Vmac V900082 Installation guide

System V900082

2005 - 2007 Ford F-250 - F-550

Triton 5.4L 3 Valve V8 Gas

www.vmacair.com

VR70 UNDERHOOD

AIR COMPRESSOR

INSTALLATION MANUAL

VMAC – Vehicle Mounted Air Compressors 
Toll Free: 1-800-738-8622 
Fax: 1-250-740-3201 
1 
 
Installation Manual for VMAC 
System V900082 
 
Ford 2005 - 2007 
 
Triton 5.4 L 3-valve F250-F550 
 
 
General Information ..................................................................... 3 
Before You Start ....................................................................... 3 
Part 1:  Preparing for Installation ............................................... 4 
1.1 Preparing for Installation .................................................... 4 
Part 2:  Installing the Tank and Hoses ....................................... 6 
2.1 Installing the Tank and Mount Brackets ............................. 6 
Part 3:  Installing the Cooler, Bracket and Compressor .......... 9 
3.1 Installing the Oil Cooler ...................................................... 9 
3.2 Installing the Main Bracket and Compressor ..................... 11 
3.3 Installing Drive Belts and Components .............................. 12 
3.4 Installing the Hoses ............................................................ 13 
3.5 Adding Oil to the System .................................................... 15 
Part 4:  Installing the Control Components .............................. 16 
4.1 Installing the Components .................................................. 17 
4.2 Connecting the In-cab Wiring ............................................. 18 
4.3 Connecting the Underhood Wiring ..................................... 21 
4.4 Completing and Testing the Installation ............................. 21 
Part 5: Finishing the Installation ................................................ 23 
5.1 Before Starting the Engine Checklist ................................. 23 
5.2 After Starting the Engine Checklist..................................... 23 
5.3 Setup, Performance Testing and Adjustments ................... 24 
5.4 System Identification and Warnings ................................... 25 
5.5 Auxiliary Air Receiver ......................................................... 26 
Accessory Products from VMAC ............................................... 27 
 
 

VMAC – Vehicle Mounted Air Compressors

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Fax: 1-250-740-3201

2

Document #1930075

Installation Manual for VMAC System V900082

Ford 2005 - 2007 5.4L Triton 3-valve F250-F550

Changes and Revisions

Version

Revision Details

Revised by/date

Approved

Implemented

00

Original manual

IB 22 Oct 2004

SC 26 Nov 2004

07 Dec 2004

a

Application change

IB 14 Dec 2004

SM 21 Jan 2005

21 Jan 2005

b

Update to 2006

IB 15 Sep 2005

SC 20 Sep 2005

23 Sep 2005

c

ECN 06-170

IB 02 Aug 2006

SM 02 Aug 2006

04 Aug 2006

d

ECN 06-145

IB 05 Nov 2007

SH 23 Nov 2007

26 Nov 2007

Important Information

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 underhood mechanical work. Any

grinding, bending or restructuring operations for correct fit in modified

vehicles must follow standard shop practices.

These instructions are a general guide for installing this system on

standard production trucks and do not contain information for

installation on non-standard trucks. This system may not fit special

order models or those which have had other changes without

additional modifications. If you have difficulty with the installation,

contact VMAC.

The VMAC 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.

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.

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

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

3

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 model years and different

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

the components and identify them.

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

¾

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

¾

Foot-pounds (ft-lb)

40

60

90

180

320

Newton meter (N•m)

54

81

122

244

434

METRIC CLASS 10.9

Size

M8

M10

M12

M14

M16

Foot-pounds (ft-lb)

19

41

69

104

174

Newton meter (N•m)

25

55

93

141

236

Hose Coding

Different frame designations will affect the tank mounting position. If

you have to move the tank, the lines may be too short. Measure the

hose shortfall and order a Hose Extender Kit. The following table

shows the color code used by VMAC to identify hose diameters.

Hose Diameter

Colour-Coded Label

1/2 inch

5/8 inch

3/4 inch

1 inch

Blue

Green

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Part 1: Preparing for Installation

1.1 Preparing for Installation

Preparation for installation is very important. Missing an item can

cause problems in the installation or even damage to components.

Check off each item as it is completed so that you do not miss any

preparation steps.

□ Disconnect the battery.

□ Drain the coolant.

□ Remove the air box, the air cleaner and the trunking.

□ Remove the 1 inch coolant expansion-fill bottle to engine hose,

disconnect the 5/16 inch hose from the radiator and remove the

expansion-fill bottle.

□ Remove the upper radiator hose.

□ Disconnect the lower radiator hose from the radiator.

□ Remove the fan and the fan shroud together.

□ Remove the OEM ground connector attached to one of the

studs, then remove and discard the three OEM M10 bolts with

the M8 studded ends from the driver’s side of the cylinder head.

□ Remove the air cleaner support bracket attached to the driver

side of the engine. Discard the bracket but keep the nut.

□ Remove the radiator hold-down brackets, raise the radiator just

enough to clear the locating pins and move it sideways so that it

sits above the mount bracket (optional).

□ Remove the rubber protective flaps attached to the cross-

member under the radiator.

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□ Protect the inside surface of the radiator with a piece of

cardboard.

□ Unplug the cam position sensor connector on the front of the

driver’s side cylinder head, disconnect the harness from the

hold-downs and move it on top of the valve cover. The cam

sensor wire harness must be adjusted to prevent the harness

from hitting the belt. Open the protective loom at the connector

and pull out an additional 4 inches of wire from the main loom.

Do not damage the foil covering. Cover it with a piece of loom

and tape the junction securely.

□ Reposition the group of brake lines from in front of the master

cylinder to behind the sensor on the bottom of the master

cylinder by carefully bending them out of the way. Move the

rubber vibration isolator as required so the lines do not touch.

□ Clean the front of the engine on the driver’s side.

□ Clean the center of the OEM crank pulley.

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Part 2: Installing the Tank and

Hoses

2.1 Installing the Tank and Mount Brackets

The tank (Figure 2.1) will mount to the passenger side frame rail

behind the front cab mount. The recommended location is about 1

inch back from the end of the cab floor stiffener, a rib with an

attached ground wire.

1/4” and 3/16” tubes

3/4” hose fitting

1/2” hose fitting

C-clamp

Tank strap mount

Upper frame clip

Tank strap cable

Lower frame clip

Spacer

Oil filter

5/16” nuts and

washer

Figure 2.1

□ Place the tank on a work bench with the front (oil filter end) of the

tank to your left and remove the oil filter.

□ Remove the two 1/4 inch clamp bolts from the C-clamps. Expand

the clamps slightly and slide them over the front of the tank.

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□ Position the front clamp approximately 11 inches from the filter

end of the tank and the rear clamp approximately 12 inches from

the front clamp.

□ Place the two L-shaped tank strap mounts under the C-clamps

with the right-angle ends facing you and hanging over the edge

of the work bench. Apply Loctite and thread 5/16 x 1/2 inch bolts

with flat washers into the bottom hole on each bracket, but do

not tighten.

□ Install the 1/4 inch clamp bolts into the C-clamps so that the

heads of the bolts face toward you and install the nuts but do not

tighten. Rotate the tank so that the directional arrow on the end

of the tank is parallel to the work bench and faces toward you.

□ Apply Loctite and insert 5/16 x 1/2 inch bolts through the C-

clamp and thread them into the mount brackets, but do not

tighten.

□ Install a suitable 3/4 inch fitting (not supplied) in the back of the

tank.

□ Check tank alignment then tighten the C-clamp bolts and the

mounting bolts.

□ Insert the cable straps through the tube of the upper frame clips.

□ Fit the cables onto the tank strap mounts behind the steel lines,

with the cables in the grooves of the mounts and the clips above

the right-angle end of the tank strap (Figure 2.1).

□ Support the tank and L-bracket assembly in place on the outside

of the frame between the cab mounts, with the short part of the

L-bracket over the top of the frame.

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3/16” tube

1/4” tube

Figure 2.2

□ Pass the upper frame clip between the frame rail and the body

and clip it onto the top of the frame. Insert the threaded end of

each cable strap through the tubes on the lower frame locating

U-clips. Install the spacers (if necessary for narrow frames) and

nuts and tighten just enough to hold the tank in position.

□ Position the tank between the two cab mounts to provide

clearance for installing the lines and filter. Make sure that the

tank mounting system does not interfere with any transmission

components.

□ When the tank is correctly positioned, tighten the securing cable

retaining nuts until the cables pull tight and snug around the

frame. Do not over-tighten.

□ Install a second 5/16 inch nut and tighten it securely against the

first to act as a locknut.

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Part 3: Installing the Cooler,

Bracket and Compressor

3.1 Installing the Oil Cooler

□ Apply Loctite, insert M10 x 90 mm bolts into the top of the two

mount brackets (Figure 3.1) and thread them into the holes in the

top of the cooler mounting bracket. Hand-tighten the bolts

leaving about a 1/4 inch gap between the bracket and the cooler

so that the brackets can be repositioned easily.

□ Position the brackets so that they are horizontal (parallel with the

top of the cooler) and point to the passenger side of the truck.

Lift the cooler into position on the inside of the cross-member

under the radiator (slide it toward the passenger side) fit the

brackets over the cross-member and pivot them down so that

they align with the holes in the bottom of the cooler mounting

bracket.

□ Insert M10 x 90 mm bolts through the bottom holes and thread

them into the mount bracket.

□ Adjust the cooler so that the passenger side bracket is against

the power steering cooler bracket and tighten the mounting bolts

(Figure 3.2).

□ Connect the OEM hose to the passenger side cooler spigot and

secure it with a hose clamp.

□ Loosen the clamp on the other cooler hose, connect it to the

engine, adjust for best fit and secure it with clamps.

□ Connect the 1/2 inch hose from the VR tank to the passenger

side fitting on the cooler.

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M10 x 90 mm bolts

with washers

Mount brackets

Cross-member

Cooler mount bracket

Figure 3.1

To engine

To radiator

Cross-member

1/2” hose to compressor 1/2” hose from tank

Figure 3.2

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3.2 Installing the Main Bracket and Compressor

Tensioner assembly

Back

idlers

Ribbed

idler

Support bracket

Engine timing cover

OEM belt

M16

M8x110

M8x110 without

flat washer

M10x35 M10x30

Figure 3.3

□ Remove the idlers and the tensioner assembly from the bracket

(Figure 3.3).

□ Place the support bracket on the bottom of the driver’s side

cylinder head, insert the M16 bolt through the tube part of the

bracket into the OEM hole in the cylinder head and hand tighten.

□ Place the main bracket in position to locate the mounting points

on the engine and install the M8 x 110mm bolts where the OEM

studs were removed, just enough to hold it in position.

The top M8 bolt does not use a flat washer as it must fit

into a hole that is counter-sunk. The lower M8 bolts

require flat washers.

□ Push the bracket against the engine, check to make sure it fits

properly and install the M10 x 35mm fastener with washer in the

lower mounting point lightly snug down all the fasteners.

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□ Route the wiring harness from the valve cover behind the top

edge of the bracket so that it is not pinched between the bracket

and the engine when the bracket is tightened in position. Feed

the cam sensor wire through the hole in the bracket.

□ Install the two M10 x 30 mm bolts with washers through the base

plate into the support bracket and snug them.

□ Check the fit of the bracket on the engine and support bracket to

make sure that everything aligns properly, then torque all

fasteners to specifications.

□ Place the compressor in position on the mounting bracket.

□ Thread the three M8 double-serrated nuts onto the compressor

mounting studs and torque to specifications.

3.3 Installing Drive Belts and Components

□ Install the VR crankshaft pulley onto the OEM pulley using three

M10 x 70 mm bolts with washers and torque to specifications.

□ Install the tensioner assembly (including the locknut on the back

of the bracket) and idlers on the bracket and torque the fasteners

to specifications.

□ Install the supplied fan spacer on the water pump pulley.

□ Install the VR drive belt (Figure 3.4). Make sure that it is aligned

correctly and clears all components, including the cam position

sensor wire harness.

□ Place the supplied mounting tie-strap around the cam position

sensor wire and fasten it to the front of the VR bracket with a #10

socket head screw.

□ Install the replacement air cleaner support bracket to the two

driver’s side bolts on the upper alternator securing bracket but do

not tighten the bolts until the other air inlet components are

installed. Attach the OEM ground connection under the alternator

bracket so that it touches bare metal.

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Compressor

Crankshaft

Ribbed idler

Back idler

Tensioner

Figure 3.4

3.4 Installing the Hoses

□ Route the straight end of the 3/4 inch and the longest 1/2 inch

hoses over the cab mount and thread them into the matching

fittings on the tank but do not tighten.

□ Insert the 1/4 and 3/16 tubes into the fittings on the back of the

tank and cover them with high temperature loom. Route them

along with the other hoses over the cab mount outside the frame

into the engine compartment and across the rear of the engine.

□ Route the 1/2 hose along the passenger side frame rail to the

underside of the radiator, clear of suspension pinch points.

□ Route the 3/4 inch hose from the VR tank to the compressor and

connect the 45 degree end to the matching fitting.

□ Connect the shortest 1/2 inch hose between the compressor and

the driver’s side of the cooler. (90O connection on the cooler)

□ Route the 3/16 and 1/4 inch tubes up over the engine (clear of

the exhaust manifold) and connect them to the matching fittings

on the compressor air inlet control valve.

□ Tighten all hose connections at the tank, cooler and compressor.

Prevent the hoses from twisting during tightening.

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□ Bunch all hoses together, secure them with tie-straps and protect

them where they might rub. Make sure that they are clear of hot

exhaust parts or moving parts, including the steering column.

Secure the hoses to the firewall using 2 inch insulated P-clips

onto the 6 mm OEM studs using the supplied 6 mm nuts.

□ Apply a light film of compressor oil to the filter gasket and install

the filter on the tank. Tighten the filter an additional 3/4-1 turn

after the gasket contacts the base.

□ Measure 11 inches (around the bend) from the engine end of the

OEM coolant fill hose (with the large arrow on the hose) and cut

the hose at this point. Discard the 90 degree coolant bottle end

of the cut hose.

□ Connect the hose to the engine spigot with the large arrow facing

the coolant bottle, not the engine spigot. Install the supplied

plastic hose connector in the open end of the hose and adjust

the position of the hose so that is flush with the rear support

racket and clear of all bolts and other objects.

□ Install the coolant expansion tank.

□ Connect the long end of the supplied hose to the bottom of the

coolant expansion tank so that the hose is snug against the front

of the coolant tank and runs down in front of the compressor

regulator. Connect it to the other end of the plastic fitting in the

cut OEM hose from the engine spigot. Adjust the hoses to

provide clearance and tighten the clamps. Protect the hose with

plastic loom if it will rub on any objects.

□ Replace the OEM hose clamp on the engine end of the upper

radiator hose with the supplied clamp to provide clearance for

the air cleaner assembly support bracket. After installing the air

cleaner assembly, tighten the upper alternator bracket bolts that

hold the support bracket.

□ Install all other OEM components.

□ Fill the cooling system with the manufacturer recommended

coolant.

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3.5 Adding Oil to the System

You must use the VMAC supplied and approved

compressor oil in this system. Failure to use this

special oil will result in damage to the compressor and

will void your warranty.

□ Remove the fill plug from the air inlet control valve and pour oil

into the oil fill hole on the inlet control valve using a funnel. Turn

the compressor clutch clockwise with a ratchet and a 1/2 inch

socket using the hex head bolt at the centre of the compressor

clutch during the fill process.

□ Allow 5 minutes for the oil to drain into the tank, then check the

level at the sight glass at the front of the tank. Continue adding

oil until the level is correct.

□ Install the fill plug in the inlet control valve and tighten it securely.

Do not overfill the system. Overfilling the system with

oil can flood the sight glass window and make the

system appear empty.

!

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Part 4: Installing the Control

Components

Control Box White

Interface

Connector

Throttle

Controller

Throttle

Controller

Green 4 pin

connector

White

Red

White

Compressor

Inlet valve

Clutch

G

r

e

n

Black

Connect to accelerator pedal

OEM Connector from

accelerator pedal

Black 3 pin

connector

To ground

Connect

Blue

Connect to OEM circuit 294 white wire with light blue stripe key switched 12 volts

Connect to green wire with red stripe at the park brake switch

Connect to OEM circuit 76 light green wire with white stripe clean tach out

AUTOMATIC TRANSMISSION

Connect long blue wire to the

green wire with the red stripe

at the blunt-cut harness

Do not use short blue wire with

crimp connector

MANUALTRANSMISSION

Connect the blue wires

Throttle

Controller

Blue

ENGINE COMPARTMENT

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4.1 Installing the Components

Lay out all of the control components and identify the wiring and

connections according to the wiring diagram.

□ Remove the driver-side plastic door frame base panel and the

plastic molding ahead of the base panel.

□ Mount the control box using the supplied sheet metal screws

(Figure 4.1). Route the wire harness under the floor covering,

along the inside of the door where it will be covered by the trim

piece and up under the dash.

Control box

Cut a notch for the wire

in the door trim

Driver’s Seat

Figure 4.1

□ Cut a notch in the edge of the trim piece through the saw-tooth

section just inside the edge of the trim so that the wire is not cut

when the trim is installed. Place the floor covering back into

position and replace the kick panel and door trim.

□ Remove the trim panel from under the dash.

□ Tie-wrap the throttle control to the dash support bracket to the

right of the steering column, behind the diagnostic connector

(Figure 4.2) with the adjusting screws facing out.

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Diagnostic

connector

Throttle pedal

connector

Tie-wrap to this bracket

Figure 4.2

4.2 Connecting the In-cab Wiring

□ Unplug the OEM cable from the accelerator pedal and plug it into

the matching connector from the throttle control box. Plug the

cable from the throttle control into the matching connector on the

accelerator pedal.

□ Connect the two white interface connectors together.

□ Connect the red wire from the throttle controller to the matching

red wire from the control box.

□ Connect the green wires from the interface connector and the

throttle control to a good ground.

□ Connect the single red wire from the interface connector to

switched 12 volts. You can use circuit 294 (white with light blue

stripe wire) under the dash near the diagnostic connector (Figure

4.3).

□ Connect the white wire from the throttle controller to the “clean

tach out” circuit 76 (green with white stripe wire) at the blunt-cut

harness under the dash near the park brake (Figure 4.4).

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Vmac V900082 Installation guide

Vmac V900082 Installation guide

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