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Installation Manual
For The
System #9014
UNDERHOOD AIR COMPRESSOR
TEL: 250-754-6997
FAX: 250-754-6972
TOLL FREE: 800-738-8622
1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3
DOCUMENT 19295
1996-1999 GMC CK2500, CK3500 & HD3500
454 W/WOAC
Installation Manual
VR7000 Underhood Air Compressor
System Number 9014
Application: 1996-1999 GMC CK2500, CK3500 & HD3500 454 W/WOAC,
Revision Date: March 2000
Publication Number: 19295
Origination Documents: #19295a - introduction
#19296 - compressor and oil cooler installation
#19297 - air tank and line installation
#19298 - throttle controller installation
#19299 - control unit installation
#19300 - illustrated parts list
#19130 - warranty registration
Registered Trademarks:
VR7000, VMAC and Throttle Commander are registered trademarks of VMAC, a division of
Mangonel Corporation.
GMC, CK2500, CK3500 and HD3500 are registered trademarks of General Motors
Corporation
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 1999
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, FILTER, REGULATOR
AND OIL COOLER ....................................................................................9
1.1 PREPARING FOR INSTALLATION ................................................................................... 11
1.2 INSTALLING THE BRACKET AND COMPRESSOR ..................................................................13
1.3 INSTALLING THE REMOTE FILTER AND REGULATOR ..............................................................14
1.4 INSTALLING THE OIL COOLER ......................................................................................14
1.5 COMPLETING THE INSTALLATION ..................................................................................17
PART 2: INSTALLING THE AIR TANK AND LINES .............................................21
2.1 INSTALLING THE TANK MOUNTS AND THE TANK .................................................................23
2.2 CONNECTING THE AIR AND OIL LINES ............................................................................27
2.3 ADDING OIL TO THE SYSTEM ......................................................................................31
2.4 COMPLETING THE INSTALLATION ..................................................................................32
PART 3: INSTALLING THE THROTTLE CONTROLLER .....................................33
3.1 INSTALLING THE THROTTLE CONTROL ............................................................................35
PART 4: INSTALLING THE CONTROL UNIT ........................................................39
4.1 INSTALLING THE CONTROL UNIT ...................................................................................41
4.2 CONNECTING THE WIRES ..........................................................................................42
PART 5: ILLUSTRATED PARTS LIST...................................................................45
WARRANTY REGISTRATION .................................................................................51
1
2
General Information
System #9014
1996-1999 GMC CK2500, CK3500 & HD3500
454 W/WOAC
UNDERHOOD AIR COMPRESSOR
3
DOCUMENT 19295a
4
General Information
Introduction
This book provides installation instructions for:
VMAC underhood air compressor installation kit
VMAC Throttle Commander
This kit has been designed for:
1996-1999 GMC CK2500, CK3500 & HD3500 454 W/WOAC
Installation steps
The installation procedure in this manual has four main steps:
Part 1: Installing the Compressor, Cooler, Filter and Regulator
Part 2: Installing the Air Tank and Lines
Part 3: Installing the Control Unit
Part 4: Installing the Throttle Commander
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)
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.
5
NOTE
WARNING
!
DOCUMENT 19295a
Installation Notes
1. It is important that you complete all the installation steps before operating the system.
Refer to the Owner’s Manual before operating the system for the first time.
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 possibility exists that the primary installer may be color-blind. Always ensure
that another person confirms the color codes on the wires.
6
T
y
pe Grade 8 plated Class 10.9 unplated
Size In Cast or
Steel
In
Aluminum
In Cast or
Steel
In
Aluminum
3/8 48 45
7/16 77 70
1/2 117 95
M8 25 20
M10 45 40
M12 80 70
M14 145 130
DOCUMENT 19295a
Ordering Parts
To order parts, contact VMAC at:
Telephone 250-754-6997
Facsimile 250-754-6972
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 must be attached to the vehicle at the time of
installation. This plate provides information, which allows VMAC to assist in customer inquiries and
ordering of parts. It is important that this plate is affixed to the vehicle.
Instructions
Locate the plate on the front body support on the passenger side of the in front of the hood stop
(Figure 1). Drill the two hole locations using a 7/64” drill bit. Place the plate in position and fix in
place with the two #6 pan head self tapping screws provided.
Figure 1
Changes and improvements
These products and documents are subject to changes or improvements without notice.
7
DOCUMENT 19295a
8
Part 1
Installing
the Compressor, Filter
and
Oil Cooler
System #9014
1996-1999 GMC CK2500, CK3500 & HD3500
454 W/WOAC
UNDERHOOD AIR COMPRESSOR
9
DOCUMENT 19296
10
Part 1: Installing the Compressor, Filter, Regulator
and Oil Cooler
1.1 Preparing for installation
1. Disconnect the battery.
2. Drain the coolant from the cooling system and remove the OEM radiator hoses.
3. Remove the upper radiator cowling .
4. Remove the OEM belt, then remove the cooling fan.
5. Remove the lower radiator cowling. On 4X4 models, remove the rock guard.
6. Disconnect all the wire harnesses that are connected to the air condtioning compressor
(Figure 1.1). Also disconnect the loom from the AC bracket.
7. Remove the four (4) OEM hex head cap screws retaining the air conditioning compressor.
Lift the compressor from the mounting bracket and place it on the intake manifold or on top
of the alternator.
11
WARNING
!
Do not disconnect the air conditioning lines from the compressor. Do not damage the
air conditioning lines and do not permit the compressor to hang from the lines.
DOCUMENT 19296
Remove These Fasteners
Disconnect These Harnesses
Remove the OEM Belt Figure 1.1
8. Mark the position of the power steering pump pulley in relation to the pump shaft so that
you can install it back into the original position.
9. Remove the power steering pump pulley using a manufacturer approved puller.
10. Remove the three (3) OEM hex head cap screws retaining the power steering pump to the
bracket and the 10mm hex head cap screw from the cylinder block support bracket.
11. Remove the stud from the cylinder head that is used to locate and retain the OEM air
conditioning and power steering bracket.
12. Remove the OEM fasteners retaining the air conditioning compressor/power steering pump
mounting bracket to the cylinder head and discard the bracket. Figure 2 shows the engine
block with the OEM bracket removed and the power steering pump pulley removed.
Figure 2
13. Clean all dirt and debris from the inside of the OEM crankshaft pulley.
14. Remove the OEM fasteners holding the OEM pulley in place on the crankshaft.
15. Install the VR7000 pulley in place over the OEM crankshaft pulley.
16. Install and tighten the three (3) supplied 3/8 x 3-1/2 inch NF hex head cap screws and one
(1) 1/2 x 3/8 inch NF hex head cap screw in the center of the pulley.
12
DOCUMENT 19296
Three C
y
linder Head Locations
Two Cylinder Block Locations
13
1.2 Installing the bracket and compressor
1. Apply Loctite to the five (5) 7/16 x 1-1/4 hex head cap screws and fasten the VR7000
bracket in place of the OEM air conditioning and power steering mounting bracket
(Figure 1.3).
2. Apply Loctite to the OEM hex head cap screws and install the power steering pump. Install
the supplied block support bracket to the rear of the power steering pump to the using
OEM bolts. Figure 1.3 shows the bracket in place on the cylinder block with the power
steering pump mounted on the bracket.
Figure 1.3
3. Apply Loctite to the three (3) 8 mm studs and thread them into the locations on the bottom
of the compressor.
4. Position the compressor in place on the VR7000 bracket, install the 8 mm nuts and 3/8 inch
flat washers and torque to 25 ft-lb.
5. Install the power steering pump pulley, making sure that your marks are correctly aligned.
6. Remove the hex head cap screw retaining the VR7000 idler, apply Loctite, install the cap
screw and torque it to 80 ft-lb.
7. Check the fastener on the VR7000 belt tensioner. Make sure that the Nylok nut is torqued
to 45 ft-lb.
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Three 10 x 30 mm supplied hex head cap screws
14
DOCUMENT 19296
7. Install the air conditioning compressor using two (2) OEM hex head cap screws in the rear
holes and two (2) supplied 8 mm hex head cap screws in the front holes.
Figure 1.4
1.3 Installing the remote filter and regulator
1. Mount the remote filter assembly to the inside of the VR7000 mounting bracket in the
location between the air conditioning compressor and the alternator (Figure 1.4) using three
(3) 1/4 x 3/4 inch hex head cap screws with serrated washers. Make sure that the wire
harness is kept clear of the housing
1.4 Installing the oil cooler
1. Before attempting to install the cooler, determine whether the vehicle is a standard model or
a heavy duty model.
2. Remove the OEM hex head cap screws which retain the radiator to the body.
3. Raise the radiator a few inches to provide better access to the crossmember under the
radiator.
1.4.1 For all standard models
1. Fit the cooler and mount bracket to the body section under the radiator, using the locations
indicated in Figure 1.5. Make sure that the cooler is fitted in the correct direction, with the
outlets facing toward the passenger side of the vehicle.
2. Attach the cooler and mount assembly to the body section using three (3) 1/4 x 1 inch
supplied hex head cap screws, flat washers and Nylok nuts through the holes shown in
Figure 1.5. Tighten the fasteners.
A DIVISION OF MANGONEL CORPORATION
15
DOCUMENT 19296
VR7000 Oil Cooler
Mount Bracket
Radiator
VR7000 Oil Cooler
Vehicle Body
Crossmember
Use These Two
Existing Holes
For Heavy Duty
Installation
Drill These Two Holes
For Heavy Duty Installation
Use These Three Holes
For Standard Model Installation
1.4.2 For heavy duty models
1. Remove the the two (2) hex head cap screws holding the flat cooler mounting bracket to the
oil cooler.
2. Attach the bracket to the crossmember using two (2) of the supplied 1/4 x 1 inch hex head
cap screws through the holes shown in Figure 1.5. Tighten them just enough to hold the
bracket snug on the crossmember.
3. Using the bracket as a guide, drill two 1/4“ holes in the locations shown in Figure 1.5.
4. Remove the two hex head cap screws and remove the mount from the body section.
5. Attach the bracket to the cooler using the hex head cap screws that you removed
previously. Use Locktite on these caps screws and tighten them securely.
6. Locate the cooler and bracket under the body section.
7. Install the the four (4) 1/4“ x 1“ supplied hex head cap screws in the body section from under
the radiator and install the flat washers and Nylok nuts. Tighten the fasteners securely.
Figure 1.5
16
DOCUMENT 19296
Figure 1.6
NOTE
Figure 1.7 shows the completed installation with cooling hoses and oil lines attached.
1.4.3 All models
1. Slide a hose clamp over the ends of the VR7000 coolant hoses.
2. Insert the hoses on the radiator fitting and the water pump fitting.
3. Tighten all of the clamps securely.
VR7000 Oil Cooler
Part #92051
HS28 Clamp
FRONT OF TRUCK
HS24
Clamps
TO WATER PUMP
TO LOWER RADIATOR
CONNECTION
DOCUMENT 19296
17
Figure 1.7
1.5 Completing the installation
1. Lower the radiator back into place and install the OEM fasteners which hold it in place.
Tighten the fasteners.
2. Install the lower radiator cowling. Replace the fan OEM fan studs with the supplied
8 x 55 mm studs, then install the fan and the supplied fan spacer using Loctite on the
threads. Tighten the fasteners.
3. Install the OEM belt following the belt routing shown in Figure 1.8. Be sure to identify the
correct application. The illustration shows routing for engines with and without air
conditioning and with and without Air Injection Reaction (air pump).
Hose To Lower Radiator Connection
Hose To Water Pump Connection
Cross-Member In Front Of The Radiator
18
DOCUMENT 19296
4. Install the VR7000 belt following the belt routing shown in Figure 1.9. For units without air
conditioning, remove the OEM idler from the OEM bracket and mount it onto the pad on
the front of the VR7000 bracket. Figure 4 shows the belts and idlers in place.
Crankshaft
VR7000 Air Compressor
VR7000 Tensioner
VR7000 Idler
5. Install the upper fan cowling.
A/C
A/C
Alternator Alternator
Alternator Alternator
Idler Idler
Idler
Idler Idler
Idler
P/S P/S
P/S P/S
Crankshaft Crankshaft
Crankshaft Crankshaft
Tensioner Tensioner
Tensioner Tensioner
Water Pump Water Pum
p
Water Pump Water Pum
p
A.I.R. Pump A.I.R. Pum
p
WITH AIR CONDITIONING WITHOUT AIR CONDITIONING
WITH AIR CONDITIONING WITHOUT AIR CONDITIONING
WITH
AIR PUMP
WITHOUT
AIR PUMP
Figure 1.8
Figure 1.9
/
