Vmac V900029 Installation guide

Installation Manual

For The

System #V900029

UNDERHOOD AIR COMPRESSOR

TEL: 250-740-3200

FAX: 250-740-3201

TOLL FREE: 800-738-8622

1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3

DOCUMENT 1900602

1993-2001 DODGE 360 MAGNUM WAC/WOS

Installation Manual Document 1900602

VR7000 Underhood Air Compressor

System Number V900029

Application: 1993-2001 DODGE 360 MAGNUM WAC/WOS

Publication Date: November, 2001

Publication Number: 1900602

Origination Documents: #1900602a - introduction

#1900603 - compressor and oil cooler installation

#1900604 - air tank and line installation

#1900605- throttle controller installation

#1900606- control unit installation

#1900607 - illustrated parts list

#1900130 - warranty registration

Registered Trademarks:

VR7000, VMAC and Throttle Commander are registered trademarks of VMAC

Dodge and Magnum are registered trademarks of Daimler-Chrysler AG.

Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.

Nylok is a registered trademark of Nylok Fastener Corporation.

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 COMPRESSOR AND OIL COOLER ................................ 9

1.1 PREPARING FOR INSTALLATION .......................................................................................... 11

1.2 INSTALLING THE BRACKET AND COMPRESSOR ...................................................................... 13

1.3 INSTALLING THE OIL COOLER ............................................................................................ 15

PART 2: INSTALLING THE AIR TANK AND LINES ................................................... 19

2.1 INSTALLING THE TANK MOUNTS AND THE TANK .................................................................. 21

2.2 CONNECTING THE AIR AND OIL LINES ................................................................................ 23

2.3 ADDING OIL TO THE SYSTEM ............................................................................................ 25

2.4 COMPLETING THE INSTALLATION ...................................................................................... 26

PART 3: INSTALLING THE CONTROL UNIT ............................................................... 27

3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 29

3.2 CONNECTING THE WIRING ................................................................................................ 30

PART 4: INSTALLING THE THROTTLE CONTROLLER ........................................... 33

4.1 INSTALLING BRACKET ....................................................................................................... 35

4.2 CONNECTING THE CABLE ................................................................................................. 36

4.3 INSTALLING THE POLYTUBES ............................................................................................. 38

ILLUSTRATED PARTS LIST .............................................................................................. 39

WARRANTY REGISTRATION .......................................................................................... 45

1

2

General Information

System #V900029

1993-2001 DODGE 360 MAGNUM WAC/WOS

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 1900602a

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 Pneumatic Throttle Control

This kit has been designed for:

1993-2001 Dodge 360 Magnum WAC/WOS.

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 Pneumatic Throttle Control

Terms and symbols

This manual uses the following terms and symbols:

•WAC -With air conditioning

•WOS - Without smog pump

•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)

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DOCUMENT 1900602a

NOTE

WARNING

!

Installation Notes

1. It is important that you complete all the installation steps before operating the system.

2. Follow all safety precautions for underhood 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).

8. The above fastener torque values are applicable when Loctite is used

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DOCUMENT 1900602a

WARNING

!

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

If the threads are dry add 20% to the torque values.

Ordering Parts

To order parts, contact VMAC at:

Telephone 250-740-3200

Facsimile 250-740-3201

Office Hours 8:00 AM to 4:30 PM Pacific Time

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.

Locate the S/N plate on the drivers side frame member in front of the battery. 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.

IMPORTANT

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.

Changes and improvements

These products and documents are subject to changes or improvements without notice.

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DOCUMENT 1900602a

8

Part 1

Installing

the Compressor and

Oil Cooler

System #V900029

1993-2001 DODGE 360 MAGNUM WAC/WOS

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 1900603

10

Part 1: Installing the Compressor and Oil Cooler

1.1 Preparing for installation

1. Disconnect the battery cables.

2. Drain the coolant.

3. Remove the upper and lower radiator hoses.

4. Remove the air cleaner assembly and associated ducting (Figure 1.1).

5. Disconnect the hoses from the coolant expansion bottle and remove the bottle from the fan

shroud (Figure 1.1).

6. Disconnect the hoses and remove the windshield washer bottle from the fan shroud.

7. Unscrew the fan from the water pump (Figure 1.1).

8. Remove the fasteners holding the fan shroud in place and remove the fan and shroud

together (Figure 1.1).

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DOCUMENT 1900603

Nut Holding A/C Lines

Fan

Air Cleaner

and Ducting

Cap Screw

Holding

Dipstick

Coolant

Expansion

Bottle

Shroud

Figure 1.1

9. Remove the OEM belt.

10 Remove the OEM belt idler pulley from the aluminum alternator mounting bracket.

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DOCUMENT 1900603

13. Loosen the six (6) 3/8” OEM hex head cap screws holding the aluminum alternator

mounting bracket so that the bracket assembly can be moved forward from the engine

block along the cap screws (Figure 1.2). This allows easier access to a hex head cap

screw behind the assembly which holds the tensioner bracket to the engine.

14. Remove the OEM belt tensioner and ignition coil from the tensioner mounting bracket.

15. Remove the three (3) OEM hex head cap screws holding the tensioner mount bracket on

the engine and remove the bracket.

VR7000 belt pulley procedures differ between models produced from 1993 - 1999 and

those produced in 2000. The crankshaft damper pulley assembly produced on the 1993

- 1999 is a split design, the 2000 assembly is a one piece unit. All model VR7000 crank

pulley assemblies are shown in Fig 1.3.

Six (6) OEM Hex Head Cap Screws

Figure 1.2

11. Remove the 8 mm hex head cap screw which holds the dipstick tube to the alternator

bracket.

12. Remove the 3/8” nut from the stud which secures the air conditioning lines to the alternator

bracket.

OEM Vibration damper

OEM Belt pulley

Pulley drive hub (2000)

Pulley drive hub

(1993-1999)

VR7000 pulley

Six (6) 5/16” x 2-3/4” cap screws

Three (3) 5/16” x 1-3/4”

cap screws

3/4” x 4” cap screw and washer

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DOCUMENT 1900603

1.2 Installing the bracket and compressor

1. Make sure that the mounting areas on the cylinder block and head where the VR7000

bracket will mount are clean and free of cast flashing that might interfere with a good, flat

mount. The bracket will be fastened at four (4) locations (Figure 1.4).

16. On 1993-1999 models, remove and discard the six (6) 5/16” hex head cap screws retaining

the OEM crank pulley to the crankshaft.

17. On all models, remove and discard the OEM crank pulley center bolt.

18. On all models, make sure that there is no accumulated dirt or debris in the pilot hole and

surrounding mating surface that will affect the mounting of the VR7000 pulley.

19. For 1993-1999 models, position the pulley drive hub in the center of the crankshaft damper

pulley assembly, push it in until it is fully seated and align the holes. Place the VR7000

pulley into position against the drive hub and secure it with the supplied six (6) 5/16" x 2 -

3/4" hex head cap screws. Install the supplied 3/4" x 4" hex head cap screws, complete

with washer, through the center of the pulley. Use Loctite and torque all fasteners to

specifications.

20. For 2000 models, position the pulley drive hub in the center of the crankshaft damper

pulley assembly, align the key with the keyway and push it in until it is fully seated. Place the

VR7000 pulley into position against the drive hub, align the holes and secure using three (3)

5/16" x 1 3/4" hex head cap screws. Place the supplied pulley washer onto the supplied 3/

4" x 4" HHCS, install through center of pulley and secure. Use Loctite and torque all

fasteners to specifications.

Figure 1.3

VR7000 Mount Bracket

VR7000 Idler Pulley

Idler Bolt Spacer

Idler Bolt

VR7000 Tensioner

Tensioner Bolt

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DOCUMENT 1900603

Figure 1.5

2. Make sure that the threads in the lower location on the block are clean and dry.

3. Remove the tensioner and idler pulley from the VR7000 mounting bracket. Be careful not

to lose the idler bolt spacer. Figure 1.5 shows the components including the bracket.

4. Apply Loctite to the four (4) supplied 3/8” x 1-1/4” hex head cap screws.

5. Locate the bracket in place (Figure 1.6), align the mounting holes and install the four cap

screws. Torque them to specifications.

Figure 1.4

Three (3) Head and Block Locations

One (1) Location Behind Alternator

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DOCUMENT 1900603

Figure 1.6

6. Apply Loctite to the VR7000 idler bolt, slide the bolt through the spacer sleeve and idler

pulley and install it on the VR7000 mounting bracket. Torque it to specifications.

7. Apply Loctite to the VR7000 tensioner bolt, slide the bolt through the tensioner and install

the tensioner, making sure that the locating pin aligns correctly with the hole in the bracket.

Torque it to specifications.

8. Apply Loctite and thread the three (3) 8 mm mounting studs into the bottom of the

compressor housing. Install the serrated ends into the compressor using two (2) 8mm nuts

as jam nuts to tighten the studs.

9. Apply Loctite to the exposed ends of the studs and place the compressor on the mounting

bracket with the studs through the mounting holes.

10. Install the three (3) 8 mm nuts and three (3) 5/16” flat washers onto the studs and tighten

them securely.

11. Push the alternator mounting bracket back into position and torque the 3/8” hex head cap

screws to specifications.

12. Apply Loctite and install the OEM belt tensioner onto the VR7000 mounting bracket.

Tighten the fastener.

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DOCUMENT 1900603

4. Slide the backing tab inside the chassis cross-member (under the radiator), through the 2”

OEM hole in the back side of the cross-member. Align the threaded holes in the backing

tab with the two 1” OEM holes on either side of the 2” hole in the cross-member.

5. Install the cooler mounting bracket by inserting two (2) 3/8” x 1” flange-lock cap screws

(use Loctite on the threads) through the holes in the cooler bracket and the 1” holes in the

cross-member. Thread them into the backing tab.

6. Install the two (2) 3/8” x 1” flange-lock cap screws through the ends of the mounting

bracket and the two (2) OEM holes in the flange on the front of the cross-member flange.

Use Loctite on the threads and install the two 3/8” nuts. Figure 1.8 shows the assembly in

relation to the cross-member. Figure 1.7 shows the cooler installed on the vehicle.

7. Torque all fasteners to specifications.

8. Place the cooler on the bracket and fasten it in place using the two (2) 3/8” x 5/8” hex head

cap screws. Use Loctite on the threads and torque them to specifications.

9. Fit the suppled radiator hose with clamps attached to the front spigot on the cooler. The 90

Degree end fits on the cooler. Rotate the hose on the cooler spigot to give clearance around

the fan shroud and connect the other end to the lower radiator spigot. Use a screwdriver

to unlock the spring clamps to secure the hose in position.

Figure 1.7

1.3 Installing the oil cooler

1. Remove the two (2) 3/8” x 5/8” hex head cap screws holding the oil cooler to the mounting

bracket (Figure 1.7).

2. Remove the two (2) 3/8” x 1” flange-lock cap screws holding the backing tab to the cooler

mounting bracket (Figure 1.7).

3. Remove the two (2) 3/8” x 1” flange-lock cap screws and nuts from the mounting bracket

(Figure 1.7).

Cooler

Mounting

Location

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DOCUMENT 1900603

Figure 1.8

Figure 1.9

10. Fit the OEM lower radiator hose with the U bend to the rear cooler outlet tube, connect the

other end to the engine. Use OEM spring clamps on hose.

NOTE

The hose is reversed from the original installation.

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DOCUMENT 1900603

17. Install the OEM belt following the manufacturer’s routing information or use the routing

shown in Figures 1.10 & 1.11.

18. Install the VR7000 belt according to the routing shown in Figure 110.

Figure 1.11

10. Install the VR7000 fan spacer to the fan hub, then install the fan and the fan shroud together.

Tighten the fan onto the spacer.

11. Install the fasteners which retain the shroud in place.

12. Install the windshield washer bottle and the coolant expansion bottle on to the shroud.

Connect all hoses and tighten all clamps and fasteners.

13. Gently bend the air conditioning hoses up just enough so that they clear the compressor.

Install the supplied spacer under the bracket, then fasten the air conditioning hoses to the

alternator mounting bracket using the 3/8” nut which you removed in preparation.

14. Attach the dipstick tube to the alternator mounting bracket using the 8 mm cap screw which

you removed in preparation.

15. Install the top radiator hose using the OEM hose clamps.

16. Fill the cooling system with OEM recommended coolant.

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Vmac V900029 Installation guide

Vmac V900029 Installation guide

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