Installation Manual
For The
System #9018
UNDERHOOD AIR COMPRESSOR
1999 NAVISTAR INTERNATIONAL
Cummins ISB M11 Engine
TEL: 250-754-6997
FAX: 250-754-6972
TOLL FREE: 800-738-8622
1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3
DOCUMENT 19250
Installation Manual
VR7000 Underhood Air Compressor
System Number 9018
Application: 1999 Navistar International equipped with the Cummins ISB
M11 Engine
Publication Date: January 1, 1999
Origination Documents: #19250a - introduction
#19252 - compressor installation
#19253 - tank and line installation
#19254 - throttle commander installation
#19255 - control unit installation
#19256 - illustrated parts list
#19130 - warranty registration
Copyright 1998
The contents of this manual may not be reproduced in any form without the express
written permission of VMAC
General Information
System #9018
1999 NAVISTAR INTERNATIONAL
Cummins ISB M11 Engine
UNDERHOOD AIR COMPRESSOR
DOCUMENT 19250a
General Information
Introduction
This book provides installation instructions for:
VMAC underhood air compressor installation kit
VMAC Throttle Commander
This kit has been designed for:
1999 Navistar International equipped with a Cummins M11 engine.
Installation steps
The installation procedure in this manual has four main steps:
Part 1: Installing the Compressor
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)
NOTE
WARNING
!
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.
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 under-hood 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
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
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.
Changes and improvements
These products and documents are subject to changes or improvements without notice.
Part 1
Installing
the Compressor
System #9018
1999 NAVISTAR INTERNATIONAL
Cummins ISB M11 Engine
UNDERHOOD AIR COMPRESSOR
DOCUMENT 19252
Part 1: Installing the Compressor
1.1 Preparing for installation
1. Disconnect the batteries.
2. Drain the coolant.
3. Remove the tube which crosses over the top of the engine and connects the inter-
cooler to the turbocharger inlet.
4. Remove the air conditioning compressor. Lift it upward and set it on top of the
engine.
WARNING
!
5. Remove and discard the air conditioning compressor mounting bracket.
6. Remove the OEM serpentine belt.
7. Remove the five (5) OEM fasteners which retain the crankshaft pulley and harmonic
balancer and discard them. Remove and discard the 8
3″ thick spacer washer from
behind the fasteners.
8. Remove the lower radiator hose and clamps. Keep them for later installation.
9. Remove and discard the cast aluminum lower radiator hose-to-engine block inlet and
support bracket on the right side of the engine. Discard the two (2) M10 hex head cap
screws, the M8 hex head cap screw and the bracket.
10. Remove the engine oil filter. Cover the filter to prevent contamination if you will be
reinstalling the same filter.
11. Remove and discard the four (4) OEM hex head cap screws which secure the engine
dipstick tube support plate to the right-hand side of the engine.
12. Remove the power steering reservoir from the support bracket. Keep the OEM
fasteners.
13. Drain the oil from the power steering reservoir.
14. Remove and discard the ½″ oil hose from the reservoir to the steering box. Remove
the ¾″ hose from the reservoir, but do not discard this hose.
Do not disconnect the air conditioning lines.
15. Remove the ½″ NF cap screws holding the radiator and firewall tie-rod bracket to the
frame on the left-hand side.
16. Remove the 16
5″ NC nuts from the bracket holding the radiator tie-rod to the left-hand
side of the radiator.
17. Swing the tie-rod bracket away from the frame, remove and discard the power
steering reservoir mounting bracket and support plate from behind the tie-bar mount-
ing plate on the frame rail.
1.2 Installing the compressor oil cooler
1. Apply Loctite to the four (4) M10 × 30 mm hex head cap screws supplied with the
installation kit.
2. Attach the VR7000 cooler to the engine block over the dipstick tube support plate
using these hex head cap screws. Torque them to 45 ft-lb.
3. Push the supplied 2½″ × 6″ long coolant hose onto the 90° elbow. Place an HS4 hose
clamp over this connection and tighten the clamp. Slip the second HS4 clamp over
the hose, but leave it loose at this time.
4. Push the other end of the 2½″ × 6″ long coolant hose on the rear fitting of the oil
cooler.
5. Attach the supplied 90° flange elbow to the engine where OEM aluminum housing
for the lower radiator hose was originally mounted. The 90° elbow must point to the
rear (Figure 1). Use the supplied gasket, a suitable gasket sealant and two (2)
supplied M10 × 25 mm socket head cap screws. Torque the fasteners to 45 ft-lb.
Figure 1
Oil Cooler
Line Fittings
Lower Radiator
Hose Fitting
Gasket
Replacement Fitting
For OEM Aluminum
Must Point Rearward
Connecting Hose
HS44 Clamps
6. Slide the second HS4 clamp into position over the cooler connection and tighten the
clamp.
7. Install the OEM lower radiator hose to the cooler inlet. Tighten all hose clamps.
8. Install the oil filter. If you are using a new filter, fill it with clean, OEM recom-
mended oil before installation.
9. Fill the cooling system to the correct level using OEM recommended coolant and
check for leaks.
1.3 Installing the compressor
NOTE
1. Install the main mounting bracket for the VR7000 to the side of the timing cover
using the eight (8) threaded holes shown in Figure 2.
Make sure that the surfaces that the main mounting bracket will contact are clean and
free of contaminants or debris. If the mounting bracket does not seat correctly
against the timing cover or engine block, the compressor and crankshaft pulleys will
not align correctly.
2. Thread the two (2) M10 × 35 mm hex head cap screws into the two holes on the side
of the engine block (Figure 3). Use 8
3″ flat washers behind the cap screws.
3. Thread four (4) M10 × 35 mm hex head cap screws in the four (4) threaded holes
originally used to mount the OEM air conditioning compressor mounting bracket
(Figure 3). Use 8
3″ flat washers behind the cap screws.
4. Thread two (2) M10 × 35 mm hex head cap screws into the two holes on the rear of
the timing cover (Figure 3). Use 8
3″ flat washers behind the cap screws.
Figure 2
OEM Air Conditioning
Compressor Mounting
Bracket Holes (4)
Timing Cover
Threaded Holes
(
2
)
Cylinder Block
Threaded Holes
(
2
)
5. Torque the cap screws which thread into the cast engine block to 45 ft-lb. Torque the
cap screws which thread into the aluminum timing cover to 35 ft-lb.
Figure 3
1.4 Installing and mounting components
1. Install the VR7000 pulley over the OEM pulley and harmonic balancer. Align the
mounting holes.
2. Apply Loctite and install five (5) M14 1.5 × 80 mm hex head cap screws. Torque
them to 145 ft-lb.
3. Install the VR7000 pressure regulator to the mounting bracket using the supplied
fasteners (Figure 4). Tighten the fasteners.
4. Fit the VR7000 belt tensioner to the front of the mounting bracket using the M12 × 80
mm hex head cap screw (Figure 4). Apply Loctite and torque it to 80 ft-lb.
NOTE
5. Remove the ½″ × 1¼″ UNC flange lock bolt securing the back idler to the bottom of
the mounting bracket. Apply Loctite and torque to 117 ft-lb. Be careful not to lose
the aluminum spacer that fits over the lock bolt and into the center of the idler.
If the VR7000 belt tensioner is already fitted on the mounting bracket, remove it,
apply Loctite to the M12 × 80 mm hex head cap screw and torque it to 80 ft-lb.
M10 x 35 (4)
M10 x 35 (2)
M10 x 30 (2)
Figure 4
6. Install the OEM 8-rib drive belt as shown in Figure 5 and tension it to manufacturer’s
specifications.
Figure 5
OEM Air Conditionin
g
Compressor
Mounting Holes
VR7000 Compressor
Mounting Holes
VR7000 Mountin
g
Bracket
Hole For 1/2“ NC Air Conditionin
g
Ad
j
uster Bolt
VR7000 6-Rib Belt Tensioner
Tensioner Mounting Bolt
Mount Regulator Here
VR7000 Back Idler
Back Idler Mountin
g
Bolt And Spacer
Harmonic Balancer
Fan Pulley
OEM Tensioner
OEM Crankshaft
Pulley
7. Install the OEM air conditioning compressor to the top of the VR7000 bracket using
the OEM fasteners. Thread two fasteners into the front slots in the bracket on the
engine side of the air conditioning compressor and two fasteners into the slots on the
outside of the bracket.
NOTE
8. Install the supplied V-belt on the air conditioning and engine drive pulleys.
9. Install the OEM ½″ NC adjuster bolt and locking nut to the under-side of the air
conditioning compressor base-plate and adjust the drive belt to OEM specifications.
10. Torque all air conditioning fasteners to OEM specifications.
WARNING
!
11. Fit the VR7000 compressor to the mounting bracket. Apply Loctite to three (3)
M8 × 25 mm hex head cap screws, install them and torque them to 25 ft-lb.
12. Install the supplied 6-rib VR7000 drive belt over the crankshaft pulley, VR7000
compressor pulley and the VR7000 tensioner (Figure 6). Check alignment of the
pulleys and belt using a straight edge.
NOTE
Do not tighten these fasteners at this time.
These fasteners are threaded into aluminum. Over-tightening will damage the
aluminum threads.
If the pulleys and belt do not line up correctly, check the installation of the mount-
ing bracket. If the fasteners have not been tightened properly or if the bracket has
not been installed flat against the timing cover, the pulleys will not align correctly.
Figure 6
Harmonic Balancer
VR7000 Compressor Pulley
VR7000 Tensioner
VR7000 Back Idler
VR7000 Crankshaft
Pulley
1.5 Installing the power steering bracket
1. Swing the tie-rod bracket away from the frame rail and insert the supplied power
steering bracket underneath the tie-rod bracket.
2. Swing the tie-rod bracket back into place, align the holes and install the ½″ NF cap
screws back into the frame, through both brackets.
3. Align the radiator tie-rod bracket with the holes in the radiator frame and install the
8
5″ NC nuts.
4. Torque all fasteners to OEM specifications.
1.6 Installing the power steering reservoir
1. Attach the power steering reservoir to the VR7000 bracket so that the OEM
clamp-style mounting bracket sandwiches the VR7000 bracket.
2. Secure the reservoir with the OEM fasteners and torque them to specifications.
3. Install the supplied ½″ hose and clamps between the reservoir and the steering box.
Tighten the clamps.
4. Remove 3/4" power steering hose from the steering box and reservoir.
5. Install the 3/4" replacement hose with elbow.
6. Tighten all hose clamps.
7. Refill the reservoir with the OEM recommended fluid.
8. Install the tube which connects the intercooler to the turbocharger inlet.
9. Make sure that the tube clears the air conditioning compressor and all other items
before tightening the clamps.
Figure 7 shows the general assembly. Figure 8 shows a close-up view of the new power
steering bracket installation behind the tie-rod bracket on the frame.
Figure 7
Figure 8
Pressure Regulator
Power
Steering
Reservoir
VR7000
Power
Steering
Bracket
VR7000
Power
Steering
Hose
Frame Tie-rod Bracket
Radiator
Tie-rod
Radiator
Tie-rod
Bracket
VR7000 Air
Compressor
VR7000
Mounting
Bracket
OEM Air Conditioning Compressor
Radiator
Tie-rod
OEM
Tie-rod
Bracket
Frame
VR7000
Power
Steering
Reservoir
Bracket
OEM Cap
Screws
Part 2
Installing the
Air Tank and Lines
System #9018
1999 NAVISTAR INTERNATIONAL
Cummins ISB M11 Engine
UNDERHOOD AIR COMPRESSOR
DOCUMENT 19253
Part 2: Installing the Air Tank and Lines
2.1 Installing the air tank
1. Install the tank brackets to the frame rail using the rear exhaust hanger support bolts
(Figure 9). The front bracket is part #12173 and the rear bracket is part #12174.
2. Attach the tank assembly to the brackets with the oil level window facing forward and
with the drain plug at the bottom. Make sure that the tank is installed in the correct
position by checking the “THIS WAY UP” arrow at the oil level window. Tighten the
straps.
2.2 Connecting preliminary air and oil lines
NOTE
1. Install the oil and air lines between the components shown in Figure 10 according to
the following steps. Route all air and oil lines along chassis rail so that they are clear
of all moving parts, heat sources and sharp objects. Retain the lines using the
supplied stainless steel tie wraps and chassis clips.
For information about the location of the lines on the components, refer to the
diagrams within this section.
Figure 9
The lines from the tank to the other components have been designed with extra length
to accommodate different situations and applications. Excess line can be stored
under the cab, along the top of the transmission.
Tank Mount Brackets
Attached with Exhaust
Supports
Frame
Front Bracket
Part #12173
Rear Bracket
Part #12174
Figure 10
2. Connect the end of the ¾″ × 136″ main air line (part #17229) with the ¾″ JIC 45°
swaged fitting to the matching top fitting on the air tank at location 1 (see Figure 16).
Route the line along the frame, under the cab and connect the other end to the match-
ing fitting on the back of the compressor (Figure 11).
Figure 11
1
1
6
6
22
33
4
55
4
Main Air Line
Part #17229
Air Pressure Control Line
Part #17228
Oil Scavenge Line
Part #17221
Oil Return Line
Part #17227
Cooler-Compressor Line
Part #17222
Compressor Control Line
Part #17223
OIL COOLER
TANK
REGULATOR
COMPRESSOR
Wire Harness
OIL LEVEL
(
ch eck cold
)
MAX
ADD
THIS
WAY
UP
IMPORTANT
UP
Tank
Compressor
1
3/4” x 136” Main Air Line
Part # 17229
4. Connect the ½″ SAE 90° swaged fitting on the ½″ × 43″ cooler-compressor line
(part #17222) to the matching fitting on the bottom of the compressor at location 5
(see Figure 16). This line can be secured to the cross-member in front of the engine
and then attached to the front fitting on the oil cooler (Figure 12).
Figure 12
5. Connect one end of the ½″ × 151″ oil return line (part #17227) to the matching lower
fitting on the air tank at location 4 (see Figure 16). This line can be routed under the
engine, behind the sump and then attached to the rear fitting on the oil cooler (Figure
13).
Figure 13
Oil Cooler
Tank
Compressor
5½ x 43 Cooler-Compressor Line
Part #17222
Oil Cooler
Tank
Compressor
4½ x 151 Oil Return Line
Part #17227
6. Connect one end of the ¼″ × 151″ air pressure control line (Part #17228) to the upper
outside fitting on the tank at location 2 (see Figure 16). Route the line along the
frame, under the cab and attach the other end to the matching fitting on the regulator
(Figure 14).
Figure 14
2.3 Adding oil to the system
1. Make sure that the vehicle is level.
2. Remove the four (4) M8 socket head cap screws which retain the air inlet control
valve (Figure 15).
Figure 15
Oil Cooler
Tank
Pressure Regulator
Compressor
2
¼ x 151 Air Pressure Control Line
Part #17228
M8 Socket Head Cap Screws
Air Inlet Control Valve
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