Vmac V900014 Installation guide

Installation Manual

For The

System #V900014

UNDERHOOD AIR COMPRESSOR

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

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

DOCUMENT 1900533

1996-2000 GMC C2500, C3500 & HD3500

454 W/WOAC - 2 WHEEL DRIVE

Installation Manual

VR70 Underhood Air Compressor

System Number V900014

Application: 1996-2000 GMC C2500, C3500 & HD3500 454 W/WOAC,

Revision Date: July 2000

Publication Number: 1900533

Origination Documents: #1900533a - introduction

#1900534 - compressor and oil cooler installation

#1900535 - air tank and line installation

#1900536 - controller installation

#1900537 - illustrated parts list

#1900130 - warranty registration

Registered Trademarks:

VR70, VMAC and Throttle Commander are registered trademarks of VMAC, a division of

Mangonel Corporation.

GMC, CK2500, CK3500 and HD3500 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 COMPRESSOR AND OIL COOLER ...........................9

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

1.2 INSTALLING THE BRACKET AND COMPRESSOR ..................................................................13

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

1.4 COMPLETING THE INSTALLATION ..................................................................................16

PART 2: INSTALLING THE AIR TANK AND LINES .............................................21

2.1 INSTALLING THE TANK MOUNTS ...................................................................................23

2.2 INSTALLING THE TANK ..............................................................................................24

2.3 CONNECTING THE AIR AND OIL LINES .............................................................................26

PART 3: INSTALLING THE CONTROL UNITS .....................................................29

3.1 INSTALLING THE THROTTLE CONTROL ............................................................................31

3.2 INSTALLING THE CONTROL UNIT ...................................................................................34

3.3 CONNECTING THE WIRE HARNESSESS ...........................................................................35

PART 5: ILLUSTRATED PARTS LIST...................................................................39

WARRANTY REGISTRATION .................................................................................45

1

2

General Information

System #V900014

1996-2000 GMC C2500, C3500 & HD3500

454 W/WOAC - 2 WHEEL DRIVE

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 1900533a

4

General Information

Introduction

This book provides installation instructions for:

VMAC underhood air compressor installation kit

Installation steps

The installation procedure in this manual has three main steps:

Part 1: Installing the Compressor and Oil Cooler

Part 2: Installing the Air Tank and Lines

Part 3: Installing the Control Units

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.

Refer to the Owner’s Manual before operating the system for the first time.

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.

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.

5

NOTE

WARNING

✁

DOCUMENT 1900533a

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 correctly torqued. Torque specifications are in

foot-pounds (ft-lb). Always use manufacturer’s torque values for OEM fasteners.

Note: The above fastener torque values are applicable when Locktite is used.

If threads are dry, add 20% to torque value.

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 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.

6

DOCUMENT 1900533a

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

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 1900533a

8

Part 1

Installing

the Compressor, Filter

and

Oil Cooler

System #V900014

1996-2000 GMC C2500, C3500 & HD3500

454 W/WOAC - 2 WHEEL DRIVE

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 1900534

10

1.1 Preparing for installation

1. Disconnect the battery.

2. Drain the coolant from the cooling system and remove the OEM radiator hoses.

3. Remove the upper radiator cowling .

4. Remove the OEM belt, then remove the cooling fan.

5. Remove the lower radiator cowling.

6. Disconnect all the wire harnesses that are connected to the air condtioning compressor.

Also disconnect the loom from the AC bracket.

7. Mark the position of the power steering pump pully in relation to the pump shaft so that you

can install it in the original position.

8. Remove the power steering pump pulley using a manufacturer approved puller.

9. Remove the four (4) OEM hex head cap screws retaining the air conditioning compressor.

Lift the compressor from the mounting bracket and place it on top of the intake manifold or

the alternator.

11

DOCUMENT 1900534

Remove These Fasteners

Disconnect These Harnesses

Remove the OEM Belt

Removing components in preparation for installation

Part 1: Installing the Compressor and Oil Cooler

10. Remove the three (3) OEM hex head cap screws retaining the power steering pump to the

bracket and the 10mm hex head cap screw from the cylinder block support bracket.

11. Remove the stud from the cylinder head that is used to locate and retain the OEM air

conditioning and power steering bracket.

12. Remove the OEM fasteners retaining the air conditioning compressor/power steering pump

mounting bracket to the cylinder head and discard the bracket.

Mounting locations on the head and block

13. Clean all dirt and debris from the inside of the OEM crankshaft pulley.

14. Remove the OEM fasteners holding the OEM pulley in place on the crankshaft.

15. Install the VR70 pulley in place over the OEM crankshaft pulley.

16. Install and tighten the three (3) supplied 3/8 x 3-1/2 inch NF hex head cap screws and one

(1) 1/2 x 3/8 inch NF hex head cap screw in the center of the pulley.

17. Remove the ribbed idler and the tensioner from the VR70 bracket before installing the

bracket.

18. Inspect the mounting location to ensure that it is clean. Place the bracket in position and

make sure that there is nothing interferes with the fit. Grind off any casting flashing on the

manifold, if necessary.

12

DOCUMENT 1900534

Three C

y

linder Head Locations

Two Cylinder Block Locations

13

1.2 Installing the bracket and compressor

1. Apply Loctite to the five (5) 7/16 x 1-1/4 hex head cap screws and install the 7/16 flat

washers. Fasten the VR70 bracket in place of the OEM air conditioning and power

steering mounting bracket, then torque the fasteners to specifications.

2. Apply Loctite to the OEM hex head cap screws and install the power steering pump. Install

the supplied block support bracket (PN12200) to the rear of the power steering pump to

the pump using OEM bolts. Figure 1.3 shows the bracket in place on the cylinder block

with the power steering pump mounted on the bracket.

Bracket and power steering pump in place

3. Install the power steering pump pulley, making sure that the marks are aligned correctly.

4. Install the ribbed idler with the 1/2” NC cap screw and spacer, then torque to

specifications.

5. Install the belt tensioner using the Nylok nut and washer, then torque to specifications.

6. Apply Loctite to the burred-ends of the three (3) 8 mm studs and thread them into the

bottom of the compressor. Use two nuts jammed together on each stud to screw them in

past the burred section.

7. Position the compressor in place on the VR70 bracket, install the 8 mm nuts and 5/16 h flat

washers and torque to specifications (use lock tite on nuts).

8. Install the air conditioning compressor using two (2) OEM hex head cap screws in the rear

holes and two (2) supplied 10 x 80 mm hex head cap screws in the front holes.

DOCUMENT 1900534

Three 10 x 30 mm supplied hex head cap screws

14

DOCUMENT 1900534

VR70 compressor and AC compressor in place

1.3 Installing the oil cooler

1. Remove the OEM hex head cap screws which retain the radiator to the body.

2. Raise the radiator a few inches and support it to provide better access to the crossmember

under the radiator. You can also remove the radiator for better access.

3. Clean all dirt and debris from the area under the radiator.

Backing plate in position on the crossmember

4. Drill out the existing hole in the center of the crossbeam under the radiator using a 7/16 inch

drill.

15

DOCUMENT 1900534

5. Detach the cooler backing plate from the cooler assembly and fit underneath the crossbeam

(body pan) under the radiator. Fit a 3/8 x 1 inch hex flange lock cap screw and nut through

the drilled out hole with the bolt head upward and align plate square with crossbeam.

6. Mark the location of the two outer holes, then remove the cap screw and backing plate.

7. Center-punch and drill the two outer holes using the 7/16 inch drill.

Drilling out the holes

8. Place the backing plate in position on top side of the cross beam (body pan).

9. Place the cooler in position under the crossbeam and fit the three (3) 3/8 x 1 inch hex head

cap screws down from the top and through the cooler. Fit the lock washers and nuts.

Tighten the cap screws.

Cooler in position

11. Install the radiator and radiator support.

12. Cut the OEM lower radiator hose at the second bend from the radiator outlet.

13. Install the 45 degree elbow between the cut pieces.

14. Install two (2) #28 hose clamps for the connections at the 45 degree fitting, one (1) #32

hose clamp for the connection at the oil cooler and the OEM clamp for connection at the

radiator fitting.

15. Install the hose assembly between the radiator fitting and the rear-most (longest) fitting on

the cooler. Rotate the hoses so that they fit correctly without binding, then tighten the hose

clamps.

Lower hose cut and connected in place

16. Install the supplied radiator hose between the remaining cooler fitting and the water pump,

with the longest end of the hose to the water pump. You may have to trim a small amount

from the cooler end of the hose to get a correct fit. Use the provided #32 clamp on the

cooler end and the OEM clamp at the water pump. Tighten the clamps.

16

DOCUMENT 1900534

1.4 Completing the installation

1. Install the lower radiator cowling. Replace the fan OEM fan studs with the supplied

8 x 55 mm studs, then install the fan and the supplied fan spacer using Loctite on the

threads. Tighten the fasteners.

2. Install the OEM belt following the OEM belt routing. Be sure to identify the correct

application. The illustration shows routing for engines with and without air conditioning and

with and without Air Injection Reaction (air pump).

DOCUMENT 1900534

17

Installed hoses viewed from under the vehicle

A/C

Alternator Alternator

Idler Idler

Idler

Idler Idler

Idler

P/S P/S

Crankshaft Crankshaft

Tensioner Tensioner

Water Pump Water Pump

A.I.R. Pum p A.I.R. Pum p

WITH AIR CONDITIONING W ITHOUT AIR CONDITIONING

WITH

AIR PUMP

WITHOUT

AIR PUMP

OEM belt routing

3. Install the VR70 belt following the belt routing diagram on the next page. For units without

air conditioning, remove the OEM idler from the OEM bracket and mount it onto the pad

on the front of the VR70 bracket.

4. Connect any wiring or hoses removed in preparation for installation.

5. Install the upper fan shroud and any attached components.

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DOCUMENT 1900534

NOTE

When operating the engine for the first time following installation, be sure to allow the

engine to reach full operating temperature and ensure that the cooling system level is

correct. Failure to do so could result in an overheat condition and possible engine

damage.

Crankshaft

VR70 Air Compressor

VR70 Tensioner

VR70 Idler

VR70 belt routing

6. Install the top radiator hose between the radiator fitting and the thermostat housing, routing it

over the VR70 compressor.

7. Adjust the hose for a proper fit and tighten the hose clamps.

8. Install the hose retainer over the top radiator hose. This retainer will be secured into the

spare hole on the throttle controller mounting bracket using a 1/4 x 1 inch NC bolt, washers

and Nylok nut. Make sure that the hose clears all pulleys and belt once it is fastened in

place.

9. Check all hoses, lines, wire harnesses and cables to make sure that they clear all the belts,

pulleys or other objects that could cause damage.

10. Fill the cooling system with the OEM recommended coolant mixture to the correct level.

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Vmac V900014 Installation guide

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