Installation Manual
For The
System #V900053
UNDERHOOD AIR COMPRESSOR
1995.5-1997 FORD F250-F350
7.3 Power Stroke Diesel
TEL: 250-740-3200
FAX: 250-740-3201
TOLL FREE: 800-738-8622
1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3
DOCUMENT 1900682
Installation Manual
VR70 Underhood Air Compressor
System Number V900053
Application: 1995.5-1997 Ford F250-F350 with the 7.3 Power Stroke Diesel
Publication Date: Revised by S. Large, August / 2001
Publication Number: 1900682
Origination Documents: #1900682a - General Information
#1900682b - Installing the air tank and lines
#1900682c - bracket, compressor and cooler installation
#1900682d -Control component installation
#1900682e - Illustrated parts list
#1900130 - Warranty registration
Registered Trademarks:
VR70, VMAC and Throttle Commander are registered trademarks of VMAC.
Ford, Super Duty, F250-F350, Power Stroke Diesel are registered trademarks of Ford Motor
Company
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 INSTALLING THE BRACKETS AND TANK ............................................................................... 11
1.2 INSTALLING THE TANK ..................................................................................................... 12
1.3 CONNECTING AND ROUTING THE LINES ............................................................................. 12
2.1 PREPARING FOR INSTALLATION .......................................................................................... 17
2.2 INSTALLING THE COMPONENTS ......................................................................................... 19
2.3 INSTALLING THE OIL COOLER .............................................................................................21
2.4 CONNECTING THE LINES .................................................................................................. 22
2.5 FILLING THE SYSTEM WITH OIL ....................................................................................... 23
PART 3: INSTALLING THE CONTROL UNIT ............................................................... 25
3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 27
3.2 INSTALLING THE SWITCHING BOX ....................................................................................... 27
3.3 INSTALLING THE THROTTLE CONTROLLER ......................................................................... 28
3.4 CONNECTING THE PARK BRAKE WIRE .............................................................................. 30
ILLUSTRATED PARTS LIST.............................................................................................. 33
WARRANTY REGISTRATION.......................................................................................... 39
1
PART 2: INSTALLING THE COMPRESSOR, OIL COOLER AND OIL FILTER.......15
2.6 COMPLETING THE INSTALLATION ...................................................................................... 23
2
General Information
System #V900053
1995.5-1997 FORD F250-F350
7.3 POWER STROKE DIESEL
UNDERHOOD AIR COMPRESSOR
3
DOCUMENT 1900682
4
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.
General Information
Introduction
This book provides installation instructions for:
VMAC underhood air compressor installation kit
VMAC Throttle Controller
This kit has been designed for:
1995.5-1997 Ford F250-F350 equipped with a 7.3 Power Stroke Diesel
Installation steps
The installation procedure in this manual has four main steps:
Part 1: Installing the Compressor
Part 2: Installing the Oil Cooler, Air Tank and Lines
Part 3: Installing the Control Unit
Part 4: Installing the Throttle Control
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)
NOTE
WARNING
!
5
Installation Notes
1. It is important that you complete all the installation steps before operating the system.
2. Follow all safety precautions for under-hood 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).
WARNING
BEFORE OPERATING THE VR70 UNDERHOOD AIR COMPRESSOR
SYSTEM ALWAYS MAKE SURE THAT THE
VEHICLE IS IN PARK (AUTOMATIC TRANSMISSION) OR
NEUTRAL (MANUAL TRANSMISSION) AND THAT THE PARK
BRAKE IS FIRMLY ENGAGED.
6
STANDARD GRADE 8 NATIONAL COARSE THREAD
Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4
Foot-pounds 9 18 35 55 80 110 170 280
STANDARD GRADE 8 NATIONAL FINE THREAD
Size 3/8 7/16 1/2 5/8 3/4
Foot-pounds 40 60 90 180 320
METRIC CLASS 10.9
Size M8 M10 M12 M14 M16
Foot-pounds 19 41 69 104 174
The above fastener torque values are applicable when Loctite is used .
If the threads are dry add 20% to the torque values.
WARNING
!
Ordering parts
To order parts, contact your nearest VMAC dealer.
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 enclosed System Identification Number Plate (S/N) must be attached to the vehicle at the time
of installation. This S/N plate provides information, which allows VMAC to assist in customer
inquiries and/or ordering of parts. It is important that this S/N plate is affixed to the vehicle.
Locate the S/N plate on the front body support on the driver’s side of the vehicle near the hood
stop (Figure 1) . Drill the two hole locations using a 7/64” drill bit. Place the S/N plate in position
and fix in place with the two #6 pan head self tapping screws provided.
Figure 1 Location of System Identification Number Plate
Changes and improvements
These products and documents are subject to changes or improvements without notice.
7
8
Special installation notes
If you intend to use an auxiliary air receiver with this system you must observe the following
installation procedure (Figure 2) . Failure to observe this procedure will result in damage to the
system.
1. The line from the VR70 tank to the auxiliary air receiver must have a one-way check valve
installed to prevent blowback from the auxiliary tank and to prevent moisture from entering
the VR70 tank.
2. The line to the auxiliary tank must not be installed in the bottom of the tank, but must be
installed as high as possible to prevent water from clogging the line.
VR70 Tank
Auxiliary Receiver
One-way check valve
Install the line as high as
possible, NOT on the
bottom of the tank
Figure 2
Part 1
Installing the
Air Tank and Lines
System #V900053
1995.5-1997 FORD F250-F350
7.3 POWER STROKE DIESEL
UNDERHOOD AIR COMPRESSOR
9
DOCUMENT 1900682
10
1.1 Installing the brackets
1. Enlarge the four tank mounting holes on
the frame using a 13/32 drill bit.
2. Place the forward tank bracket (the one
with the wide two-hole spacing) on the
outside of the passenger frame rail
under the cab, just in front of the
transmission cross-member.
3. Install flat washers on two (2) 3/8 NC x
1-1/4 inch hex head cap screws and
insert them through the bracket and the
two existing holes in the frame.
4. Place flat washers on each of the cap
screws on the inside of the frame and
thread 3/8 inch NC Nylok nuts on the
cap screws.
5. Place the rear tank bracket (the one
with the narrow three-hole spacing) on
the outside of the passenger frame rail
under the cab, in the middle of the
upward bend area behind the cross-
member.
6. Install flat washers on two (2) 3/8 NC x
1-1/4 inch hex head cap screws and
insert them through the lower holes on
the bracket and the two drilled holes in
the frame.
7. Place flat washers on each of the cap
screws on the inside of the frame and
thread 3/8 inch NC Nylok nuts on the
cap screws.
8. Torque the fasteners to specifications.
9. Cut the plastic tie-wraps from the tank
mount brackets and remove the two
retaining straps.
11
Part 1: Installing the Air Tank and Lines
Forward tank mounting location
Rear tank mounting location
Brackets mounted in position
12
1.2 Installing the tank
1. Insert the four (4) 5/16 NC x 1-1/4 hex
head cap screws through the holes in
the tank brackets.
2. Place the tank in position in the tank
brackets on the frame. Use suitable
supports to hold tank temporarily in
place.
3. Place the forward and rear tank
overstraps on the tank and over the
5/16 inch hex head cap screws on the
front and rear brackets.
4. Install 5/16 inch washers and 5/16
inch NC hex nuts on the cap screws.
5. Align the tank so that the direction
arrow on the rear of the tank points
upward.
Tank alignment is extremely
important. Improper installation
can result in personal injury,
death or damage to the
equipment. Ensure the tank sits
horizontally
6. Move the tank as necessary so that the
distance between the front of the tank
and the center of the front cab mount is
approximately 11-1/2 inches. This may
vary on different cab configurations.
7. Torque the overstrap fasteners to
specifications.
1.3 Connecting and routing the lines
1. Feed the flexihose section of the 1/4
inch pressure control line inside the
front and rear tank brackets on the
frame rail side of the tank. Route hose
WARNING
!
Line attaching points and tank alignment
Tank installed in position
1/4 and 5/16 lines over mount
13
up and over the cab mount. Thread the
fitting on the steel tube attached to the
end of the 1/4 inch pressure control
line into the upper threaded fitting,in the
rear of the tank.
2. Routethe flexihose section of the 5/16
inch scavenge hose alongside the 1/4
inch pressure control line and up and
over the cab mount. Thread the fitting
on the steel tube attached to the 5/16
inch hose into the lower threaded fitting
in the rear of the tank.
3. Fit the two (2) supplied tube clamps
over the 1/4 inch and 5/16 inch steel
tubes and bolt into the threaded holes in
the front and rear tank brackets using
the two (2) supplied 5/16x 1/2 inch
Hex Head Cap Screw bolts and two
(2) 5/16 flat washers.
4. Connect the straight end of the 1/2 x 76
inch tank to cooler oil return line to the
matching lower fitting on the front of
the tank. Hand-tighten the fitting. Route
the hose over the cab mount and up
along the chassis rail towards the front
of the engine
5. Route the 45 Degree end of the 3/4
inch main air discharge hose up
towards the front of the engine up over
the cab mount. Connect the straight end
to the fitting on the front of the tank.
6. Tie wrap all hoses to the frame and
protect any areas of the lines which may
be exposed to sharp or hot objects with
plastic loom.
Cooler and discharge line connections
1/2 and 3/4 lines installed over mount
Protective loom on lines
7. Remove the oil filter from the front of the
tank and apply a small amount of oil to
the rubber gasket and refit oil filter.
Tighten by hand
14
Part 2
Installing the
Compressor and Cooler
System #V900053
1995.5-1997 FORD F250-F350
7.3 POWER STROKE DIESEL
UNDERHOOD AIR COMPRESSOR
15
DOCUMENT 1900682
16
2.1 Preparing for installation
1. Disconnect the batteries.
2. Drain the coolant from the radiator.
3. Remove the fan from the water pump.
4. Disconnect the top radiator hose from
the radiator.
5. Disconnect the expansion tube and
remove the lower radiator hose.
6. Remove the fasteners from the fan
shroud, then remove the fan and shroud
from the vehicle.
7. Remove the OEM belt.
8. Remove the OEM fasteners securing
the alternator and move it out of the
way.
9. Remove the OEM tensioners and idlers
from the alternator bracket.
10. Remove the OEM alternator bracket.
11. Remove the plastic cover from the air
inlet on top of the engine.
12. Remove the heater hose and the fitting
from the inside of the right cylinder.
17
Part 2: Installing the Compressor and Cooler
Engine prior to installation
OEM mounting bracket before removal
Mounting location on the cylinder head
18
13. Remove and discard the plastic battery
cable holder from the radiator bulk-
head.
14. Remove the radiator from the vehicle.
15. Remove the hose from the bottom of
the pressure tank, cut 1 inch from the
hose and install it back on the fitting.
16. Remove the small top hose from the
pressure tank, cut 3/4 inch from the
spigot and install the hose back on the
fitting.
17. Cut 6 inches from the hose that runs
from the block to the heater.
18. Remove the speed clips from the
radiator bulkhead flange.
19. Remove the radiator supports.
20. Peen the edge of the valve cover flat
against the cylinder head in the area
where the compressor mounting
bracket will attach. This allows the
compressor mounting bracket to sit
flush with the cylinder head surface.
This is important for belt alignment
21. Remove the OEM fasteners holding the
OEM crankshaft pulley in place.
22. Clean the inside of the crankshaft pulley
where the VR70 pulley will fit.
Cut 3/4” from the end
of the spigot
Cut 1” from the end of
this hose
Coolant
expansion
bottle
Peen this area
Mounting locations
Cut the spigot and the hose
Peen the valve cover flat
Clean the inside of the pulley
NOTE
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