6

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

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

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

PART 1: INSTALLING THE AIR TANK AND LINES ...................................................... 9

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

1.2 INSTALLING THE BRACKETS AND TANK ............................................................................... 12

PART 2: INSTALLING THE COMPRESSOR AND COOLER ...................................... 17

2.1 INSTALLING THE BRACKET AND THE COMPRESSOR ................................................................ 19

2.2 INSTALLING THE CRANK PULLEY ....................................................................................... 20

2.3 INSTALLING THE OIL COOLER ............................................................................................ 21

2.4 CONNECTING THE HOSES .................................................................................................. 22

2.5 COMPLETING THE INSTALLATION ...................................................................................... 23

PART 4: INSTALLING THE CONTROL UNIT ................................................................25

3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 27

3.2 CONNECTING THE WIRING HARNESS ................................................................................... 28

PART 4: INSTALLING THE THROTTLE CONTROLLER ........................................... 31

4.1 INSTALLING THE THROTTLE CONTROLLER ASSEMBLY ........................................................... 33

4.2 CONNECTING THE CABLE ................................................................................................. 34

4.3 ADJUSTING THE CABLE ..................................................................................................... 35

ILLUSTRATED PARTS LIST .............................................................................................. 37

WARRANTY REGISTRATION ..............................................................................................

1

2

General Information

System #9039

1996-1999 GMC

C2500 & C3500

5.0L (305) & 5.7L (350)

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 19622

4

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:

1996-1999 GMC C2500 & C3500 with a 5.0L (305) or a 5.7L (350)

Installation steps

The installation procedure in this manual has four main steps:

Part 1: Installing the Compressor, Filter, Regulator and Oil Cooler

Part 2: Installing the 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

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.

DOCUMENT 19622

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 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).

The above fastener torque values are applicable when Loctite is used .

If the threads are dry add 20% to the torque values.

DANGER

Never operate the system unless the vehicle transmission is in neutral (standard

transmission) or park (automatic transmission) with the park brake fully applied. A

sudden increase in engine RPM when the system is engaged will cause the vehicle to

move suddenly if the transmission is left in drive.

6

DOCUMENT 19622

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

WARNING

!

Ordering Parts

To order parts, contact VMAC at:

Telephone 250-754-6997

Facsimile 250-754-6972

Customer Service 800-736-8622

Office Hours 8:00 AM to 4:30 PM Pacific 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. This plate provides information, which allows VMAC to assist in customer inquiries and

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

Instructions

Locate the plate on the front body support on the passenger side of the in front of 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.

Figure 1

Changes and improvements

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

7

DOCUMENT 19622

8

DOCUMENT 19622

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 VR7000 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 VR7000 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.

VR7000 Tank

Auxiliary Receiver

One-way check valve

Install the line as high as

possible, NOT on the

bottom of the tank

Figure 2

Part 1

Installing the

Air Tank and Lines

System #9039

1996-1999 GMC

C2500 & C3500

5.0L (305) & 5.7L (350)

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 19622

10

11

DOCUMENT 19622

Part 1: Installing the Air Tank and Lines

1.1 Preparing for installation

1. Disconnect all battery cables, then undo the battery hold down and remove the

battery from the passenger side of the vehicle.

2. Drain the coolant from the cooling system and remove the lower radiator hose.

3. Remove and discard the rock guard from under the radiator. Keep the OEM

fasteners for use with the replacement rock guard.

4. Disconnect the top radiator hose from the radiator end but not from the engine.

5. Disconnect and remove the air inlet box.

6. Remove the positive battery cable from its position on the fan shroud.

7. Remove the upper and lower sections of the fan shroud and the fan.

8. Remove the OEM belt and the fan.

9. Disconnect the transmission and vehicle oil cooler lines from the radiator. Undo the

upper radiator support bolts, then lift out the radiator.

10. On vehicles with or without air conditioning, the OEM idler on the alternator bracket

is discarded with the bracket.

11. Disconnect and remove the wiring from the alternator.

12. Remove the OEM retaining bolts from the alternator and remove the alternator.

13. Remove the heater hoses, air conditioning line and alternator cable from the plastic

locating bracket fastened to the alternator mounting castings (Figure 1.1).

14. Remove the OEM belt tensioner from the alternator mounting bracket (Figure 1.1).

15. Remove and discard the OEM cast aluminum alternator mounting bracket (Figure

1.1).

16. Remove and discard the heater hose (complete with metal S-shaped pipe) from

between the water pump and the firewall (Figure 1.1).

Do not disconnect the heater return hose quick-coupler at the manifold as it may

leak if removed and refitted.

NOTE

OEM Alternator Bracket

Bracket Holding Heater Hoses,

Air Conditioning Line And

Alternator Cable

OEM Heater Hose With Metal S-shaped Pipes

On Vehicles With Or Withoutout A/C Discard

The Idler Which Is Attached Here

On Vehicles

With A/C, Fit The

Supplied Aluminum

Idler To The Cast

AluminumBracket At

This Location

1.2 Installing the brackets and tank

The tank mounts supplied with this system are designed so that they can be mounted on the

frame without drilling holes. The tank is secured to the frame using two L-brackets that

hook over the chassis rail and are secured with wire cables and backing straps. The tank

and clamps then locate on the L-brackets

1. Remove the two (2) 1/4 inch bolts from both of the C-clamps supplied. Expand the clamps

and fit them over the front of the tank. Position the first C-clamp at seven (7) inches from

the rear of the tank and rotate it so the flat mounting section is aligned with the “up” arrow

on the rear of the tank. Locate the front C-clamp at three (3) inches from the front of the

tank and rotate to the same position as the rear C-clamp. Tighten both clamps untill they

hold the tank. Do not over tighten.

2. Connect the swivel nut on the end of the steel line coupled to the 1/4inch pressure control

line, to the upper location on the rear of the tank. Run the steel line along the inside of the

tank. (See figure 1.2)

Figure 1.1

3. Connect the swivel nut on the end of the steel line coupled to the 5/16 scavenge line, to the

lower connection at the rear of the tank. Route the steel line down the inside of the tank

alongside the 1/4 pressure control line. (See figure 1.2)

12

DOCUMENT 19622

4. Fit the two (2) supplied “P” clips over the 1/4 and 5/16 inch steel lines and postion them to

align with the upper fixing slots on both C-clamps.

5. Attach the L-shaped tank brackets to the C-clamps on the tank using the supplied 5/16 x

1/2 inch cap screws. Two 5/16 washers are used on the lower bolts and the “P” clips with

the upper bolts. Use locktite on the bolts.

Connections at the rear of the tank Connections at the front of the tank

6. Make sure that the brackets are at their lowest point on the adjustment

slots (the tank will mount as high as possible). Tighten the cap screws.

7. Remove the two (2) 5/16 inch nuts and washer from the threaded ends of the wire cable

and remove the threaded ends from the backing strap.

9. Place the two backing straps in position on the inside of the frame, one in front of the

transmission crossmember mount and one behind the mount, with the cables over the top of

the frame. (See figure 1.4)

10. Support the tank on adjustable jackstands or a suitable support system (so that you can

locate the tank and lift it into position) under the body on the passenger side of the truck

between the two body mounts.

11. Route the 1/4 inch and 5/16 inch lines between the body mount and the body, up over the

frame rail on the passenger side and up towards the front of the engine compartment.

12. Raise the tank into position along the side of the frame (between the two body mounts) with

the top of the L-bracket over the top of the frame.

13. Fit the cable into the two slots on each of the L-shaped brackets and insert the threaded

end through the bottom holes of each backing strap.

13

Figure 1.2 Figure 1.3

DOCUMENT 19622

14. Slide the flat washers onto the threaded ends of each wire cable and install one of the 5/16

inch nuts on each cable. Do not tighten until all the hoses are installed.

15. Slide the tank rearward on the frame to provide clearance for attaching the remaining lines.

14

DOCUMENT 19622

Figure1.5 Figure 1.6

Figure 1.4

DOCUMENT 19622

15

It is recommended that you leave the tank loose in the clamps until all of the lines are

connected to allow you to adjust tank position during the line connection process.

NOTE

Figure 1.8

Figure 1.7

DOCUMENT 19622

16

The lines must be installed in the correct locations or the system will not function

properly. In addition, a hazardous situation may develop from oil spray, potential

fire or explosion.

WARNING

!

16. Connect the 45 degree fitting end on the 3/4 inch main air hose to the upper fitting on the

front of the tank. Angle the hose to route up and over the cab mount and along the frame rail

towards the front of the engine compartment.

17. Fit the 90 degree fitting end of the longer 1/2 inch oil return hose to the lower fitting on the

front of the tank. Angle the hose up over the cab mount with the 3/4 hose and the two hoses

from the rear of the tank.

20. Move the tank forward on the frame until there is 7 inches between the front of the tank and

the cab mount

21. Tighten the 5/16 inch nut on the cable clamps to hold the tank in position, then install a

second 5/16 inch nut on each clamp and tighten them to lock the nuts and prevent them

from loosening.

22. Tighten all hoses on the tank securely.

Part 2

Installing

the Compressor,

and

Oil Cooler

System #9039

1996-1999 GMC

C2500 & C3500

5.0L (305) & 5.7L (350)

UNDERHOOD AIR COMPRESSOR

17

DOCUMENT 19622

18

Page is loading ...

Vmac 9039 Installation guide

Vmac 9039 Installation guide

Related papers