Vmac V900112 Installation guide

System V900112

2014-2011 Ford SuperDuty F250-F350

6.2L Gas V8 Engine

www.vmacair.com

VR70 UNDERHOOD

AIR COMPRESSOR

INSTALLATION MANUAL

VMAC – Vehicle Mounted Air Compressors 
Toll Free: 1-888-241-2289 
Fax: 1-250-740-3201 
1 
   
Installation Manual for VMAC 
System V900112  
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 .................................................. 8 
Part 3:  Installing the Main Bracket, Compressor & Cooler ........ 15 
3.1 Installing the Main Bracket and Compressor ......................... 15 
3.2 Installing Drive Belts and Pulleys ........................................... 19 
3.3 Installing Other Components ................................................. 20 
3.4 Installing the Cooler ............................................................... 23 
Part 4:  Installing the Tank and Hoses .......................................... 28 
4.1 Installing the Tank and Mount Brackets ................................. 28 
4.2 Installing the Hoses ................................................................ 31 
4.3 Adding Oil to the System ....................................................... 33 
Part 5:  Installing the Control Components .................................. 34 
5.1 Installing the Components ..................................................... 35 
5.2 Connecting the In-cab Wiring ................................................. 35 
5.3 Connecting the Underhood Wiring ......................................... 36 
Part 6: Finishing the Installation .................................................... 37 
6.1 Reinstall OEM components. .................................................. 37 
6.2 Before Starting the Engine Checklist ..................................... 39 
6.3 Safety Test ............................................................................. 40 
6.4 After Starting the Engine Checklist ........................................ 41 
6.5 Setup, Performance Testing and Adjustments ...................... 42 
6.6 Auxiliary Air Receiver ............................................................. 43 
Accessory Products from VMAC ................................................... 44 
 
 
 

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Document #1930169

Installation Manual for VMAC System V900112

Ford 2014 - 2011 6.2L Gas V8 Superduty F250-F350

Changes and Revisions

Version

Revision Details

Revised by/date

Checked by/date

Reviewed by/date

Implemented

F

ECN 12-127, 12-148

SAR 10 Sep 2012

MH 15 Oct 2012

N/A

16 Oct 2012

G

ECN 12-157

SAR 29 Oct 2012

MH 13 Nov 2012

N/A

14 Nov 2012

H

ECN 13-013, 14-006

JR 19 Feb 2014

MH 13 Mar 2014

RD 20 Mar 2014

24 Mar 2014

J

ECN 15-084

RR 28 Jul 2015

CH 28 July 2015

GB 28 July 2015

28 July 2015

K

ECN 17-131

MSP 27Jul 2017

CM 03 Aug2017

AMG 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.

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.

!

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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.

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

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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.

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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-inch 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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Figure 1.1

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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

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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.

□ Remove the air filter box cover, filter, and intake tube from the

truck.

□ 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.

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□ Remove the vacuum pump and tank from the passenger side

of the fan shroud (if equipped).

□ Remove the upper radiator hose.

□ 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

□ 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).

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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 upper fan shroud

and remove the coolant overflow hose from the upper fan shroud.

□ 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.

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□ Swing the lower fan shroud section forward 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”

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.

□ Remove the accessory drive belt.

□ Remove the 4 pulley bolts, and the coolant pump pulley.

□ Remove the 4 pump bolts and the coolant pump.

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□ 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 O-ring on the supplied pump 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.

□ Install the coolant pump pulley and 4 bolts.

□ Install the accessory drive belt.

!

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□ 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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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)

This corner gets trimmed

This tab gets removed

Figure 3.1

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□ 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).

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

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□ Remove the two driver side front cover bolts (Figure 3.5).

□ Remove the bolt from the idler on the driver's side of the

engine. Leave the idler and OEM belt on the engine. The idler

is resting on a post and will not release belt tension. (Figure

3.5).

□ Remove wire hold down clip from wire loom on front cover.

Secure with supplied barbed tie strap in back of same hole

(Figure 3.5).

□ Fit the main bracket over the front of the engine making sure

that wires are not pinched.

□ Secure the bracket to the engine with the bolts supplied as

shown in Figure 3.6. Position bracket tight against engine and

install all 5 bolts. Do not tighten until all bolts have been

bottomed against the bracket and the bracket has been

checked to ensure it is positioned correctly and tight against

the engine. Then snug all bolts, gradually tightening at first,

then finally tighten the two M16 bolts, and then finish with

tightening the three M8 bolts.

If this procedure is not followed, the bracket and

fasteners may be excessively stressed and may lead to

failure.

5/8 WASHER

M16 X 35 BOLT

MAIN BRACKET

5/16 WASHER

M8 X 120 BOLT

BACK IDLER

10MM FENDER WASHER

M10 X 25 BOLT

6 RIB IDLER

TENSIONER PIVOT POST

TENSIONER

M8 X 100 BOLT

5/16 WASHER

Figure 3.6

M10 x 30 BOLT

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Vmac V900112 Installation guide

Vmac V900112 Installation guide

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