System V910012
2014-2011 Ford SuperDuty F250-F350
6.2L Gas V8 Engine
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
1
Installation Manual for VMAC
System V910012
2014-2011 Ford SuperDuty F250-F350
6.2L Gas V8 Engine
General Information ........................................................................ 4
Before You Start ........................................................................... 4
Additional Requirements .............................................................. 4
Part 1: Warranty and System ID ..................................................... 5
Part 2: Preparing for Installation................................................... 9
Part 3: Installing the Main Bracket, Compressor & Cooler ........ 16
3.1 Installing the Main Bracket and Compressor ......................... 16
3.2 Installing Drive Belts and Pulleys ........................................... 20
3.3 Installing Other Components.................................................. 22
3.4 Installing the Cooler ............................................................... 25
Part 4: Installing the Tank and Hoses .......................................... 30
4.1 Installing the Tank and Mount Brackets ................................. 30
4.2 Installing the Hoses ................................................................ 34
4.3 Adding Oil to the System ........................................................ 36
Part 5: Installing the Control Components .................................. 37
5.1 Installing the Components ...................................................... 38
5.2 Connecting the In-cab Wiring ................................................. 38
5.3 Connecting the Underhood Wiring ......................................... 39
Part 6: Finishing the Installation .................................................... 40
6.1 Reinstall OEM components.................................................... 40
6.2 Before Starting the Engine Checklist ..................................... 42
6.3 Safety Test ............................................................................. 42
6.4 After Starting the Engine Checklist ........................................ 43
6.5 Setup, Performance Testing and Adjustments ...................... 44
6.6 Auxiliary Air Receiver ............................................................. 45
Accessory Products from VMAC ................................................... 46
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Document #1930171
Installation Manual for VMAC System V910012
2014-2011 Ford 6.2L Gas V8 Superduty F250-F350
Changes and Revisions
Version
Revision Details
Revised by/date
Checked by/date
Reviewed by/date
Implemented
C
ECN 12-116
SAR 24 Jul 2012
MH 27 Jul 2012
N/A
31 Jul 2012
D
ECN 12-139
SAR 01 Oct 12
MH 15 Oct 2012
N/A
22 Oct 2012
E
ECN 13-013
SH 21 Aug 2013
SM 26 Aug 2013
N/A
26 Aug 2013
F
ECN 14-006
JR 19 Feb 2014
MH 13 Mar 2014
RD 20 Mar 2014
31 Mar 2014
G
ECN 15-084
RR 28 Jul 2015
CH 28 July 2015
GB 28 July 2015
28 July 2015
H
ECN 17-131
MSP 27 Jul 2017
CM 10 Aug 2017
GB 09 Aug 2017
10 Aug 2017
Important Information
This symbol is used to call your attention to instructions
concerning your personal safety. Watch for this symbol; it
points out important safety precautions, it means “attention,
become alert! Your personal safety is involved. Read the
message that follows and be alert to the possibility of personal
injury or death. Be alert; your safety is involved. While it is
impossible to warn about every conceivable hazard, let good
common sense be your guide.
This symbol is used to call your attention to additional
instructions or special emphasis on a specific procedure.
The information in this manual is intended for certified VMAC
installers who have been trained in installation procedures and for
people with mechanical trade certification who have the tools and
equipment to properly and safely perform the installation. Do not
attempt this installation if you do not have the appropriate
mechanical training, knowledge and experience.
Follow all safety precautions for underhood mechanical work. Any
grinding, bending or restructuring operations for correct fit in
modified trucks must follow standard shop practices.
All hoses, tubes, and wires that are rerouted or shifted
during installation must be secure so that they do not
contact excessively hot areas or sharp edges. Where
possible, use rubber coated P-clips. Follow the routing
suggestions in this manual and cover all hoses with
the supplied plastic loom.
!
VMAC – Vehicle Mounted Air Compressors
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Fax: 1-250-740-3201
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These instructions are a general guide for installing this system on
standard production trucks and do not contain information for
installation on non-standard trucks. This system may not fit special
order models or those which have had other changes without
additional modifications. If you have difficulty with the installation,
contact VMAC.
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.
To order parts, contact your VMAC dealer. Your dealer will ask for
the VMAC serial number, part number, description and quantity. To
locate your nearest dealer, call 1-888-241-2289.
Copyright 2017
All trademarks used in this manual are the property of the respective
copyright holder. The contents of this manual may not be reproduced in
any form without the express written permission of
VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3
Printed in Canada
VMAC – Vehicle Mounted Air Compressors
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4
General Information
Before You Start
Read this manual before attempting installation so that you can
familiarize yourself with the components and how they fit on the
truck. Identify variations for different model years and different
situations that are listed in the manual. Open the package, unpack
the components and identify them.
All fasteners must be torqued to specifications. Use manufacturers
torque values for OEM fasteners. Apply Loctite 242 or equivalent
on all engine-mounted fasteners. Torque values are with Loctite
applied unless otherwise specified.
STANDARD GRADE 8 NATIONAL COARSE THREAD
Size
1/4
5/16
3/8
7/16
1/2
9/16
5/8
¾
Foot-pounds (ft-lb)
9
18
35
55
80
110
170
280
Newton meter
(N•m)
12
24
47
74
108
149
230
379
STANDARD GRADE 8 NATIONAL FINE THREAD
Size
3/8
7/16
1/2
5/8
¾
Foot-pounds (ft-lb)
40
60
90
180
320
Newton meter (N•m)
54
81
122
244
434
METRIC CLASS 10.9
Size
M8
M10
M12
M14
M16
Foot-pounds (ft-lb)
19
41
69
104
174
Newton meter (N•m)
25
55
93
141
236
Additional Requirements
Special Tools
Pneumatic fan wrench removal set (such as Lisle 43300) or a
manual fan pulley holder (such as KD3900)
OEM flywheel locking tool part number J42386.
Hose Information
Different frame designations will affect the tank mounting position.
If you have to move the tank, the lines may be too short. Measure
the hose shortfall and order a Hose Extender Kit.
VMAC – Vehicle Mounted Air Compressors
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Part 1: Warranty and System ID
□ Complete the warranty form. 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.
System Identification and Operating Instructions
The System Identification Number Plate must be attached to the
vehicle at the time of installation. This plate provides information
that allows VMAC to assist in customer inquiries and the ordering
of parts.
□ Mark and drill two 7/64” holes in the top of the cross member
between the driver's side headlight and the air filter box then
secure the plate with self-tapping screws.
□ Affix the VMAC belt routing diagram to an appropriate place
near the OEM belt diagram.
□ As part of the installation process, ensure that the safety and
operational instruction decal is affixed in an obvious location
so that it can be seen by vehicle operators. A good spot for
this is usually on the inside of the door or on the panel
underneath the steering wheel. (Figure 1.1).
VMAC – Vehicle Mounted Air Compressors
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Fax: 1-250-740-3201
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Figure 1.1
VMAC – Vehicle Mounted Air Compressors
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□ To alert any technicians that may service the vehicle, affix the
servicing caution/contact label in the engine compartment near
the hood latch in a visible location. Thoroughly clean the
selected area before affixing the label (figure 1.2)
Figure 1.2
□ As part of the installation process, ensure that the caution
decal regarding the heavy duty water pump is affixed in an
obvious location so that it can be seen by maintenance
personnel. (figure 1.3)
Figure 1.3
VMAC – Vehicle Mounted Air Compressors
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To order parts, contact your VMAC dealer. Your dealer will ask for
the VMAC serial number, part number, description and quantity. To
locate your nearest dealer, call 1-888-241-2289.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
9
Part 2: Preparing for Installation
Preparation for installation is very important. Missing an item can
cause problems in the installation or even damage to components.
Check off each item as it is completed so that you do not miss any
preparation steps.
□ Locate the blunt-cut OEM SEIC wire harness, on the driver’s
side just below the OBDII port. You will need to find the
transmission park signal (blue with grey stripe wire).
□ Use a multi-meter to verify the transmission park signal. Turn
the key to the IGN2 position (do not start the truck), as to
supply power to the dash display. The resistance should read
close to 0-ohms in park and open circuit in all other gears. If
this is correct, put the car in park and turn the key to the off
position.
There are multiple blue wires with various coloured
stripes. The transmission park signal needs to be
electrically verified with a multi-meter to ensure the
correct wire is read.
□ Mark transmission park signal wire for connection later in
installing control components section
□ Disconnect the battery.
□ Drain the coolant, and save for re-use later.
□ Remove the air filter box cover, filter, and intake tube from the
truck.
□ Remove the upper radiator hose.
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□ Remove the power steering reservoir from the driver's side of
the fan shroud keeping all the lines connected. Temporarily tie
the reservoir up and out of the way of the shroud. Note: The
cap will leak if the reservoir is not kept upright.
□ Remove the vacuum pump and tank from the passenger side
of the fan shroud (if equipped).
□ Remove the air filter box and coolant degas bottle assembly
from the truck. Cut the assembly into three pieces as shown in
Figure 2.1.
Air Box Mount
Air Box
Degas
Bottle
Figure 2.1
□ Cut away the webbing on the top of the air box (Figure 2.2).
Remove all webbing on
top of Air Box
Figure 2.2
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□ Cut away all of the webbing on the bottom of the air box mount. Do
not remove the webbing on top of the air box mount (Figure 2.3).
Remove all webbing on
bottom of Air Box mount
Leave webbing on top of
Air Box mount
Figure 2.3
□ Measure 2-1/4” back from the front edge of the air intake horn and
cut ¾” and discard the cut section (Figure 2.4)
2-1/4”
3/4”
Air Intake
Horn
Figure 2.4
□ Reattach the two cut air horn pieces. Overlap the two pieces by ½”
and drill pilot holes. Using the supplied self-tapping screws re-
assemble the air intake horn (Figure 2.5).
Re-assembled Air
Intake Horn
Self-Tapping
Screws
Figure 2.5
□ Remove the upper and lower bolts locating the fan shroud and
remove the coolant overflow hose from the upper section of the fan
shroud.
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□ Unbolt and disconnect the fan wire harness from the fan shroud.
□ Unclip the large wire bundle and radiator hose from the bottom of
the fan shroud.
□ Swing the lower fan shroud section forward by pushing the tabs
along the bottom up, from underneath and lock it in place.
□ Remove the fan (right-hand thread) and pull it out of the engine
bay with the shroud.
For ease of fan removal and installation, it is
recommended that a pneumatic fan wrench removal set
(such as Lisle 43300) or a manual fan pulley holder (such
as KD3900) is used.
□ Modify the fan shroud by cutting away the hatched area shown.
(Figure 2.6)
1 3/8”
1 3/8”
1 3/8”
Fan Wiring Connector
Bracket OEM Mount
Location
Front
7/8”
1/4"
Figure 2.6
□ Loosen the 4 coolant pump pulley bolts, Refer to Figure 2.7.
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□ Remove the accessory drive belt.
□ Remove the 4 pulley bolts, and the coolant pump pulley.
□ Remove the 4 pump bolts and the coolant pump.
□ Inspect and clean sealing surfaces.
Before installing the supplied coolant pump, align the
bolt holes prior to inserting the coolant pump and
insert the coolant pump straight into the coolant pump
cavity. Do not rotate the coolant pump once installed
in the coolant pump cavity or damage to the O-ring
may result, causing the pump to leak coolant.
Figure 2.7
□ Lubricate the new water pump O-ring with clean engine coolant.
□ Install the supplied coolant pump reuse OEM bolts. Tighten the 4
bolts in a criss-cross pattern in 3 stages:
o Stage 1: finger-tighten the bolts.
o Stage 2: Tighten to 20 Nm (15 ft-lb.)
o Stage 3: Tighten an additional 45 degrees.
!
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□ Install the coolant pump pulley and 4 bolts.
□ Install the accessory drive belt.
□ Tighten the 4 bolts for the coolant pump pulley to 25 Nm (18 ft-lb.).
□ Remove the bolt and two nuts securing the ABS hydraulic control
unit (HCU) module to the driver's side suspension tower and install
the two supplied relocation brackets as shown in (Figure 2.8).
M8 Nut
ABS HCU Module
ABS HCU Bracket
Driver Side Suspension
Tower
ABS HCU Bracket
OEM Nuts
M8 Nuts
5/16 Washers
M8 x 16 Bolts
OEM Bolt
5/16 Washer
Rotate The Flexible Brake
Lines To Avoid Kinking
Figure 2.8
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□ It may be necessary to rotate the brake lines that connect the
master cylinder to the ABS HCU module to avoid kinking the
flexible rubber hoses. To do this, have a helper press gently on
the brake pedal as you reposition the brake lines. This will help
avoid air entering the brake system due to brake fluid being forced
out rather than air let in. Do not pump the brakes at any time while
the brake lines are loose or air may be drawn into the system.
If you are at all concerned that air has entered the
brake system consult your local Ford dealer or repair
shop for truck specific HCU brake bleeding
instructions.
Loosen the brake lines one at a time just enough to rotate them
into a relaxed and kink-free position, then quickly tighten them
while constant pedal pressure is being applied. If a significant
amount of fluid escapes from the fittings, the pedal is being
pressed too hard and/or the fitting has been loosened too much.
Do not allow the brake master cylinder to run dry
during these steps as the master cylinder may be
damaged if operated without fluid.
Be sure to wipe up any fluid as soon as possible as it can damage
painted and plastic surfaces. After wiping up any fluid, rinse the
area with water. Ensure that the fluid reservoir is topped when
finished.
Do not use any fluid other than clean brake fluid from
an unopened container that meets Ford specifications.
If you do not follow these instructions you risk system
contamination, brake component damage and serious
personal injury.
!
!
!
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VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
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Part 3: Installing the Main
Bracket, Compressor & Cooler
3.1 Installing the Main Bracket and Compressor
□ Determine which valve covers your vehicle has been
manufactured with (Figure 3.1). If your vehicle was
manufactured before 05-Dec-2011 no modifications are
required.
As of 05-Dec-2011 Ford has issued a running change to
the valve covers installed on 6.2L V8 gas engines. Valve
covers on vehicles manufactured before 05-Dec-2011 can
be identified by the wire harness/spark plug wire stud
mounts and are made of aluminum. Valve covers on
vehicles manufactured after 05-Dec-2011 are composite
and black in color. (Figure 3.1)
The main bracket supplied has been designed and
machined to fit valve covers on vehicles manufacture
before and after 05-Dec-2011. However valve covers on
vehicles manufactured after 05-Dec-2011 require
modifications for proper fitment.
Valve Covers Manufactured
Before 05-Dec-2011
(Aluminum)
Valve Covers Manufactured
After 05-Dec-2011
(Composite)
Figure 3.1
□ On Vehicles manufactured after 05-Dec-2011 with composite
valve covers remove the webbed area shown using a die
grinder or pneumatic cut off wheel (Figure 3.2).
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Remove Shaded Area Shaded Area Removed
Figure 3.2
When modifying the valve cover it is important to only remove
the webs indicated and not cut past the face shown in Figure
3.3. Cutting into the main valve cover body may risk cutting the
O-ring sealing the valve cover to the cylinder head.
Before Webs Removed After Webs Removed
Do Not Cut Past
This Face
Figure 3.3
□ On Vehicles manufactured after 05-Dec-2011 with composite
valve covers remove the wire harness mounting tab shown
using a die grinder or pneumatic cut off wheel (Figure 3.4).
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Remove Wire Harness
Mounting Tab Mounting Tab Removed
Figure 3.4
When fitting the main bracket it is important the bracket
sits flush on all mounting surfaces. Ensure the bracket is
not touching the valve cover when installed. If necessary
trim the valve cover as required until proper fitment is
obtained.
Wire Hold
Down Clip
Figure 3.5
□ Remove the two driver side front cover bolts (Figure 3.5).
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