Vmac 9048 Installation guide

Category
Engine
Type
Installation guide

Vmac 9048 is a versatile underhood air compressor system designed to enhance the capabilities of your vehicle. With its powerful compressor and durable air tank, you can enjoy the convenience of having compressed air on demand for a wide range of tasks, including:

  • Inflating tires: Vmac 9048 makes it easy to maintain optimal tire pressure, ensuring a smoother ride, improved fuel efficiency, and extended tire life.

  • Powering air tools: Connect your air tools to the system's air outlet and enjoy the freedom to work on projects without the hassle of cords or hoses.

  • Cleaning: Utilize the compressed air to remove dirt, dust, and debris from hard-to-reach areas, making cleaning tasks a breeze.

Vmac 9048 is a versatile underhood air compressor system designed to enhance the capabilities of your vehicle. With its powerful compressor and durable air tank, you can enjoy the convenience of having compressed air on demand for a wide range of tasks, including:

  • Inflating tires: Vmac 9048 makes it easy to maintain optimal tire pressure, ensuring a smoother ride, improved fuel efficiency, and extended tire life.

  • Powering air tools: Connect your air tools to the system's air outlet and enjoy the freedom to work on projects without the hassle of cords or hoses.

  • Cleaning: Utilize the compressed air to remove dirt, dust, and debris from hard-to-reach areas, making cleaning tasks a breeze.

Installation Manual
For The
System #9048
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 19457
1999-2000 GMC SIERRA & CHEVROLET SILVERADO
CK2500 5.3 L
Installation Manual
VR7000 Underhood Air Compressor
System Number 9048
Application: 1999 GMC SIERRA & CHEVROLET SILVERADO CK2500 5.3 L
Publication Date: February 2000
Publication Number: 19457
Origination Documents: #19457a - introduction
#19459 - air tank and line installation
#19458 - compressor and oil cooler installation
#19460 - control unit installation
#19461 - throttle controller installation
#19462 - illustrated parts list
#19130 - warranty registration
Registered Trademarks:
VR7000, VMAC and Throttle Commander are registered trademarks of VMAC.
GMC, CHEVROLET, SIERRA and CK2500 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.
Copyright 2000
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 ...........................................................................13
1.3 INSTALLING THE OIL COOLER ......................................................................................16
1.4 INSTALLING THE RADIATOR HOSES ...............................................................................17
1.5 CONNECTING THE OIL RETURN LINES .............................................................................18
1.6 COMPLETING THE INSTALLATION OF THE TANK, COOLER AND LINES .........................................19
PART 2: INSTALLING THE MOUNTING BRACKET AND COMPRESSOR .........21
2.1 INSTALLING THE BRACKET .........................................................................................23
2.2 INSTALLING THE CRANKSHAFT PULLEY ..........................................................................24
2.3 INSTALLING THE COMPRESSOR ....................................................................................27
2.4 FILLING THE SYSTEM WITH OIL ...................................................................................28
PART 3: INSTALLING THE THROTTLE CONTROLLER .....................................29
3.1 INSTALLING THE THROTTLE CONTROL ............................................................................31
3.2 CONNECTING THE POLY LINES ....................................................................................31
3.3 CONNECTING THE THROTTLE CABLE .............................................................................32
3.4 COMPLETING THE INSTALLATION ..................................................................................34
PART 4: INSTALLING THE CONTROL UNIT ........................................................35
4.1 INSTALLING THE CONTROL UNIT ...................................................................................37
4.2 CONNECTING THE WIRING HARNESS .............................................................................38
PART 5: ILLUSTRATED PARTS LIST...................................................................43
WARRANTY REGISTRATION .................................................................................49
1
2
General Information
System #9048
1999-2000 GMC SIERRA & CHEVROLET SILVERADO
CK2500 5.3 L
UNDERHOOD AIR COMPRESSOR
3
DOCUMENT 19457a
4
General Information
Introduction
This book provides installation instructions for:
VMAC underhood air compressor installation kit
VMAC Throttle Controller
Installation steps
The installation procedure in this manual has four main steps:
Part 1: Installing the Air Tanks and Lines
Part 2: Installing the Compressor and Cooler
Part 3: Installing the Control Unit
Part 4: Installing the Throttle Controller
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)
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 19457a
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.
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).
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
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 19457a
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 form has been designed as a convenient mailer, just fold along the
lines, tape the edge and apply sufficient postage.
System Identification Number Plate
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. 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 19457a
8
Part 1
Installing the
Air Tank and Lines
System #9048
1999-2000 GMC SIERRA & CHEVROLET SILVERADO
CK2500 5.3L
UNDERHOOD AIR COMPRESSOR
9
DOCUMENT 19459
10
11
1.1 Preparing for installation
1. Disconnect the battery.
2. Remove the air intake tube and
resonator box.
3. Remove the skid pan.
4. Drain the coolant from the cooling
system and remove the OEM radiator
hoses from the radiator end and tuck
them out of the way. The spring clamp
on the radiator end of the lower hose
must be removed from the hose so that
it can be repositioned to clear the
cooler.
5. Remove the upper radiator fan shroud.
6. Remove the cooling fan.
7. Remove the lower radiator fan shroud.
8. Remove the OEM drive belt.
9. Disconnect the alternator wiring and
remove the alternator.
10. Mark the position of the power steering
pump pulley in relation to the pump
shaft so that you can install it back into
the original position. Remove the
power steering pump pulley with the
recommended puller.
Part 1: Installing the Air Tank and Lines
Disconnect the battery terminals
Remove intake components and shroud
Remove the fan and lower shroud
12
DOCUMENT 19459
11. 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.
12. Remove the bracket holding the large,
red battery cable splitter box from the
alternator and power steering pump
bracket.
Keep the two 6 mm OEM cap screws
for use with compressor bracket.
13. Remove the OEM aluminum alternator
and power steering pump mounting
bracket. The OEM cap screws are not
used during the installation.
14. Remove the OEM back idler from the
bracket.
15. Remove the plastic cover from the
intake manifold.
16. Clean all dirt and debris from the OEM
crankshaft pulley.
17. Remove the OEM crankshaft pulley
center bolt.
18. Clean all dirt an debris from the driver’s
side of the engine in preparation for
mounting the VR7000 bracket.
Remove the cylinder block support bolt
Remove the OEM bracket
All OEM components removed
DOCUMENT 19459
13
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 se-
cured 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. In preparation for mounting, thoroughly
clean the frame under the cab on the
passenger side of the vehicle.
The upper line connections on the
tank will not be easily accessible
after the tank has been installed on
the frame. It is recommended that
you attach these two lines before
installing the tank on the frame.
2. Connect one end of the 5/16 x 102 inch
scavenge line to the tank at location 3
and tighten the fitting.
3. Connect one end of the 1/4 x 99 inch
pressure control line to the tank at
location 2 and tighten the fitting.
4. Attach the L-shaped tank brackets to
the C-clamps on the tank using the
supplied 5/16 x 1/2 inch cap screws
and 5/16 inch flat washers. Apply
Loctite to the cap screws.
5. 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.
6. 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.
NOTE
OIL LEVEL
(
check cold
)
MAX
ADD
THIS
WAY
UP
IM PORTANT
U
P
1
3
2
4
1/4” Pressure
Control Line 5/16” Oil
Scavenge
Line
3/4” Main
Discharge
Line
1/2” Oil Return Line
Backin
g
stra
p
Wire cable
5/16” nuts
L-bracket
C-clamp
mounting
cap screws
Tank bracket components
Line connections at the tank
Connections at the top of the tank
14
DOCUMENT 19459
7. Remove the cap screw and wire
harness retaining bracket (mid-point
between the cab mounts) from the top
of the frame, as it will interfere with the
rear tank mount. Remove the bracket
from the harness.
8. 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.
9. 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.
10. Route the 1/4 inch and 5/16 inch lines
between the body mount and the body,
up the passenger side of the firewall
(behind the heat shield on the firewall)
and along the back of the engine to the
driver’s side.
11. 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.
12. 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. 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.
Remove the OEM clamp
Cable clamps over the frame
Tank ready to install
DOCUMENT 19459
15
12. Slide the tank rearward on the frame to
provide clearance for attaching the
remaining lines.
13. Route the 3/4 x 77 inch main discharge
line along the back of the engine, behind
the heat shield and outside the body
mount to the tank.
14. Connect the 3/4 inch line to the top
fitting at the front of the tank at location
1. Tighten the fitting.
15. Route the 90 degree end of the 1/2 x
64.5 inch oil return line along the frame
rail and between the front body mount
and the body to the tank.
16. Connect the 90 degree fitting to the
tank. Position the line at approximately
the 1 o’clock position and tighten the
fitting
17. Move the tank forward on the frame
until there is 3.5 inches between the
fitting boss on the rear of the tank and
the front of the rear body mount.
18. 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.
Route all lines so that they are clear of
moving parts and secure all lines using
the stainless steel clips to keep them in
place. Do not allow lines to contact hot
engineor exhaust components. Place
short lengths of plastic covering over
the lines in locations where the hoses
might rub together or against vehicle
body parts, such as the heat shield.
Lines routed behind the heat shield
Oil return line connected to the tank
Main discharge line connected to the tank
NOTE
16
DOCUMENT 19459
1.3 Installing the oil cooler
1. The oil cooler is installed on the
passenger side of the vehicle, just
below the corner of the radiator.
2. On 4 x 4 models, remove the hex head
cap screw on the bottom of the frame
that holds the tow hook in place.
3. On 2 x 4 models, remove the nut and
washer from the supplied 12 x 30 mm
hex head cap screw and insert it
through the hole in the frame from the
inside of the frame.
3. Remove the two (2) hex head cap
screws from the bumper support
bracket.
4. Replace the inner hex head cap screw
on the bumper support with the
supplied 10 x 30 hex head cap screw
without a flat washer. Tighten the cap
screw.
5. Remove the clips holding the wire
harness to the radiator frame as it will
interfere with the cooler positioning.
Move the harness up and out of the
way.
6. Place the cooler in position on the
frame. On 2 x4 models, be careful not
to push the 12 x 30 mm hex head cap
screw back inside the frame.
7. Install the 10 x 40 mm hex head cap
screw with flat washer into the outer
mount hole where the bumper support
bracket is attached. Torque the cap
screw to specifications.
Cooler mounting location
Inserting the cap screw on a 2 x 4
Replacement cap screw on the bumper support
DOCUMENT 19459
17
8. On 4 x 4 models, apply Loctite and
install the 12 x 30 hex head cap screw
with spring washer through the bottom
cooler mount and thread it into the tow
hook. Torque the cap screw to
specifications.
9. On 2 x 4 models, place the spring
washer over the 12 x 30 mm hex head
cap screw and thread the nut into place.
Tighten the nut using an air or electric
impact tool, as you cannot place a
wrench over the head of the cap screw.
10. Route the OEM wire harness so that it
does not touch the cooler and fasten it
securely out of the way.
The cooler will become hot during
operation and if the wire harness
touches the cooler, it could be
damaged.
1.4 Installing the radiator hoses
1. Place two (2) supplied hose clamps on
the hose with the 90 and 45 degree
bends and install it between the lower
radiator hose fitting and the vertical
fitting on the oil cooler. Tighten the
hose clamps.
2. Install the OEM lower radiator hose on
the angled cooler fitting and install the
OEM spring clamp in position.
NOTE
Cooler mounted in position
Cooler mounted and viewed from above
Cooler to radiator hose installation
18
DOCUMENT 19459
1.5 Connecting the oil return lines
1. Route the 1/2 x 64.5 inch tank to
cooler oil return line along the frame to
the top fitting on the oil cooler. Tighten
the fitting.
2. Secure the line to the frame using
stainless clamps.
3. Route the 90 degree end of the 1/2 x
74 inch cooler to compressor oil return
line across the front of the vehicle
below the radiator, across the top of
the cooler and down to the lower fitting
on the cooler.
4. Connect the 90 degree end of the line
to the lower fitting on the oil cooler.
Tighten the fitting
5. Secure the line under the radiator using
stainless clamps or ties.
6. Route the other end of the line along the
drivers side of the engine compartment
to the engine, near the power steering
pump for connection to the compressor
once it is installed.
OEM hose installation
Installation of the oil lines at the cooler
Top view showing OEM wire harness location
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Vmac 9048 Installation guide

Category
Engine
Type
Installation guide

Vmac 9048 is a versatile underhood air compressor system designed to enhance the capabilities of your vehicle. With its powerful compressor and durable air tank, you can enjoy the convenience of having compressed air on demand for a wide range of tasks, including:

  • Inflating tires: Vmac 9048 makes it easy to maintain optimal tire pressure, ensuring a smoother ride, improved fuel efficiency, and extended tire life.

  • Powering air tools: Connect your air tools to the system's air outlet and enjoy the freedom to work on projects without the hassle of cords or hoses.

  • Cleaning: Utilize the compressed air to remove dirt, dust, and debris from hard-to-reach areas, making cleaning tasks a breeze.

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