Vmac 9014 Installation guide

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.

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.

DOCUMENT 19296

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

Alternator Alternator

Idler Idler

Idler

Idler Idler

Idler

P/S P/S

Crankshaft Crankshaft

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 PUMP

WITHOUT

AIR PUMP

Figure 1.8

Figure 1.9

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Vmac 9014 Installation guide

Vmac 9014 Installation guide

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