Vmac 9048 Installation guide

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.

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

driver’s 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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