Vmac A700226 Installation guide

VMAC – Vehicle Mounted Air Compressors

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1

A700226 Retrofit Instructions

Intake Tube on Ford 6.7L VR150

Existing Kits

Instructions for VMAC Accessory A700226

V910010 Intake Tube Retrofit

V8 6.7L Diesel

Document: 1901035

Changes and Revisions

Version

Revision Details

Revised by /date

Checked by /date

Reviewed by /date

Implemented

A

Initial Release

MSP 8 Jan. 2016

DSB 13 Jan. 2016

CJH 13 Jan. 2016

13 Jan. 2016

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 mechanical work. Any grinding,

bending or restructuring operations for correct fit in modified trucks must

follow standard shop practices.

Notice

Manuals are subject to change without notice.

Registered Trademarks

All trademarks mentioned in this manual are the property of their

respective owners. Their use by VMAC is for identification of the

manufacturers’ products only and does not imply any affiliation or

endorsement by said companies.

Loctite, Klean N’ Prime, 242 and PST are registered trademarks of

Henkel AG & Company KGaA.

Nylok is a registered trademark of Nylok Fastener Corporation.

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 engine models and different

situations that are listed in the manual. Open the package, unpack the

components and identify them.

Torque Specifications

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

3/4

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

3/4

Foot-pounds (ft-lb)

40

60

90

180

320

Newton meter (N•m)

54

81

122

244

434

METRIC CLASS 10.9

Size

M6

M8

M10

M12

M14

M16

Foot-pounds (ft-lb)

4.5

19

41

69

104

174

Newton meter (N•m)

6

25

55

93

141

236

Ordering Parts

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 1-800-738-8622 or online at

www.vmacair.com

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Important Safety Notice

The information contained in this manual is based on sound engineering

principles, research, extensive field experience and technical

information. Information is constantly changing with the addition of new

models, assemblies and service techniques. If a discrepancy is noted

in this manual, contact VMAC prior to initiating or proceeding with

service. Current information may clarify the issue. Any person with

knowledge of such discrepancies who performs service and repair

assumes all risks.

Only proven service procedures are recommended. Anyone who

departs from the specific instructions provided in this manual must first

assure that their safety and that of others is not being compromised and

that there will be no adverse effects on performance or the operational

safety of the equipment.

VMAC will not be held responsible for any liability, injuries, loss or

damage to individuals or to equipment as a result of the failure of any

person to properly adhere to the procedures set out in this manual or

standard safety practices. Safety should be your first consideration in

performing service operations. If you have any questions concerning

the procedures in this manual or require any more information on details

that are not included in this manual, please contact VMAC before

beginning repairs.

Safety Messages

This manual contains various warnings, cautions and notices that must

be observed to reduce the risk of personal injury during service or repair

and the possibility that improper service or repair may damage the

equipment or render it unsafe.

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 instructions on a

specific procedure that if not followed may damage or

reduce the useful life of the compressor.

This symbol is used to call your attention to additional

instructions or special emphasis on a specific procedure.

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Preparing for Installation

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.

□ Disconnect both batteries, (second one under driver’s door,

mounted to frame or other location), clean off any dirt, dust or

debris from air intake tube and air filter box areas.

□ Loosen hose clamps and remove both rubber elbows and intake

tube between air filter box lid and the rubber bellows leading to

the engine.

Figure 1.1 – Filter Box and Intake Tube

*Existing parts may differ slightly from that shown above.

Ensure no dirt or debris enters rubber bellows or air filter

box openings.

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Air Box Lid Removal

□ Disconnect MAF Sensor.

□ Remove Air Filter box lid, and filter element.

□ Remove the MAF sensor and the filter minder from the lid, and set

aside for re-use.

Lower Air Box Removal

□ Remove fastener at left front of air filter box where the 1/2"

compressor hose is held to the air filter box with a ‘p-clip’.

□ Remove nut, in bottom of air filter box and lift out filter box.

□ Remove rubber intake sleeve from front of air box. Keep the

sleeve, as it will be used with the modified air box. Do not reuse if

it has been modified. (Figure 1.2)

Rubber Sleeve

Figure 1.2 – Rubber Intake Sleeve

□ Remove foam piece from rear bottom of air box and save for

reuse later.

□ Remove fastener holding rear air filter box support bracket

(1200604) to inner fender and discard, if not previously removed.

Air Dam

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□ Remove OEM steel support bracket which had been locating the

air filter box, if not previously removed. (Figure 1.3)

Figure 1.3 – Air Filter Box Support Bracket

□ Remove OEM air dam. (Figure 1.4)

Figure 1.4 – OEM Air Dam

Remove OEM air duct

for modification

Air Dam

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Wiring Harness Protection and Routing

□ Locate the wiring harness guide. (Figure 1.5 / 1.6)

Figure 1.5 – Wiring Harness Guide

Figure 1.6 – Wiring Harness Guide Location

Plastic wiring harness guide

Second Threaded

OEM Hole

Forward Threaded

OEM Hole

OEM Air Duct to

be removed

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□ Unclip plastic wiring harness guide from sub frame by pressing on

clip and discard. (Figure 1.7)

Figure 1.7 – Wiring Harness Guide Clip

 Remove wiring harness wrap so middle branch out of wiring can

be relocated towards the firewall. (Figure 1.8)

Figure 1.8 – Wiring Harness “Middle Branch”

Clip location on plastic guide

Wrap to be removed

Middle branch out of wiring

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□ Now that wiring harness wrap is removed take middle branch out

of wires and shift back along main wiring harness. (Figure 1.9)

Figure 1.9 – Relocate Middle Branch

□ Use electrical tape and wrap harness to secure middle branch out

of wires to main harness. (Figure 1.10)

Figure 1.10 – Tape Wrap

Middle branch out of wires

relocated back

Electrical tape wrap

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Glow Plug Module Bracket

□ Undo battery terminals on glow plug module bracket and remove

fuse block from bracket.

□ Remove fasteners holding glow plug module bracket to inner

fender, firewall and in wheel-well.

□ Undo fasteners holding the glow plug module on the bracket and

discard the glow plug bracket.

□ Attach the glow plug module to the new bracket using the supplied

fasteners.

Figure 1.11 – Glow Plug Module Bracket

□ Modify both OEM battery cable ends (positive and negative) by

removing the threaded stud from the battery cable ends and then

enlarging the stud holes to allow them to fit over each of the studs

on the glow plug module. The clamping portion of the battery

cable ends can also be cut off. (Figure 1.12)

Use caution when modifying the battery cable ends. Use

a vice or other means to hold and support the cable end

when drilling. A ‘step drill’ is recommended.

M8 Flat head Bolt (Supplied)

Positive Terminal Lock Nut

Negative Post

To Stud

on Firewall

Install Glow Plug Module

using M6 bolts (Supplied)

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Figure 1.12 – Modifying Battery Cables

□ If the battery cable clamping portions are not cut off it will look like

the image below. Be sure to wrap any exposed ‘positive’ clamp

with black electrical tape to prevent short circuiting. (Figure 1.13)

Figure 1.13 – Wrap Any Exposed “Positive” Clamp

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Updating the Hood Struts

□ Using a hammer, flatten the sheet metal, raised edge around the

lower hood strut area. (Figure 1.14)

Figure 1.14 – Preparing for UHMW Pad

□ Ensure there are no sharp edges remaining.

□ Remove countersunk fastener holding long leg of the glow plug

bracket to inner fender.

□ Align UHMW pad, supplied, with these two holes in inner fender

and the large portion of pad forward of holes. Reinstall glow plug

bracket flathead fastener. (Figure 1.15)

□ Install lower hood strut bracket with supplied fasteners. (Figure

1.15)

Flatten Sheet metal

edge

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Figure 1.15 – Lower hood Strut and Glow Plug Module

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

install into strut relocating bracket. Install relocating bracket with

supplied fasteners as shown. Note the 8mm hex nut may need to

be oriented to fit in the slot in hood. (Figure 1.16)

Figure 1.16 – Upper Hood Strut

□ Reinstall passenger side hood strut.

M8 x 16 Hex head Bolt

Lower Hood Strut

Relocating Bracket

M8 x 20 Flat head Bolt

UHMW Guard Pad

Glow Plug Module

OEM Hood

Strut Ball Stud

M8 Nut

Relocation Bracket

M8 x 18mm Bolts

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Complete Harness Routing

□ Use the 1.5” ID x 16.0” long protective wrap supplied and wrap

harness as shown. (Figure 1.17)

Figure 1.17 – Protective Wrap

□ Remove previously installed M6 screw and M6 nut from glow plug

module bracket and discard. Take loomed wire and route along

the top of main harness as shown. (Figure 1.18)

□ Use supplied 4.0” section of protective wrap and cover wiring

harness. (Figure 1.18)

□ Secure wiring harness to glow plug module using supplied M6 x

25mm screw, washer, P-Clip and M6 nut. (Figure 1.18)

Ensure protective wrap covers

harness fully down to bottom

section

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Figure 1.18 – Short Harness Wrap

□ Once installed bend P-clip down toward glow plug module to

provide clearance between P-clip and air box once installed.

(Figure 1.18 / 1.19)

Figure 1.19 – Harness Routing

□ Take washer fluid tube and loomed wire and route along the top of

the main wiring harness. Secure with supplied tie wraps.

(Figure 1.19)

Securing middle branch out of

wiring harness to bracket using

supplied P-clip, M6 bolt and nut

Route loomed wiring along top of

harness

Supplied 4.0” plastic wrap

covering wiring harness

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Figure 1.20 – Harness and Washer Fluid Tube Routing

□ Locate the sub frame nut insert which the front of the air box

mounts to, measure 6.0” down along sub frame and using 5.5mm,

or (13/64) drill until break through into hollow section. (Figure

1.21)

Figure 1.21 – Drill for P-Clip

□ Using supplied larger P-clip and secure wiring harness to sub

frame using self-tapping screw supplied. (Figure 1.22)

□ Once installed push down on P-clip toward fender liner to create

clearance for air box.

Tie wraps

Loomed wire, washer fluid

tube routed on top of main

harness

Sub frame nut insert

Drill here until break through

In to hollow section

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Figure 1.22 – Flatten P-Clip for Clearance

□ Install the supplied modified air dam.

□ Locate passenger side headlight wire and mass air flow sensor

wire and route overtop modified air dam once installed. (Figure

1.23)

Figure 1.23 – Wire Routing Around Modified Dam

□ 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 1.24)

Mass airflow connector wire

Head light wire

Note P-Clip is flattened

towards fender liner for

clearance

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Figure 1.24 – Anti-Abrasion Shell

Modify Inlet Valve Fittings

□ If the 3/16” push-to-connect fitting in the inlet valve is a straight

fitting, then remove the fitting and replace it with the supplied

3/16” 90 degree push-to-connect fitting. (Figure 1.25)

Figure 1.25 – Note Orientation of Fitting

This should be a 90 degree fitting

(Note orientation)

Protective shell

Metallic heat tape

Ensure his is a 90 degree fitting and Note orientation

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Intake Tube Brace

□ Remove OEM fastener holding ground-strap to firewall. (Figure

1.26)

Figure 1.26 – Intake Tube Brace and OEM Ground Wire

□ Use the OEM fastener to tap threads into the existing OEM hole

1-3/4” above the ground-strap hole. Remove OEM fastener and

retain. (6mm tap may also be used).

□ Install supplied brace and ground strap using OEM fastener into

lower hole and then the supplied fastener into the new threaded

hole above it. The brace should sit flush against the firewall with

the ground strap on top of the brace. Ensure the brace does not

make contact with the electrical connector on the firewall.

(Figure1.27)

Figure 1.27 – Intake Tube Brace and OEM Ground Wire

Tap hole using OEM Fastener

Remove OEM Fastener

from Ground Strap

OEM Ground Strap

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Inlet Brace Replacement

□ Remove the existing brace from the inlet and the front of the EGR

and discard fasteners.

□ Replace with the supplied thicker EGR brace. (Use supplied M6

specifications). (Figure 1.28)

Figure 1.28 – EGR Brace Bolt Locations

□ Replace inlet brace and install fasteners finger tight only. (Do not

use Loctite on these two (2) bolts). (Figure 1.29)

Figure 1.29 – Longest Bolts are used with Inlet Brace

Lower portion of inlet brace bolts here.

Lower Portion of Inlet Brace Bolts Here

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Vmac A700226 Installation guide

Vmac A700226 Installation guide

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