Vmac 9043 Installation guide

Installation Manual

For The

System #9043

UNDERHOOD AIR COMPRESSOR

1998½-2000 DODGE

5.9 CUMMINS 24 VALVE DIESEL

(without air conditioning)

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

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

DOCUMENT 19399

Installation Manual

VR7000 Underhood Air Compressor

System Number 9040

Application: 1998½-2000 Dodge with the 5.9 Cummins 24 Valve Diesel Engine without Air

Conditioning

Publication Date: January 2000

Publication Number: 19399

Origination Documents: #19399a - introduction

#19400 - compressor and regulator installation

#19401 - oil cooler, air tank and line installation

#19402 - control unit installation

#19403 - throttle controller installation

#19404 - illustrated parts list

#19130 - warranty registration

Registered Trademarks:

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

Dodge and Magnum are registered trademarks of Daimler-Chrysler AG.

Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.

Nylok is a registered trademark of Nylok Fastener Corporation.

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 THROTTLE CONTROLLER ... 9

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

1.2 INSTALLING THE BRACKET .........................................................................................14

1.3 INSTALLING THE VR7000 COMPRESSOR AND OTHER COMPONENTS ..........................................14

1.4 INSTALLING THE THROTTLE CONTROLLER ASSEMBLY ..........................................................20

PART 2: INSTALLING THE OIL COOLER, TANK AND LINES ............................21

2.1 INSTALLING THE OIL COOLER ......................................................................................23

2.2 INSTALLING THE TANK MOUNTS ...................................................................................23

2.3 CONNECTING THE LINES ...........................................................................................25

2.4 ADDING OIL TO THE SYSTEM ......................................................................................28

2.5 COMPLETING THE INSTALLATION ..................................................................................29

PART 3: INSTALLING THE CONTROL UNIT ........................................................31

3.1 CONTROL UNIT INSTALLATION ....................................................................................33

3.2 CONNECTING THE WIRING ..........................................................................................34

PART 4: INSTALLING THE THROTTLE CONTROLLER .....................................37

4.1 INSTALLING THE CABLE ............................................................................................39

ILLUSTRATED PARTS LIST ..................................................................................43

WARRANTY REGISTRATION .................................................................................49

1

2

General Information

System #9043

1998½-2000 DODGE

5.9 CUMMINS 24 VALVE DIESEL

(without air conditioning)

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 19399a

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 under-hood air compressor installation kit #10143I

VMAC Pneumatic Throttle Control # 5035

This kit has been designed for:

1998½-2000 Dodge equipped with a Cummins 5.9 24 valve ISB diesel engine without air

conditioning.

Installation steps

The installation procedure in this manual has four main steps:

Part 1: Installing the Compressor

Part 2: Installing the Oil Cooler, 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)

5

WARNING

!

NOTE

DOCUMENT 19399a

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 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).

6

T

y

pe 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

DOCUMENT 19399a

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, Monday through Friday

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 (S/N) must be attached to the vehicle at the time

of installation.

Locate the S/N plate on the front body support on the passenger side of the vehicle where the

OEM decals are located (Figure 1) . Drill the two hole locations using a 7/64” drill bit. Place the S/

N plate in position and fix in place with the two #6 pan head self tapping screws provided.

IMPORTANT

This S/N plate provides information, which allows VMAC to assist in customer inquiries and/or

ordering of parts. It is important that this S/N 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

DOCUMENT 19399a

8

Part 1

Installing

the Compressor

and Throttle Controller

System #9043

1998½-2000 DODGE

5.9 CUMMINS 24 VALVE DIESEL

(without air conditioning)

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 19400

10

Part 1: Installing the Compressor

1.1 Preparing for installation

1. Disconnect the batteries.

2. Remove the air cleaner to turbo inlet ducting and immediately cover the inlet to the

turbocharger.

3. Remove the OEM drive belt.

4. Disconnect the wiring from the alternator. Also disconnect the wiring plug beside the

passenger-side battery (Figure 1.1) and remove the retaining clip from the battery tray.

Figure 1.1 Wiring plug beside the battery

5. Remove the alternator top support bracket, the alternator and the alternator tie mount from

the engine.

6. Remove the battery positive cable from the top of the radiator.

7. Drain the coolant.

8. Remove the top radiator hose.

9. Remove the coolant expansion tank and the windshield washer reservoir from the fan

shroud.

10. Remove the lower radiator hose.

11. Remove the coolant return hose from the transmission cooler at the square block tee

connector (Figure 1.2).

11

DOCUMENT 19400

12. Loosen the securing clamp which retains the two 1/2” steel coolant lines near the exhaust

manifold.

13. Remove the heater return hose from the square block tee connector.

14. Remove the fan belt tensioner, the engine cooling fan and the fan shroud.

15. Remove and discard the lifting lug from the engine.

16. Remove the electric horns from the top-side of the fender panel.

17. Remove the hex head cap screws from the OEM crankshaft pulley.

18. Remove and discard the transmission heat exchanger supply pipe and hose from the front of

the transmission cooler to the cylinder head outlet (Figure 1.3) labelled “E” in Figure 1.4.

19. Remove the T-connector in the bottom hose housing (Figure 1.2).

20. Remove the three (3) M12 hex head cap screws and the three (3) M10 hex head cap

screws retaining the OEM mounting unit to the engine block.

21. Remove and discard the entire assembly from the engine block (Figure 1.3).

- C -

Transmission Heat Exchanger Supply Pipe

Three (3) M10 Socket Head Cap Screws

(two hidden from view)

Three (3) M12 Hex Head Cap Screws

Transmission Heat

Exchanger Return Hose

Cab Heater Coolant

Return Pipe

Lower Radiator Hose

Location

Engine Block

Tee Connector

12

DOCUMENT 19400

Figure 1.2 Location of hoses, fittings and fasteners

13

DOCUMENT 19400

Figure 1.3 Location of hoses and fittings

On automatic transmission vehicles,

remove and discard this hose and metal

line, on manual transmission vehicles,

remove the blanking plug from this location

Tee connector with heater coolant return

and transmission heat exchanger return

lines

Figure 1.4 Location of idlers, tensioner, fasteners and fittings

A

E

C

Engine

Block

OEM

Transmission

Heat Exchanger

Supply

VR7000 Back

Idler

Water Pump

Lower Radiator Hose

Housing Inlet

OEM Belt

Tensioner

Transmission Heat

Exchanger Return

Hose

VR7000 Coolant Hose To

Heat Exchanger

Heater Supply

Hose

Tee-Connector

20

o

Side View

To p Vie w

1.2 Installing the bracket

1. Check the machined surface on the engine block. Make sure that it is clean before

attempting to mount the VR7000 bracket.

2. Remove the hex head cap screw from the back idler. Apply Loctite to the fastener, install it

and torque it to specifications.

3. Remove the fastener from the VR7000 belt tensioner. Apply Loctite and torque it to

specifications.

4. Install the OEM tee connector to the rear of the bracket. Use Loctite PST thread sealant

and tighten it to the same position as in the OEM casting.

Use Figures 1.4 and 1.5 to assist in locating components.

NOTE

14

DOCUMENT 19400

Figure 1.5 Bracket, idler and tensioner installed

5. Install the VR7000 bracket to the engine block using three (3) M10 socket heat cap screws

and three (3) M12 hex head cap screws. Apply Locitite to all fasteners. Torque the

fasteners to specifications.

The roll pins on the VR7000 bracket are used to align the bracket with the front edge of

the engine block. They do not fit into any location holes.

NOTE

15

DOCUMENT 19400

6. Automatic Transmission Models: remove the NPT coolant outlet fitting for the

transmission cooler from the cylinder head. Apply Loctite PST sealant and install the

supplied NPT 45 degree angle adapter fitting. When the fitting is tightened, it should point

downward at approximately 20° and rearward to clear the VR7000 bracket (Figures 1.4

and 1.6). Apply Loctite PST sealant and install the OEM fitting into the 45 degree adapter.

7. Manual Transmission Models: remove the blanking plug in the cylinder head and install

the supplied NPT 45 degree adaptor as in step 6, then install the supplied 5/8” hose barb.

Make sure that the assembly aligns as in step 6.

Figure 1.6 Location and direction of cylinder head fitting

8. Install the provided bracket with idler to the four air conditioning mounting locations. Use

Loctite on the fasteners and torque them to specifications. Figure 1.7 shows the bracket

from under the vehicle, looking upward.

Figure 1.7 Bracket with idler installed on the VR7000 bracket

16

DOCUMENT 19400

OEM Cab Heater

Supply Line From

Manifold

Cut Heater Return

Hose Approximately

1" Before The Bend

Install The Supplied Plastic Tee

Secure Lines

With Ties

Air Conditioning Line

Cab Firewall

Figure 1.8 Connection for manual transmission models

5. Manual Transmission Models: cut the heater return hose approximately 1″ before the

bend (Figure1.8). Slide hose clamps over the cut ends of the hose, install the supplied

plastic tee-fitting and tighten the hose clamps.

6. Slide a hose clamp on the supplied 5/8“ x 50″ heater hose and install it on the tee-fitting.

Tighten the clamp.

9. Route the hose to the front of the vehicle and secure it to the air conditioning line with ties.

1.3 Installing the VR7000 compressor and other components

1. Install the supplied bracket with idler to the four air conditioning mounting locations on the

bracket. Use Loctite and torque them to specifications.

2. Install the OEM belt tensioner and idlers (Figure 1.4). Torque all fasteners to OEM

specifications.

3. Install the lower radiator hose to the outlet tube on the VR7000 bracket. Tighten the hose

clamps.

4. Automatic Transmission Models: connect the cab heater return hose (location A in

Figure 1.4) and the transmission heat exchanger return hose (location C in Figure 1.4) to the

OEM tee connector on the VR7000 bracket.

Fitting Should Be Offset 45°

From the Center-Line of the

Compressor

17

Figure 1.9 Direction of fitting on compressor

DOCUMENT 19400

10. Ensure that the fitting on the bottom of the VR7000 compressor is located as shown in

Figure 1.9.

11. Pass the 1/2” x 44-1/2” compressor to oil cooler line through the rails of the bracket.

Figure 1.10 Compressor and alternator installed on the engine

21. Modify the fan shroud as shown in Figure 1.12. Use an angle grinder or similar tool. Cut

away the three ribs and the angled section on the passenger side of the shroud.

18

DOCUMENT 19400

Alternator

Fan

Crankshaft

Water Pump

Air Conditioning

Compressor

Tensioner

Crankshaft

VR7000 Tensioner

VR7000 Idler

VR7000 Compressor

Figure 1.11 OEM and VR7000 belt routing

OEM BELT ROUTING

VR7000 BELT ROUTING

15. Install the alternator on the VR7000 bracket using the OEM fasteners.

16. Attach the OEM alternator tie to the top of the alternator using the OEM fasteners.

17. Connect the wiring to the alternator.

18. Install the VR7000 pulley in place over the OEM pulley.

19. Apply Loctite to the four (4) pulley retaining bolts, install the fasteners and torque them to

specifications.

20. Install the replacement belt for the OEM drive belt and the VR7000 belt according to the

routing shown in Figure 1.11.

NOTE

You may find it easier to install the oil return line before installing the compressor, as you

will have trouble tightening the fitting once the compressor is installed.

13. Apply Loctite to the studs on the compressor, position the compressor in place on the

VR7000 bracket, install the 8 mm nuts and flat washers and torque them to 25 ft-lb.

14. Install the supplied alternator support bracket in location where the lifting lug was removed.

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Vmac 9043 Installation guide

Vmac 9043 Installation guide

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