Vmac V910010 Installation guide

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VEHICLE MOUNTED AIR COMPRESSORS

VR150 UNDERHOOD

AIR COMPRESSOR

INSTALLATION MANUAL

System V910010

2016-2011 Ford F250-F550 6.7L Diesel

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1 
VR150 UNDERHOOD Air 
Compressor Installation Manual 
System V910010 
2016 - 2011 Ford F250 – F550, Cab & Chassis 
6.7L Diesel 
 
 
 
General Information .......................................................................... 5 
Before You Start ............................................................................ 5 
Part 1: System Identification, Warranty and Warnings ................. 6 
Part 2: Preparing for Installation ..................................................... 9 
Part 3:  Installing the Cooler, and Battery Cables .......................... 16 
3.1 Installing the Oil Cooler ........................................................... 16 
3.2 Routing Battery Cables ............................................................ 17 
3.3 Continuing Oil Cooler Installation ............................................ 19 
Part 4: Installing the Main Bracket and Compressor ..................... 21 
4.1 Installing Main Bracket ............................................................ 21 
4.2 Installing the Crank Pulley ....................................................... 28 
4.3 Installing the Compressor ........................................................ 30 
4.4 Installing the Compressor Belt ................................................. 32 
4.5 Continuing the Compressor Installation ................................... 32 
Part 5: Installing the Glow Plug bracket, Battery Box, and Washer 
Bottle .................................................................................................. 35 
5.1 Glow Plug Module Bracket ...................................................... 35 
5.2 Battery Cable and Relocated Battery Box ............................... 36 
5.3 Washer Bottle .......................................................................... 41 
Part 6: Air Filter Box ......................................................................... 44 
Part 7:  Installing the Tank and Hoses ............................................ 62 
7.1 Installing the Tank ................................................................... 62 
7.2 Installing the Hoses ................................................................. 65 
Part 8: Adding oil to the system ...................................................... 66 
Part 9: Installing the Control Components ..................................... 67 
9.1 Installing the Components ....................................................... 68 
9.2 Routing the In-cab Wiring ........................................................ 68 
9.3 Connecting the In-cab Wiring .................................................. 69 

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Part 10: Completing and Testing the Installation .......................... 71

10.1 Completing and Testing the Installation ................................ 71

10.2 Safety Test ............................................................................ 72

10.3 Before Starting the Engine Checklist ..................................... 72

10.4 After Starting the Engine Checklist ........................................ 73

Part 11: Setup, Performance Testing and Adjustments ................ 74

Part 12: Optional Accessory Installation ....................................... 75

Part 13: Auxiliary Air Receiver ........................................................ 76

Part 14: Modifying OEM cooling connectors ................................ 77

Part 15: Accessory Products from VMAC ...................................... 80

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Document #1930167

VR150 UNDERHOOD Installation Manual for VMAC System V910010

2016-2011 Ford F250-F550 6.7L Diesel

Changes and Revisions

Rev

Revision Details

Revised by/date

Checked by/date

Reviewed by/date

Implemented

H

ECN 14-018

JR 01 May 2014

MH 08 May 2014

RD 08 May 2014

12 May 2014

J

ECN 15-103

REF 03 Sept 2015

CJH 10 Sept 2015

RB 10 Sept 2015

10 Sept 2015

K

ECN 18-135 Washer bottle

MSP 12 Jun 2018

KM/GB 11 Jun 2018

AWG 12 Jun 2018

13 June 2018

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

plastic loom or equivalent hose protection.

These instructions are a general guide for installing this system on

standard production vehicles and do not contain information for

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installation on non-standard vehicles. This system may not fit special

order models or those that have had other changes without additional

modifications. If you have difficulty with the installation, contact VMAC.

The VMAC 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.

Complete the warranty form. The VMAC warranty form is located at the

back of this manual, as well as online at:

http://vmacair.com/support/warranty/

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 or online at

www.vmacair.com

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 vehicle.

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

Special Tools and Materials Required

• 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.

• 18mm, 12 pt. socket, ½” drive, (for crank bolts).

Hose Information

Depending on other installed equipment, it might be

necessary to move the air/oil separation tank from its

intended location. The hoses used in VMAC compressor

systems have a specific inner liner that is compatible with

our compressor oil. Use of hoses other than those

supplied or recommended by VMAC may cause

compressor damage and may void your warranty. Please

contact VMAC for replacement hoses and further

information.

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Part 1: System Identification,

Warranty and Warnings

Preparation for installation is very important. Missing a step or an item

can cause problems in the installation or damage to components.

Check off each item as it is completed so that you do not miss

any preparation steps.

□ Check through the illustrated parts list, ensure that no components

are missing, and that they are in the correct quantity. If any

components are missing, have the system ID ready and call VMAC

tech support at (888) 241-2289.

□ Complete the warranty form. The VMAC warranty form is located at

the back of this manual, as well as online at:

http://vmacair.com/support/warranty/

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 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 parts

and repairs.

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□ Mark and drill two 7/64-inch holes in an appropriate location, close

to the compressor. Secure the plate with supplied self- tapping

screws. (Figure 1.1)

Passenger Side

Headlight

System Identification

Number Plate

Passenger Side

Fender

Figure 1.1 – System Identification Plate

□ Install the VMAC belt routing diagram in a suitable location under

the hood.

□ Apply battery warning label to the driver’s side primary cooling

reservoir.

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□ 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 1.2)

Figure 1.2

□ 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 1.3)

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.

Ensure that you have filled out the VMAC Warranty

Registration. Install the System Identification Number

Plate and Operational Instruction Decal. (Please see Part

1 for details).

□ 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 zero ohms

in park and open circuit (or extremely high resistance) 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 chosen.

□ Mark transmission park signal wire for connection later in installing

control components section.

□ Remove the front bumper. The install can be completed with the

bumper installed but it will make the install easier to remove it.

□ Remove passenger side inner fender. This will make the installation

easier.

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□ Drain the coolant from the secondary cooling system. The drain is

located on the passenger side of the secondary radiator. Save the

coolant to be reused later. Close drain when coolant has been

drained.

□ Drain the coolant from the primary cooling system. The drain is

located on the driver's side of the primary radiator. Save the coolant

to be reused later. Close drain when coolant has been drained.

□ Disconnect batteries, (both driver and passenger side).

□ Remove passenger side battery.

□ Disconnect the mass air flow sensor connector from the top of the

filter box.

□ Remove filter box, (both upper and lower sections).

□ Remove intake tube and resonator that connects the filter box to the

turbo intake.

□ Cover turbo intake.

□ Remove passenger side hood strut and hood strut ball stud from

hood, (save for later use).

□ Remove lower hood strut ball stud from inner fender.

□ Remove positive terminal block and wiring connector panel from

passenger side battery box. To remove wiring panel pry up.

Positive terminal block has one clip and slides up to remove.

□ Disconnect windshield washer tube from joint above passenger side

battery box on top of firewall.

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□ Unplug wiring harness from windshield washer pump and remove

wiring from front lower passenger side battery box.

□ Unplug glow plug module connectors from bottom of passenger side

battery box, (3 connectors).

□ Remove the bolt from wheel well that secures inner fender to battery

box, (save for later use).

□ Remove passenger side battery box.

□ Drain washer fluid and save for reuse later.

□ Remove glow plug module from bottom of passenger side battery

box, (Torx T30 bolts), (Save module for later use).

□ Disconnect hoses from secondary coolant reservoir (attached to

passenger side of fan shroud) and remove reservoir from fan

shroud.

□ Remove upper secondary coolant hose (top hose going to water

pump on passenger side of engine).

Modifying the plastic cuff is explained in detail in the part

14 of this manual, note that the elbow shown in the

example is different than the one you will be modifying,

but the method is the same.

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□ Cut plastic cuff securing hose on secondary rad hose carefully to

preserve fitting, (discard band and hose). (Figure 2.1)

Cut Plastic Cuff To

Remove Connector

Upper Secondary

Radiator Hose

Figure 2.1

□ Install supplied hose back on connector and secure with supplied

hose clamp. (Figure 2.2)

Supplied Hose

OEM Quick

Connect

Supplied Hose

Clamp

Figure 2.2

□ Install hose coupling and flexible hose to open end of modified

secondary coolant hose. Leave about 1” gap between hoses and

secure with supplied hose clamps.

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□ Remove plastic wire guide from front of EGR on passenger side of

engine, (two bolts securing to EGR and plastic ties securing to wire).

Discard bolts and plastic. (Figure 2.3)

Figure 2.3

□ After removing plastic wire guide, install plastic protective shell over

metallic heat tape on wiring harness routed alongside and front of

engine. Secure in place using tie wraps. (Figure 2.4)

Figure 2.4

Protective shell

Metallic heat tape

Remove bolts

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□ Using knife cut insulated heat shield if required to clear hose.

Install modified hose back on secondary water pump. Ensure

notches on OEM quick connector align with notches on secondary

water pump. Point elbow towards rear of truck (opposite to the

original direction). Ensure hose is not kinked, (rotate the hose on

the OEM quick connect, if required this will remove kinks). Hose

must run underneath the injector wiring harness.

□ Ensure OEM locking clip is engaged on plastic elbow. Loop hose

towards front of truck.

□ Remove bolt securing power steering reservoir to upper fan shroud.

DO NOT remove hose from reservoir. Slide reservoir up out of the

clip securing it to the upper fan shroud.

□ Remove top radiator hose.

□ Remove 5 bolts, (3 on drivers side and 2 on passenger side), and

wire clips securing upper fan shroud and remove upper fan shroud

from truck.

□ Unplug fan wire, (unplug connector closer to the engine, not the one

right on the hub of the fan). Remove long bolt securing fan wiring

harness to engine and discard.

□ Remove the fan, (right-hand thread), and pull it out of the engine

bay.

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.

□ Remove fan stator, (the lower shroud can be left in place if the stator

is rotated to clear the lower lip).

□ Remove upper passenger side fan stator mount and save for use

later.

□ Release tension on OEM belt, (leave belt routed correctly on

passenger side of engine and remove belt from driver’s side idler

pulley).

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□ Remove 2 bolts from secondary water pump. (Figure 2.5)

Remove OEM Bolts From

Secondary Water Pump

Figure 2.5

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Part 3: Installing the Cooler, and

Battery Cables

3.1 Installing the Oil Cooler

□ Remove lower primary coolant hose and the small hoses at each

end, (attached to the primary cooler and engine). (Figure 3.1)

To

Engine

From

Radiator

Figure 3.1

□ Cut the engine side coolant hose 9” from the OEM quick connect,

(discard short section with OEM quick connect). (Figure 3.2)

9”

Discard This

Section

Figure 3.2

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□ Cut the radiator side coolant hose 8” from the OEM quick connect

(discard short section of hose with OEM quick connect). (Figure 3.3)

OEM Quick

Connect

Discard This

Section

8”

Figure 3.3

3.2 Routing Battery Cables

□ Apply loom to supplied battery cable extensions.

The red and the black battery cables will follow the same

route!

□ Route the supplied positive/red battery cable between the frame and

body from the re-located battery location that will be under the driver

side. Leave 20” of cable to the rear of the body mount hanging

under driver side door.

□ Continue routing the cable above the truck electrical harness and

below the two metal power steering lines.

□ Continue routing, careful to avoid the steering column, around front

of the steering box until the cable reaches the electrical harness

under/beside the fan shroud.

□ Feed cable along fan shroud following other truck wiring harness.

□ Continue following truck wiring harness under the air intake and

metal bracket. Route along the inner fender plastic wire guide tray

under fender and follow OEM positive cable wire harness to

relocated battery positive terminal.

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□ Route the negative battery cable from the relocated battery location

and follow the positive battery cable. Continue routing until under

the fan shroud and in such a way it will remain clear of the crank

pulley and any other sharp or moving objects.

□ Remove the OEM negative battery block bolt attaching the OEM

negative battery cable located beside the engine side coolant OEM

quick connect. (Figure 3.4)

For ease of removal the OEM negative battery block bolt

should be removed with the engine side coolant hose

disconnected. Figure 3.4 shown with coolant hose

connected to illustrate the OEM negative battery bolt

location.

OEM Negative

Battery Engine

Block Bolt

Engine Side

Coolant Hose

Front of

Engine

Figure 3.4

□ Install the supplied negative battery cable lug on top of the existing

OEM negative battery cable lug. Orientate the cable so that it travels

down and under the existing vehicle battery tray facing the front of

the vehicle towards the fan shroud. Reuse the existing OEM

negative battery bolt.

□ Secure battery cables with tie-straps as required as to clear the

crank pulley and other moving parts.

If the routing for the battery cables is unclear, read

through Part 5 of this manual.

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Vmac V910010 Installation guide

Vmac V910010 Installation guide

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