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Installation Manual
For The
System #9010
UNDERHOOD AIR COMPRESSOR
1995.5-1997 FORD F250 HD - F350, Super Duty
7.3 Power Stroke Diesel
TEL: 250-754-6997
FAX: 250-754-6972
TOLL FREE: 800-738-8622
1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3
DOCUMENT 19323
Installation Manual Document 19323
VR7000 Underhood Air Compressor
System Number 9010
Application: F250 HD - F350, F SUPER DUTY 1995.5-1997
7.3 L POWER STROKE DIESEL W/WO AC
Publication Date: October 13, 1999
Origination Documents: #19323a - introduction
#19324 - compressor installation
#19325 - air tank and line installation
#19327 - control unit installation
#19326 - throttle commander installation
#19328 - illustrated parts list
#19130 - warranty registration
Registered Trademarks:
VR7000, VMAC and Throttle Commander are registered trademarks of VMAC.
Ford, Super Duty, F250-F550, Power Stroke Diesel are registered trademarks of Ford Motor
Company
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.
Copyright 1999
The contents of this manual may not be reproduced in any form without the express written
permission of VMAC
General Information
System #9010
F250 HD - F350, F SUPER DUTY 1995.5-1997
7.3 L POWER STROKE DIESEL
UNDERHOOD AIR COMPRESSOR
DOCUMENT 19323a
General Information
Introduction
This book provides installation instructions for:
VMAC underhood air compressor installation kit
VMAC Throttle Commander
This kit has been designed for:
F250 HD - F350, F SUPER DUTY 1995.5-1997
7.3 L POWER STROKE DIESEL W/WO AC
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.
DOCUMENT 19323a
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
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 19323a
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.
DOCUMENT 19323a
Part 1
Installing the
Compressor and Cooler
System #9010
F250 HD - F350, F SUPER DUTY 1995.5-1997
7.3 L POWER STROKE DIESEL
UNDERHOOD AIR COMPRESSOR
DOCUMENT 19324
Part 1: Installing the Compressor and Cooler
1.1 Preparing for installation
1. Disconnect the batteries.
2. Drain the coolant from the radiator.
3. Remove the fan from the water pump.
4. Remove the fasteners from the fan shroud, then remove the fan and shroud from the vehicle.
5. Remove the OEM belt.
6. Remove the lower radiator hose.
7. Disconnect the top radiator hose from the radiator and tuck it back out of the way.
8. Remove the OEM fasteners holding the alternator in place and move it back out of the way.
9. Remove the OEM tensioners and idlers from the alternator bracket.
10. Remove the OEM alternator bracket.
11. Remove the plastic cover from the air inlet on top of the engine.
12. Remove the heater hose and the fitting from the inside of the left cylinder.
13. Remove and discard the plastic battery cable holder from the radiator bulkhead.
14. Remove the radiator from the vehicle.
15. Cut 1 inch from the hose that goes to the bottom of the pressure tank.
16. Cut 3/4 inch from the spigot on the coolant tank at the pressure tank end (Figure 1.1)
17. Cut 6 inches from the hose that runs from the block to the heater.
18. Remove the speed clips from the radiator bulkhead flange.
19. Remove the radiator supports.
20. Remove the OEM fasteners from the crankshaft pulley.
21. Peen the edge of the valve cover flat against the cylinder head in the area where the
compressor mounting bracket will attach. This allows the compressor mounting bracket to
sit flush with the cylinder head surface (Figure 1.2).
DOCUMENT 19324
DOCUMENT 19324
Cut 3/4” from the end
of the spigot
Cut 1” from the end of
this hose
Coolant
expansion
bottle
Figure 1.1
1.2 Installing components
1. Replace the block inlet fitting (Figure 1.2) with the brass hose barb.
2. Install the speed clips that you removed from the bulkhead flange to the radiator flange.
3. Insert the radiator between the flanges and the bulkhead and push it forward as close to the
bulkhead as possible.
4. Fasten the radiator in place using the supplied 8 x 25 mm hex head cap screws. Insert the
caps crews through the bulkhead flange , the 1/4 inch spacer and into the speed clips
(Figure 1.3). Use the OEM bolts in the lower holes.
Peen back this
area of the cover
Cylinder head mounting area
Engine block mount
Replace this OEM fitting
with the supplied brass
hose barb
Figure 1.2
5. Route the heater hose under the wires at the AC cannister. Fit the hose under the cannister
and under the lower point of the windshield washer bottle. Make sure that you do not kink
the hose.
6. Apply Loctite to the three (3) 10 x 20 mm socket head cap screws, install the VR7000
pulley over the OEM crankshaft pulley and insert the cap screws. Torque them to 45 ft-lbs.
7. Install the VR7000 compressor mounting bracket to the engine using four (4) 10 x 35 mm
hex head cap screws and flat washers. Use Loctite and torque them to 45 ft-lbs.
DOCUMENT 19324
8. Feed the battery cables and wiring harness into the space between the compressor plates
and secure them in place with nylon ties or clamps. Make sure that the positive battery
cable passes in front of the coolant bottle hose. You may have to loosen the securing
clamps on the cable and pull sufficient cable throught them to prevent the cable from rubbing
on the compressor bracket.
9. Make sure that the fitting on the bottom of the compressor will point away from the engine
when it is mounted.
10. Install the straight end of the 1/2” x 40” oil retrun hose to the 90 degree fitting on the bottom
of the compressor. Tighten the connection.
11. Apply Loctite to one end of each of the three (3) 8 mm studs and thread them into the
bottom of the compressor, then apply Loctite to the other end of the studs.
12. Install the compressor on the mounting bracket and fasten it in place using the three (3)
8 mm nuts and washers.
13. Install the OEM and VR7000 tensioners and idlers as shown in Figure 1.4. Use Loctite on
all fasteners and tighten them securely.
14. Install the OEM and VR7000 belts as shown in Figure 1.4.
Figure 1.3
OEM back idler
Alternator
Air Compressor
VR7000 Tensioner
VR7000 Ribbed idler
VR7000 Back idler
OEM ribbed idler
OEM Tensioner
VR7000 Pulley
OEM Crankshaft pulle
y
Figure 1.4
Radiator
8 x 25 mm
1/4 Spacer
Speed Clip
Mounting flange
DOCUMENT 19324
1.3 Installing the cooler
1. Remove and discard the two (2) battery 12 mm studs and nuts which retain the ground
straps on the lower left and right sides of the engine. Remove and discard the positive
battery cable locating bracket.
2. Clean the front of the engine block to ensure that the brackets will fit correctly. Install the oil
cooler, complete with attached hoses, to the front of the engine. Slide the short hose on the
cooler over the water pump fitting during installation or remove it and install it later..
3. Fasten the cooler in place (Figure 1.5) using the supplied 12 x 30 mm hex head cap screws
and serrated washers. Use Loctite and torque the fasteners to specifications.
4. Connect the lower cooler hose to the bottom radiator outlet. Tighten all hose clamps
securely.
5. On automatic transmission vehicles, fit 4 inch lengths of rubber hose around the transmission
lines where they pass the cooler bracket and fasten them in place with nylon ties.
HS28 Clamps
HS28 Clamps
To Lower Radiator Outlet
To En
g
ine Block
Connection
Bottom Radiator Hose
Line from expansion
tank
OEM ground straps and
12 x 30 mm HHCS
Figure 1.5
6. Apply Loctite to the threads on the fan spacer and install it on the fan, then apply Loctite to
the water pump and install the fan assembly along with the fan shroud. Secure the battery
cable in front of the radiator using nylon ties.
7. Install the top radiator hose, the hose between the cooler and the expansion tank and all
other components removed in preparation for assembly.
8. Refill the radiator with the OEM recommended coolant to the correct level.
9. Check all clamps, fasteners and fittings to make sure that they are tight. Check all lines and
hoses to make sure that they do not interfere with any hot or moving parts. Check the
alignment of the belts to make sure it is correct.
Part 2
Installing the
Air Tank and Lines
System #9010
F250 HD - F350, F SUPER DUTY 1995.5-1997
7.3 L POWER STROKE DIESEL
UNDERHOOD AIR COMPRESSOR
DOCUMENT 19325
Part 2: Installing the Air Tank and Lines
2.1 Installing the tank
1. Install the tank brackets on the passenger side frame under the cab as shown in Figure 2.1.
Use the supplied hex head cap screws, nuts and washers. Install the brackets through
existing holes in the frame.
Figure 2.2
Front Body Mount
Rear Body Mount
13
2
10 3/4
Ta n k
Figure 2.1
OIL LEVEL
(check cold)
MAX
ADD
THIS
WAY
UP
IMPORTANT
UP
Check Oil
Level Here
1
2
3
4
3/4 JIC Main Air Line
1/4 SAE Pressure Control Line
5/16 SAE Oil Scavenge Line
1/2 SAE Oil Return Line
2. Install the air tank into the brackets and install the supplied hex head cap screws, washers
and nuts in the tank clamp straps.
3. Rotate the tank until it is aligned as shown in Figure 2.2.
WARNING
!
This alignment is extremely important. Improper installation can result in personal
injury, death or damage to the equipment.
DOCUMENT 19325
5/16 x 55” LONG
OIL SCAVENGE
LINE (P/N 17157)
RED POLY TUBE
¼ X 56” PRESSURE CONTROL
LINE. P/N 17158 CONNECTS
HERE
Figure 2.3
4. Use the dimensions shown in Figure 2.1 to properly locate the tank. Tighten the fasteners.
2.2 Connecting the lines
1. Connect the 3/4” JIC swivel end of the main air line between the tank at location 1
(Figure 2.2). Route the hose along the chassis, through the engine compartment and
connect the other swivel end to the fitting on the back of the compressor. Tighten the
connections.
2. Connect the 1/4” hose to the tank at location 2 (Figure 2.2). Route the hose along the same
path and connect it to the side fitting on the regulator block which is attached to the
compressor. Tighten the connections.
3. Connect the straight end of the 5/16” hose to the tank at location 3 (Figure 2.2). Route the
hose along the same path and connect the 90 degree end to the 90 degree 5/16” elbow on
the side of the inlet control valve. Tighten the connections.
4. Connect one end of the 1/2” x 721/2” line to the tank at location 4 (Figure 2.2) Route the
hose along the same path and connect the other end to the the passenger side fitting on the
cooler. Tighten the connections.
5. Connect the end of the 1/2” hose from the bottom of the compressor to the driver’s side
fitting on the cooler. Tighten the connection.
The lines must be installed in the correct locations or the system will not function
properly. In addition, a hazardous situation may develop from oil spray, potential
fire or explosion.
WARNING
!
DOCUMENT 19325
2.3 Adding oil to the system
1. Make sure that the vehicle is level.
2. Remove the filler plug on the air inlet control valve.
3. Pour six (6) litres (1.6 US Gal.) of the supplied compressor oil into the large air intake
opening.
WARNING
!
4. Turn the compressor clutch clockwise with a ratchet and socket using the hex head cap
screw at the center of the compressor clutch.
5. Observe the sight glass at the front of the tank to ensure that the correct oil level is attained.
It is important not to overfill the system.
6. Install the inlet control valve filler plug and tighten it securely.
You must use the supplied compressor oil in this system. Failure to use this
special oil will result in damage to the compressor and will void your warranty.
DOCUMENT 19325
Part 3
Installing the
Throttle Commander
System #9010
F250 HD - F350, F SUPER DUTY 1995.5-1997
7.3 L POWER STROKE DIESEL
UNDERHOOD AIR COMPRESSOR
DOCUMENT 19326
DOCUMENT 19326
Part 3: Installing the Throttle Commander
3.1 Installing the Throttle Commander
1. Fasten the Throttle Commander under the dash, to the right of the steering column (Figure
3.1).
2. Unplug the two (2) cables from the foot pedal assembly and connect them to the Throttle
Commander (Figure 3.2).
Figure 3.1
Foot Pedal Assembly
Throttle Control Unit
Mounting Bracket
Steering Column
Figure 3.2
Connectors From The
Foot Pedal Assembly
DOCUMENT 19326
4. Feed the gray, three-core cable with plug through the steering column boot into the engine
compartment (Figure 3.4). Make sure that the cable is clear of all moving parts.
3. Connect the two (2) Throttle Commander cables to the foot pedal assembly
(Figure 3.3).
Figure 3.3
Figure 3.4
Connectors From The
Throttle Commander
Steering Column
Pressure Sensor Connector
5. Plug the pressure sensor cable from the Throttle Commander into the connector on the
pressure regulator (Figure 3.4).
DOCUMENT 19326
6. Connect the black wire from the back of the Throttle Commander to the parking brake
sensor switch.
7. Connect the red wire from the back of the Throttle Commander to the red wire with the
mating bullet plug at the compressor control panel.
Figure 3.5
104
78
52
26
104
78
52
26
3.2 Attaching the white wire
1. Locate the white wire with the pink stripe at the connector block on the engine side of the
firewall. Connect the white wire to this wire using the provided connector. The white/pink
wire is located at the bottom of the firewall connector near the center (Figure 3.5). This
connection cannot be made inside the cab.
Part 4
Installing the
Control Unit
System #9010
F250 HD - F350, F SUPER DUTY 1995.5-1997
7.3 L POWER STROKE DIESEL
UNDERHOOD AIR COMPRESSOR
DOCUMENT 19327
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