Vmac 9034 Installation guide

Brand: Vmac

Model: 9034

Category: Engine

Type: Installation guide

Installation Manual

For The

System #9034

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 19339

1999 GMC SIERRA & CHEVROLET SILVERADO

CK2500 5.3L & 6.0 L

Installation Manual

VR7000 Underhood Air Compressor

System Number 9034

Application: 1999 GMC SIERRA & CHEVROLET SILVERADO CK2500 5.3L & 6.0 L

Publication Date: August 09, 1999

Publication Number: 19339

Origination Documents: #19339a - introduction

#19340 - compressor and oil cooler installation

#19341 - air tank and line installation

#19343 - throttle controller installation

#19342 - control unit installation

#19344 - illustrated parts list

#19130 - warranty registration

Registered Trademarks:

VR7000, VMAC and Throttle Commander are registered trademarks of VMAC.

GMC, CHEVROLET, SIERRA and CK2500 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

General Information

System #9034

1999 GMC SIERRA & CHEVROLET SILVERADO

CK2500 5.3L & 6.0 L

UNDERHOOD AIR COMPRESSOR

DOCUMENT 19339a

General Information

Introduction

This book provides installation instructions for:

VMAC underhood air compressor installation kit

VMAC Throttle Controller

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.

NOTE

WARNING

DOCUMENT 19339a

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.

Type Grade 8 plated Class 10.9 unplated

Size In Cast or

Steel

Aluminum

In Cast or

Steel

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 19339a

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 form has been designed as a convenient mailer, just fold along the

lines, tape the edge and apply sufficient postage.

Changes and improvements

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

DOCUMENT 19339a

Part 1

Installing

the Compressor

and

Oil Cooler

System #9034

1999 GMC SIERRA & CHEVROLET SILVERADO

CK2500 5.3L & 6.0 L

UNDERHOOD AIR COMPRESSOR

DOCUMENT 19340

Part 1: Installing the Compressorand Oil Cooler

1.1 Preparing for installation

1. Disconnect the battery.

2. Remove the air intake tube, air filter and resonator box.

3. Remove the skid pan.

4. Drain the coolant from the cooling system and remove the OEM radiator hoses.

5. Remove the upper radiator fan shroud.

6. Remove the cooling fan.

7. Remove the lower radiator fan shroud.

8. Remove the OEM fan belt.

9. Disconnect the alternator wiring and remove the alternator.

10. 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. Remove the power steering pump pulley

with the recommended puller.

11. Remove the OEM air conditioning belt.

12. 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.

Discard the bracket.

13. Remove the bracket holding the large, red battery cable splitter box from the alternator and

power steering pump bracket.

14. Remove the OEM aluminum alternator and power steering pump mounting bracket.

15. Remove the OEM back idler from the bracket.

16. Remove the plastic cover from the intake manifold.

17. Remove the OEM crankshaft pulley using the recommended puller.

18. Clean all dirt an debris from the driver’s side of the engine in preparation for mounting the

VR7000 bracket. Figure 1.1 shows the engine prepared for installation, indicating the five

(5) mounting locations on the cylinder head, the single lower block mounting location (1)

and the battery cable splitter box.

DOCUMENT 19340

1.2 Installing the bracket and compressor

1. Lower the bracket into place in front of the engine. Insert the power steering pump through

the hole in the bracket and thread one OEM cap screw loosely into the pump to hold it in

place (Figure 1.2).

2. Locate the bracket by threading the 10 x 130 mm hex head cap screw a few turns into the

lower mounting hole.

DOCUMENT 19340

Battery Cable Splitter Box

Insert 1 OEM Capscrew to Hold the Power Steering Pump

Insert the 10 x 130 mm Hex Head Cap Screw to Locate the Bracket

Figure 1.1

Figure 1.2

DOCUMENT 19340

3. Apply Loctite to the five (5) 10 x 30 mm hex head cap screws and fasten the VR7000

bracket to the cylinder head. Remove the lower cap screw, apply Loctite and reinstall.

Torque the cylinder head cap screws and the lower bracket cap screw to specifications.

4. Remove the OEM 8 mm stud from the bottom rear of the power steering pump.

5. Apply Loctite to the OEM hex head cap screws and install the power steering pump on the

VR7000 bracket (Figure 1.3). Torque the cap screws to specifications.

Install the Power Steering Pump Fasteners Install the Power Steering Pump Pulley

Figure 1.3

6. Install the power steering pump pulley, making sure that your marks are correctly aligned

(Figure 1.3).

7. Install the VR7000 belt tensioner with a 7/16“ flat washer and 12 mm Nylok nut (Figure 1.4).

Torque the nut to specifications.

8. Install the OEM back idler on the VR7000 bracket (Figure 1.4). Use Loctite on the

threads and torque to specifications.

9. Install the alternator on the bracket using the OEM cap screws (Figure 1.5). The spacers

will pull into position as you torque the cap screws to specifications.

10. Apply Loctite to one end of the three (3) 8 mm studs and thread them into the locations on

the bottom of the compressor.

11. Apply Loctite to the other end of the studs, position the compressor in place on the

VR7000 bracket, install the 8 mm nuts and 3/8“flat washers and torque to specifications.

DOCUMENT 19340

12. Remove the hex head cap screw retaining the VR7000 idler, apply Loctite, install the cap

screw and torque it to specifications.

Figure 1.5

13. Thread the supplied crankshaft pulley installation tool (Figure 1.6) completely into the end of

the crankshaft. Remove the two nuts, washer and spacer.

Install the VR7000 Belt Tensioner Install the OEM Back Idler

Figure 1.4

DOCUMENT 19340

16 mm washer

Spacer

Large pulley washer

Figure 1.6

14. Place the supplied VR7000 crankshaft pulley (complete with OEM pulley and vibration

damper) on the end of the crankshaft. Make sure that you centralize and align the pulley

squarely on the end of the crankshaft.

Do not use an impact tool when installing the pulley or when installing the replacement

crank pulley retaining bolt, as this procedure may cause thread damage.

15. Install the large pulley washer (part #14156) over the installation tool and fit it into the pulley

bore. This will assist in aligning the pulley on the crankshaft. Then fit the spacer over the

installation tool

16. Slide the washer supplied with the installation tool over the tool and against the spacer.

Install the large pulley washer and thread on the two nuts.

17. Tighten the nuts to install the pulley onto the cranshaft. Continue tightening until the pulley is

completely installed on the crankshaft and bottoms. The two nuts locked together will

enable you to remove the installation tool from the crankshaft.

18. Remove the installation tool and remove the large pulley washer from the tool.

19. Install the supplied 16 x 115 mm hex head cap screw along with the large pulley washer.

Flywheel

Holding

Tool

It is recommended that you obtain the correct flywheel locking tool from the

manufacturer (Part # J42386). Remove the starter motor and install the locking tool as

shown in Figure 1.6, using one (1) M10 x 120 - 1.5 mm cap screw and one (1) M10 x

45 - 1.5 mm cap screw, torqued to 37 ft/lbs.

NOTE

Pulley Installation Tool

NOTE

DOCUMENT 19340

140

Figure 1.7

20. Tighten the crankshaft replacement cap screw to 37 ft.lbs.

21. Copy, cut out and use the degree-torque guide as shown in Figure 1.7.

22. Place the guide over the crankshaft pulley. Stick it in place using tape or glue.

23. Final torque the cap screw to 140 degrees from the 0 point in one arc.

24. Install the OEM air conditioning belt according to the manufacturer’s belt routing diagram.

25. Install the OEM drive belt according to the manufacturer’s belt routing diagram.

26. Install the VR7000 drive belt as shown in Figure 1.8.

DOCUMENT 19340

Figure 1.8

1.3 Installing the cooler

1. On 4x4 trucks, remove the two (2) 12 mm OEM cap screws from under the front of each

chassis rail which hold the tow hooks (Figure 1.9). On 2x4 trucks, use the holes in the

same locations on the chassis rail as in the 4x4.

Figure 1.9

2. Fit each of the two (2) cooler mount outer brackets (Figure 1.10) with the central drilled

holes upwards and inboard of the chassis rails, align the holes and install the OEM bolts (on

4x4 trucks) or the supplied 12 x 30 mm hex head cap screws (on 2x4 trucks). Then install

the center section of the cooler mounting bracket and tighten all the fasteners.

Remove These Cap Screws

DOCUMENT 19340

3. Install the cooler with the hose spigots for the coolant hoses facing the passenger side of the

truck. Apply Loctite and install the two (2) 3/8“ x 3/4“ flange lock bolts, then torque them to

specifications. Figure 1.11 shows the cooler in position.

4. Use the supplied hose clamps and hoses to connect between the cooler and lower radiator

hose connection and the cooler and the water pump. On the 5.3L engine, use the shorter

length of hose to connect to the radiator (Figure 1.12). On the 6.0L engine, use the longer

radiator hose with the 45 degree elbow (Figure 1.13).

Figure 1.11

Figure 1.10

DOCUMENT 19340

5. Align the hoses so that they are not kinked or stressed and tighten the hose clamps. Make

sure that the cooler bracket and hoses clear all transmission cooling lines and the steering

linkages.

Figure 1.12 5.3 radiator hose

Figure 1.13 6.0 radiator hose

1.4 Completing the installation

1. Install the lower radiator fan shroud.

2. Install the fan and the supplied fan spacer and tighten the fasteners.

3. Install the upper radiator fan shroud.

4. Check all hoses, lines, wire harnesses and cables to make sure that they clear all the belts,

pulleys or other objects that could cause damage.

5. Install the upper radiator hose and fill the cooling system with the OEM recommended

coolant mixture to the correct level.

NOTE

When operating the engine for the first time following installation, be sure to allow the

engine to reach full operating temperature and ensure that the cooling system level is

correct. Failure to do so could result in an overheat condition and possible engine

damage.

6. Install the air filter tube, filter and resonator box.

7. Attach the bracket with the red battery cable splitter box to the VR7000 bracket using the

OEM fasteners (Figure 1.14). Connect the fusible link wire and fit the plastic protective

loom around the wire.

Figure 1.14

DOCUMENT 19340

Part 2

Installing the

Air Tank and Lines

System #9034

1999 GMC SIERRA & CHEVROLET SILVERADO

CK2500 5.3L & 6.0 L

UNDERHOOD AIR COMPRESSOR

DOCUMENT 19341

Part 2: Installing the Air Tank and Lines

2.1 Installing the tank mounts and the tank

The tank mounts supplied with this system are designed so that they can be mounted on the frame

without drilling holes. The tank is secured to the frame using two L-brackets that hook over the

chassis rail and are secured with wire cables and backing straps. The tank and clamps then locate

on the L-brackets

1. In preparation for mounting, thoroughly clean the frame under the cab on the passenger side

of the vehicle.

The upper line connections on the tank will not be easily accesible after the tank has

been installed on the frame. It is recommended that you attach these two lines before

installing the tank on the frame.

2. Connect the 5/16“ x 1161/2“ scavenge line (part #17343) to the tank at location 3 and tighten

the fitting (Figure 2.1).

3. Connect the 1/4“ x 1191/2“ pressure control line (part #17344) to the tank at location 2 and

tighten the fitting (Figure 2.1).

DOCUMENT 19341

OIL LEVEL

(check cold)

MAX

ADD

THIS

WAY

IMPORTANT

Check Oil

Level Here

3/4 JIC Main Air Line

1/4 SAE Pressure Control Line 5/16 SAE Oil Scavenge Line

1/2 SAE Oil Return Line

Figure 2.1

NOTE

Figure 2.2 shows the tank mounting brackets.

NOTE

DOCUMENT 19341

Figure 2.2

4. Most applications come with the tank band clamps fitted to the tank. It is easier to fit the L

brackets loosely to the tank band clamps and install tank and L brackets together. Fit the L

brackets to band clamps as shown in Figure 2.2. Hook the two chassis L- brackets over

the frame between the two body mount brackets on the passenger side of the truck. Place

the threaded end of the wire cable through one of the slotted holes in the backing strap and

feed the cable over the frame rail with the backing strap on the inside of the frame.

5. Wrap the cable around the L-bracket and frame, then feed the threaded end of the cable

loosely through the lower slotted hole in the backing strap. install the washer and nut.

Repeat this procedure with the second bracket. Leave loose until tank alignment is

completed.

6. Locate the tank and the brackets with the air outlet to the rear, the sight glass and line

connections to the front and in the correct alignment as shown in Figure 2.1.

7. Install the front end of the tank 5” back from the rear most part (support plate) of front cab

mount.Adjust the position of the tank so that it clears the cab mounts and so that there is

sufficient room to attach the hoses. Make sure that the tank alignment is correct (Figure

2.1), then tighten the wire mount cables, making sure that the cables rest against the guide

bar. Bend the exhaust heat shield clear of the cable ends to prevent vibration noise.

Figure 2.3 shows the front tank bracket in place and Figure 2.4 shows the rear tank bracket

in place. Figure 2.5 shows another view of the tank and brackets.

Mounting nuts, flat washers and lock washers

L-bracket

Tank clamp

Clamp tightening bolt

Cable guide

Backing strap

Wire cable

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Vmac 9034 Installation guide

Brand: Vmac

Model: 9034

Category: Engine

Type: Installation guide

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Vmac 9034 Installation guide

Vmac 9034 Installation guide

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