System V900063
2002 - 2005 GMC 2500 HD - 3500
6.6L Duramax Diesel
www.vmacair.com
VR70 UNDERHOOD
AIR COMPRESSOR
INSTALLATION MANUAL
VMAC – Vehicle Mounted Air Compressors
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Installation Manual for VMAC
System V900063
General Motors 2002 – 2005 Duramax Diesel
2500 HD – 3500
General Information..................................................................... 3
Before You Start ....................................................................... 3
Special Installation Notes ......................................................... 4
Part 1: Preparing for Installation............................................... 5
1.1 Preparing for Installation................................................. 5
Part 2: Installing the Tank and Hoses....................................... 10
2.1 Installing the Tank and Brackets ........................................ 10
2.2 Installing the Tank Assembly.............................................. 13
Part 3: Installing the Main Bracket and Compressor.............. 15
3.1 Installing the Main Bracket ................................................. 15
3.2 Installing the Cooler............................................................ 18
3.3 Connecting the Hoses ........................................................ 19
3.4 Mounting the Fuel Module and Hoses ............................... 20
3.5 Completing the Installation ................................................. 26
3.6 Adding Oil to the System.................................................... 29
Part 4: Installing the Control Components .............................. 30
4.1 Installing the Components.................................................. 32
4.2 Connecting the In-cab Wiring ............................................. 33
4.3 Connecting the Under-hood Wiring.................................... 33
4.4 Connecting the Power Supply Wire ................................... 36
4.5 Completing and Testing the Installation ............................. 37
Part 5: Finishing the Installation................................................ 38
5.1 Before Starting the Engine Checklist ................................. 38
5.2 After Starting the Engine Checklist..................................... 39
5.3 Setup, Performance Testing and Adjustments................... 40
5.4 System Identification and Warnings................................... 41
5.5 Auxiliary Air Receiver ......................................................... 42
Accessory Products from VMAC............................................... 43
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Installation Manual - Document #1930014
Installation Manual for VMAC System V900063
General Motors 2002 – 2005 Duramax Diesel
2500HD - 3500
Changes and Revisions
Version Revision Details Revised by/date Approved Implemented
00 Original manual IB 10 Feb 2004 SC 23 Apr 2004 23 Apr 2004
a General revisions IB 14 Oct 2004 SM/BC 18 Jan 2005 18 Jan 2005
b Sched. review, minor graphic IB 13 Apr 2005 SC 13 Apr 2005 15 Apr 2005
c Main bracket mount IB 15 Sep 2005 SM 20 Sep 2005 23 Sep 2005
d ECN 06-179 main brkt bolt IB 13 Aug 2006
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 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.
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.
Copyright 2005
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
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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.
You may have to move the tank rearward from the standard position
on your application. If you must move the tank, the lines may be too
short. If this is the case, measure the hose shortfall and order a
Hose Extender Kit. The following table shows the color code used
by VMAC to define the different hose diameters.
Hose Diameter Colour-Coded Label
1/4 inch
5/16 inch
1/2 inch
5/8 inch
3/4 inch
1 inch
Yellow
Orange
Blue
Blue
Green
Green
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Special Installation Notes
The following special tools are required:
• 36 mm 12 point 1/2 inch drive socket for removing the OEM
crankshaft bolt
• crankshaft locking tool (GM #J-44643) or VMAC equivalent
(Part #5900010)
• VMAC crankshaft pin extraction tool (Part #5900076)
The following additional materials are recommended:
• assorted sizes of fireproof protective plastic loom
• assorted lengths of nylon tie-straps
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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 batteries.
□ Drain the coolant.
□ Disconnect the MAF sensor wire from the air cleaner and
remove the complete air intake assembly, complete with rubber
air intake pipe, air ducting and the plastic intake resonator
chamber from the top of the engine.
□ Remove the plastic inner fender liner on the passenger side.
□ Disconnect the hoses from the coolant expansion tank,
disconnect the level sensor connector and remove the tank.
□ Remove the air cleaner base mounting plate and the air cleaner
support bracket.
□ Remove the top radiator hose.
□ On trucks with an automatic transmission, remove the automatic
transmission control module (ATCM) and cover assembly from
the driver’s side of the upper fan shroud. Move the module out of
the way but do not disconnect the wire harness.
□ Remove the upper fan shroud.
□ Remove the fan using the appropriate fan wrench.
□ Remove the passenger side intercooler tube and hoses.
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□ Remove and discard the metal coolant tube between the heater
hose and the lower radiator hose.
□ Remove the bolt securing the oil filler tube to the front of the
intake manifold.
□ Disconnect the fuel inlet and outlet banjos from the fuel
management module, remove the module and move it out of the
way. Remove the rubber washers, plastic spacers, mounting
bolts and banjo fitting seals so they will not get lost.
□ Remove the OEM belt.
□ Remove all wire harness retainers from the OEM alternator
mount bracket.
□ Remove the alternator.
□ Remove the OEM idlers and tensioner from the alternator mount
bracket.
□ Remove the OEM alternator mount bracket.
□ Remove the rock guard from under the front of the truck. Keep
the bolts.
□ Remove the lower radiator hose.
□ Install a crankshaft locking tool, remove the crank pulley bolt and
remove the crank pulley. If you are using the VMAC tool:
• put the socket on the nut
• put the single-pin end of the tool on the front of the pulley with
the locking tool hanging straight down
• put a short extension and long flex-bar on the socket
• turn the engine until the pin on the tool makes contact and the
tool jams against the protruding center-piece of the cross-
member under the front of the engine
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□ Remove the crankshaft pin using the VMAC extraction tool:
• fit the split end of the tool (on the end of the shaft) over the
crankshaft pin and tap downward with the slide-hammer to
make sure that it is seated correctly
• tighten the pinch bolt securely
• use the hammer action of the slider in an upward motion to
remove the pin from the crankshaft
□ Install the replacement crankshaft/harmonic balancer locating pin
and tap it home using a brass drift and a small hammer. Ensure
that the head of the pin is aligned with the crankshaft by twisting
it into position with a crescent wrench (Figure 1.1).
High-strength
crank pin
Figure 1.1
□ Apply a light wipe of oil to the inside of the OEM crank pulley and
install the pulley back onto the crankshaft.
□ On trucks after 2004.5, remove and discard the OEM cast
mounting bracket from the front of the engine.
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1.1.1 Trucks prior to 2004.5
□ Remove the breather hose from between the lower engine block
and the check valve in the bottom of the breather chamber
casting (Figure 1.2).
Breather check valve
Figure 1.2
□ Remove the 8 mm bolt from the cast alternator mounting bracket
that holds the breather tube and wire harness (Figure 1.3).
□ Remove the bolt securing the engine breather hose and steel
pipe from the breather chamber in the cast aluminum bracket
and remove the hose and pipe.
□ Cut the tie wrap holding the loom and breather tube together.
□ Remove and discard the steel breather pipe from the end of the
rubber breather hose.
□ Remove the two nuts from the fuel bleed valve studs.
□ Remove the short fuel outlet hose and angled banjo fitting from
the engine-side fuel rail. Remove the banjo from the hose and
discard the hose.
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Engine breather chamber
Fuel bleed valve studs
8 mm bolt
for breather
tube clamp
Breather tube
Figure 1.3
□ On trucks up to 2004.5, remove the OEM check valve fitted in
the bottom of the casting.
□ Remove and discard the cast mounting bracket.
□ Remove the two OEM studs from the engine block, located
below the alternator mount, that held the OEM bracket in place.
□ Unclip the top of the wire harness plastic channel attached to the
engine fuel rail, carefully lift out the wiring and cut the ties
holding the module-end of the channel.
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Part 2: Installing the Tank and
Hoses
2.1 Installing the Tank and Brackets
The tank will mount to the passenger side frame rail between the two
body mounts (Figure 2.1).
1/4” line
5/16” line
3/4” hose fitting
1/2” hose fitting
C-clamp
Tank strap mount
Tank strap cable
Tube clamp
Oil filter
5/16” nuts and
washer
Tank strap flat bar
Figure 2.1
□ Remove the oil filter from the front of the tank, fill it with
compressor oil, cover it and place it out of the way.
□ Place the tank on a work bench with the front (oil filter end) of the
tank to your left.
□ Remove the two 1/4 inch pinch bolts from the C-clamps. Expand
the clamps slightly, slide them over the front of the tank and
position them about 6 inches from each end of the tank.
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□ 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 pinch bolts into the C-clamps so that the
heads of the bolts face toward you and install the nuts.
□ Rotate the tank so that the directional arrow on the end of the
tank is parallel to the work bench and faces toward you (Figure
2.2), check the distance of each C-clamp from the ends of the
tank and tighten the pinch bolts so that the clamps grip the tank
securely.
Figure 2.2
□ Thread the 1/4 and 5/16 inch fittings on the steel lines to the
matching fittings on the back end of the tank, but do not tighten
the fittings. Route the lines along the top of the tank across the
two C-clamps.
□ Place the two insulated tube clips over the steel lines with the
mounting holes downward and align them with the top C-clamp
mounting holes (Figure 2.3).
□ Apply Loctite and insert 5/16 x 1/2 inch bolts through the clips
and the C-clamp and thread them into the mount brackets.
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□ Center the bolts in the C-clamp slots and tighten them.
Tank strap mount
5/16" tub
e
1/4" tube
Insulated double tube clamp
5/16" x 1/2" bolt
Figure 2.3
□ Apply Loctite pipe thread sealant and install a 90 degree fitting to
the outlet on the tank. Tighten it to about the four O’clock
position (Figure 2.4) for testing, then reposition as required for
operational connections.
Figure 2.4
□ Thread the 1/2 inch 45 degree elbow and the 3/4 inch 90 degree
elbow onto the matching fittings on the front of the tank, but do
not tighten them.
□ Push the insulated tube clips toward the tank to provide
clearance for the mounting cables (Figure 2.5).
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Push forward slightly for cable clearance
Figure 2.5
2.2 Installing the Tank Assembly
□ On 2500 HD models, install the 1/2 inch spacer on each cable
strap and slide them to the stop ends of the cables.
□ Insert the threaded ends of the cable straps through the end hole
on each of the bar straps.
□ Place the bar straps in position on the inside of the frame, one in
front of the transmission cross-member and one behind, with the
cable straps over the top of the frame (Figure 2.6).
□ Lay the tank assembly under the passenger side of the vehicle
and route the 5/16 and 1/4 inch hoses over the top of the body
mount into the engine compartment.
□ Lift the tank assembly and support it in position so the tops of the
two tank strap mounts fit over the top of the frame rail. If there is
an OEM wire harness, make sure that it is outside the mounts
and is not pinched between the mounts and the frame.
□ Wrap the two tank cable straps around the tank strap mounts.
Make sure that they fit in the upper and lower cut-outs of the tank
strap mounts (Figure 2.6).
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Cable must fit
in the grooves
Figure 2.6
□ Insert the threaded end of the cable through one of the lower
holes on the tank strap flat bars. Select the appropriate hole that
best matches the frame of the vehicle.
□ Place a 5/16 flat washer and nut on each tank cable strap and
tighten just enough to hold the tank in place but loose enough to
allow the tank to be positioned along the frame.
□ Slide the tank rearward on the frame to provide clearance for
attaching the hoses.
□ Route the straight ends of the 3/4 inch hose and longest 1/2 inch
hose from the engine compartment over the body mount to the
tank, connect them to the matching fittings on the tank, but do
not tighten.
Make sure that the cable straps are behind the two steel
lines and that no OEM lines or wires are pinched
between the cable and the mount.
!
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Part 3: Installing the Main Bracket
and Compressor
3.1 Installing the Main Bracket
□ Remove the three socket head bolts and remove the belt
tensioner assembly (complete with mounting pad) from the VR
main bracket.
□ On trucks before 2004.5, transfer the OEM check valve from
the alternator cast bracket to the bottom of the VR main bracket.
□ Remove the plastic caps and remove the four M10 x 85 mm low
profile socket head screws from the bracket. Place the bracket in
position on the front of the engine.
Install OEM
back idler here
M10 x 85 mm
socket head bolts
(one behind the VR tensioner
)
Install the OEM
tensioner here
Figure 3.1
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□ Apply Loctite and thread the four M10 x 85 low profile socket
bolts in just enough to hold the bracket in place (Figure 3.1).
Check the fit of the bracket against the engine to make sure that
it fits flat and has no obstructions, tighten the bolts evenly and
then torque them to specifications.
□ Apply Loctite and install the VR tensioner, the OEM belt
tensioner and one OEM back idler (Figure 3.1).
□ Install the alternator.
□ Place the VR crank pulley in position with the two roll pins on
both sides of the counter balance weight of the OEM pulley
(Figure 3.2).
Position the roll pins here
Figure 3.2
□ Apply Loctite and thread the M18 x 100 mm center bolt with
OEM washer into the crankshaft. Install an engine-locking tool
and torque the center bolt to 200 ft-lbs (280 N.m).
□ Install the OEM belt (Figure 3.3) on trucks built before 2004.5; on
trucks after 2004.5, use the replacement belt.
□ Remove the nuts and bolt holding the compressor to the
packaging base.
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OEM ribbed idler
OEM tensioner
Alternator
OEM back idler
A/C
P/S
Fan
OEM crank pulley
Figure 3.3
□ Attach the straight end of the short 1/2 inch hose to the fitting on
the side of the compressor with the hose routed over the top of
the compressor just behind the clutch assembly. Tighten the
fitting.
□ Place the compressor on the mounting bracket, apply Loctite and
install the two nuts and the supplied bolt (shorter than the one
you discarded) to the underside of the compressor. Torque them
to 19 ft-lbs (25 N.m).
□ Install the VR drive belt (Figure 3.4).
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VR70 Tensioner
VR70 Ribbed idler
VR70 Compressor
VR70 Idler
Crankshaft pulley
Figure 3.4
3.2 Installing the Cooler
□ Apply Loctite and attach the cooler to the rock guard, (with the oil
hose connections facing to the rear) using the 5/16 x 1/2 inch NC
bolts, then install the assembly to the vehicle using the OEM
fasteners (Figure 3.5).
1/2” hose
to compressor
1/2” hose from tank
Figure 3.5
□ Remove and discard the coolant fill hose plastic alignment clips
from the OEM lower radiator hose.
□ Cut the lower radiator hose to length (Figure 3.6). The third cut
may vary slightly according to vehicle model.
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