Vmac V900044 Installation guide

Installation Manual

For The

System #V900044

UNDERHOOD AIR COMPRESSOR

1997-2001 FORD E250-E350

TRITON 5.4L V8

W/WOAC

TEL: 250-740-3200

FAX: 250-740-3201

TOLL FREE: 800-738-8622

1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3

DOCUMENT 1900676

Installation Manual

VR70 Underhood Air Compressor

System Number V900044

Application: 1997-2001 Ford E250-E350 with the Triton 5.4L V8 W/WOAC

Publication Date: Revised by S. Large, August / 2002

Publication Number: 1900676

Origination Documents: #1900676a - General information

#1900676b - Installing the air tank and lines

#1900676c - Installing the compressor

#1900676d - Installing the control unit

#1900676e - Installing the throttle controller

#1900676f - Illustrated parts list

#1900130 - Warranty registration

Registered Trademarks:

VR70, VMAC and Throttle Commander are registered trademarks of VMAC.

Ford, Super Duty, E250-E350, 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.

The contents of this manual may not be reproduced in any form without the express written

permission of VMAC

Contents

GENERAL INFORMATION................................................................................................ 3

INTRODUCTION ........................................................................................................................ 5

INSTALLATION NOTES ................................................................................................................ 6

ORDERING PARTS ...................................................................................................................... 7

WARRANTY ............................................................................................................................. 7

CHANGES AND IMPROVEMENTS .................................................................................................. 7

PART 1: INSTALLING THE TANK, OIL COOLER AND FILTER................................. 9

1.1 PREPARING FOR INSTALLATION .......................................................................................... 11

1.2 INSTALLING THE BRACKETS AND TANK ............................................................................... 13

1.3 INSTALLING THE OIL COOLER ............................................................................................ 16

1.4 SPECIAL INSTRUCTIONS FOR 2000 MODELS ........................................................................ 18

PART 2: INSTALLING THE COMPRESSOR AND CONNECTING THE LINES ...... 21

2.1 INSTALLING THE VR70 BRACKET ...................................................................................... 23

2.2 INSTALLING OTHER COMPONENTS ...................................................................................... 23

2.3 RELOCATING OEM COMPONENTS ..................................................................................... 24

2.4 INSTALLING THE COMPRESSOR ........................................................................................... 25

2.5 INSTALLING OTHER COMPONENTS ...................................................................................... 28

2.6 FILLING THE SYSTEM WITH OIL ......................................................................................... 29

2.7 COMPLETING THE INSTALLING .......................................................................................... 30

PART 3: INSTALLING THE CONTROL UNIT ............................................................... 31

3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 33

3.2 CONNECTING THE WIRING HARNESS ................................................................................... 34

PART 4: INSTALLING THE THROTTLE CONTROLLER ........................................... 37

4.1 INSTALLING THE THROTTLE CONTROLLER .......................................................................... 39

4.2 CONNECTING THE CABLE ................................................................................................. 39

4.3 CONNECTING THE POLY TUBES ......................................................................................... 41

ILLUSTRATED PARTS LIST.............................................................................................. 43

WARRANTY REGISTRATION.......................................................................................... 49

1

2

General Information

System #V900044

1997-2001 FORD E250-E350

TRITON 5.4L V8

W/WOAC

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 1900676

4

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.

5

General Information

Introduction

This book provides installation instructions for:

VMAC underhood air compressor installation kit

VMAC Pneumatic Throttle Control

This kit has been designed for:

1997-2001 Ford E250-E350 equipped with a Triton 5.4L V8

Installation steps

The installation procedure in this manual has four main steps:

Part 1: Installing the tank, oil cooler and filter

Part 2: Installing the compressor and connecting the lines

Part 3: Installing the control unit

Part 4: Installing the throttle controller

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)

•W/WOAC -With or without air conditioning)

NOTE

WARNING

!

Installation notes

1. It is important that you complete all the installation steps before operating the system.

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 suggestions 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).

6

STANDARD GRADE 8 NATIONAL COARSE THREAD

Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4

Foot-pounds 9 18 35 55 80 110 170 280

STANDARD GRADE 8 NATIONAL FINE THREAD

Size 3/8 7/16 1/2 5/8 3/4

Foot-pounds 40 60 90 180 320

METRIC CLASS 10.9

Size M8 M10 M12 M14 M16

Foot-pounds 19 41 69 104 174

The above fastener torque values are applicable when Loctite is used .

If the threads are dry add 20% to the torque values.

WARNING

!

WARNING

BEFORE OPERATING THE VR7000 UNDERHOOD AIR

COMPRESSOR SYSTEM ALWAYS MAKE SURE THAT THE

VEHICLE IS IN PARK (AUTOMATIC TRANSMISSION) OR

NEUTRAL (MANUAL TRANSMISSION) AND THAT THE PARK

BRAKE IS FIRMLY ENGAGED.

Ordering parts

To order parts, contact your nearest VMAC dealer.

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 enclosed System Identification Number Plate must be attached to the vehicle at the time of

installation. Locate the plate on the front body support on the passenger’s side of the vehicle

between the radiator mount and the OEM decal (Figure 1) . Drill the two hole locations using a

7/64” drill bit. Place the plate in position and fix in place with the two #6 pan head self tapping

screws provided.

This plate provides information, which allows VMAC to assist in customer inquiries and/

or ordering of parts. It is important that this plate is affixed to the vehicle.

Figure 1 Location of System Identification Number Plate

Changes and improvements

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

7

NOTE

8

Special installation notes

If you intend to use an auxiliary air receiver with this system you must observe the following

installation procedure (Figure 2) . Failure to observe this procedure will result in damage to the

system.

1. The line from the VR70 tank to the auxiliary air receiver must have a one-way check valve

installed to prevent blowback from the auxiliary tank and to prevent moisture from entering

the VR70 tank.

2. The line to the auxiliary tank must not be installed in the bottom of the tank, but must be

installed as high as possible to prevent water from clogging the line.

VR70 Tank

Auxiliary Receiver

One-way check valve

Install the line as high as

possible, NOT on the

bottom of the tank

DOCUMENT 1900613a

Figure 2

Part 1

Installing the

Air Tank and Lines

System #V900044

1997-2001 FORD E250-E350

TRITON 5.4L V8

W/WOAC

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 1900676

10

1.1 Preparing for installation

1. Remove the engine cover from inside

the vehicle.

2. Disconnect the batteries.

3. Disconnect the wiring from the

alternator.

4. Drain the coolant into a suitable

container.

5. In preparation for installation, remove

and keep the following components and

their fasteners for later installation:

• air cleaner

• air intake resonator

• rubber connecting bellows

• air intake ducting

• air cleaner support bracket

• plastic protective cowl from the

throttle body

• top radiator hose

• alternator

• rear alternator bracket

• engine cooling fan

• fan shroud (disconnect the rock

guard to fan shroud clips)

• OEM belt

• ground strap between the rain

channel and the right cylinder

head

• oil filler tube and bracket

11

Part 1: Installing the Air Tank and Lines

Overview of the engine compartment

Throttle body cover and dipstick bracket

Upper hose and alternator removed

12

6 Remove and save the following

components for use if the VR70 system

is removed from the vehicle:

• lower radiator hose (cut off the

clamp from the diverter)

• mounting bracket holding the

multi-pin electrical connector to

the right hand side of the engine

• 10 mm bolt with the 8 mm

studdend end from the top right

location on the timing cover (used

to hold the multi-pin electrical

connector bracket to the engine)

• three (3) 10 x 60 mm cap screws

from the crankshaft pulley

7. Remove the transmission dipstick tube.

Cut off the top mounting bracket (which

attaches to the intake manifold) flush

with the dipstick tube. Grind or file off

any sharp edges.

8. Remove the fasteners holding the plastic

EVR valve in position under the top

right side of the engine compartment

inside the vehicle.

9. Clean the right front area of the engine

so that the VR70 bracket will sit flush

on the mounting areas.

10. Unpack the VR70 mounting bracket,

remove fasteners holding the back and

ribbed idlers to the bracket, apply

Loctite, install the fasteners and torque

them to specifications.

11. Remove the back idler wheel from the

auto belt tensioner on the VR70

bracket.

Lower radiator hose connection

Multi-pin electrical connector attachment

EVP valve mounting to the compartment

Frame rail

Cable clamps

Top frame

clamps

13

1.2 Installing the brackets and tank

1. Install the 3/16 and 1/4 inch steel tube

and line assemblies to the fittings on the

back of the tank. Thread the fittings

securely into place but do not tighten

them yet.

2. Fit the C-clamps to the tank as shown

in the photo on page 14. (upper right)

Front C-clamp is fitted 2 inches from

the front of the tank.

The rear C-clamp is 16 inches back

from the rear edge of the front C-

clamp.

3. Tighten pinch bolts enough to just hold

the clamp in position on the tank. This

is to allow levelling tank when installed.

4. Place the tank mount L-brackets on the

C-clamps and install 5/16 x 1/2 inch

hex head cap screws with a flat washer

into the bottom holes on each bracket.

5. Install the two (2) small insulated

double-tube stainless clamps over the

steel tubes so that they can be fastened

to the two top C-clamp bolts

6. Place each of the insulated line clamps

in place over the C-clamp slotted holes

and insert the second 5/16 x 1/2 inch

hex head cap screws and 5/16 washer.

7. Position the L-brackets approximately

half-way in the C-clamp slots and

tighten the top and bottom cap screws

securely.

8. Tighten the line fittings on the back of

the tank.

9. Make sure that the mounting areas on

the frame are clean, so that the brack-

ets will fit correctly.

Tank straps in position on the frame

Tank retaining cables and upper clips

Insulated double line brackets

14

11. Remove the nuts and washers from the

threaded ends of the cable clamps.

12. Insert the tank rataining cable through

the upper frame rail clip as shown.

(Figure 1)

13. Repeat the above operation for the

second cable and frame rail clip.

Position the tank frame rail clips and

cable clamps in the approximat

positions as shown on the right.

14. Place the tank in position alongside the

vehicle, with the brackets on the tank

facing toward the frame. Make sure

that the tank is in the correct position,

with the two attached lines at the top

and the sight glass facing forward.

15. Feed the flexihose section of the 1/4

inch pressure control line over the

vehicle vacuum tank then over the cab

mount. From inside the wheel well,

route the hose outside of the vehicle

hydraulic brake lines. Route hose up the

right hand side of the engine towards

the front.

17. Move the tank into position against the

frame, with the bent portion of the

mounting bracket on the tank placed

over the top of the frame.

18. Place the front clip on the top of the

frame rail from the inside, with the cable

over the frame, approximately 12

inches back from the transmission

cross-member.

19. Position the front cable so that it fits into

the grooves on the top and bottom of

the mounting bracket on the tank.

20. Insert the threaded end of the cable

clamp into the bottom frame clip.

Back of the tank and the line connections

Tank supported in position

15

21. Place a thick 5/16 inch washer over

the threaded end and then install a 5/16

inch nut to hold the assembly in place.

22. Repeat this procedure with the rear

cable clamp.

23. Position the tank so that the fittings on

the front and back of the tank have

sufficient clearance and tighten the 5/16

nuts on the cable clamps. Then, thread

a second 5/16 inch nut over the first to

act as a lock nut and tighten it in place.

24. If necessary, position the frame clips

for the rear mount so they are aligned

with the mount bracket and tighten the

nut on the cable, then install the lock

nut.

25. Remove the four (4) cap screws and

remove the rock guard from the front of

the tank.

1.3 Installing system hoses at the tank

1. Remove the protective fitting cover

from the main discharge fitting on the

front of the tank and install the 45

degree fitting, but do not tighten it

2. Route the straight end of the 3/4 inch

main discharge line down from the

inside of the vehicle, over the body

mount and follow the same route as the

other two lines.

3. Connect the straight end of the 3/4 inch

main discharge line to the 45 degree

fitting, but do not tighten it yet.

4. Loosen the four (4) 5/16 inch cap

screws holding the tank to the brackets

and raise the tank as high as possible.

Tighten the cap screws securely.

Tank mounted in position

3/4” line routing, right side of the engine

Location of the main discharge fitting

Up Arrow must

be Vertical Unscrew Oil

filter, add a

thin film of

compressor

oil to the

rubber gasket

and refit the

oil filter.

Tighten by

hand

16

5. Align the fittings on the 3/4 inch line and

tighten both the 45 degree adapter and

the line fitting. Ensure that the tank is set

horizontally.

6. Connect one end of the longest 1/2 inch

oil return hose to the lower fitting on the

front of the tank. Tighten the connection

and route the hose up over the cab mount

and along the frame rail to the front of the

vehicle.

1.4 Installing the cooler and filter

1. Remove the four (4) hex head cap

screws from the two (2) sway bar

mount brackets at the front of the

frame.

2. Insert the supplied spacers between

the mount brackets and the frame and

install the replacement cap screws

through the brackets and frame.

Tighten them securely.

3. Fit the cooler assembly into position

under and in front of the radiator (with

the two radiator hose spigots pointing

to the rear of the vehicle) and locate the

two mounting holes on the radiator

supports.

4. Place flat washers on the two supplied

5/16 inch hex head cap screws and

insert them from the back of the

radiator support through the two

mounting holes.

5. Install the cooler assembly onto the

two 5/16 inch cap screws, install flat

washers, spring lock washers and 5/16

inch nuts. Tighten them securely.

6. Place hose clamps on the supplied

lower radiator hose and install it

between the passenger side cooler hose

fitting and the lower radiator hose

fitting. Tighten the hose clamps.

Sway bar spacers installed

Cooler mounted in position

Lower radiator hose installed

17

7. Place hose clamps on the supplied

cooler to diverter hose and install it

between the driver’s side cooler hose

fitting and the diverter. Tighten the hose

clamps.

8. Route the longer 1/2 inch oil return

line along the top of the frame rail and

over the body mount, following the

other three lines. Connect to the cooler

on the passenger side and at the tank

route the hose clear of sharp edge on

the cab mount.

9. Connect the 90 degree end to the

shorter oil return line to the drivers side

connection on the oil cooler. Route this

line around the steering box, up the

inner fender on the driver’s side and

across the engine for connection to the

compressor.

10. Locate any areas where the lines may

abrade or rub and protect them with the

supplied plastic loom.

11. Fasten the lines together with plastic

ties. Use stainless ties to secure the

lines to the frame rail and to the vacuum

reservoir mount.

12. Align the fitting at the cooler end to

clear all obstructions and tighten the

fitting.

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.

Correct tank alignment is extremely

important. Improper installation

can result in personal injury, death

or damage to the equipment.

Cooler to diverter hose installed

Routing the cooler to compressor line

Heater supply hose at the coolant manifold

WARNING

!

18

Temperature sensor on the coolant manifold

Positioning of the adapter block

Routing and protecting the heater hose

1.5 Special instructions for 2000

models

1. Remove the 3/4 inch heater supply

hose from the manifold outlet tube.

2. Remove the fitting from the manifold.

This can be done by using an OEM

fitting puller or by inserting a cap screw

into the fitting and using vise-grip pliers

to remove the fitting. Be careful not to

damage the intake manifold.

3. Apply Locitite 515 to the opening in the

manifold and install the supplied 5/8

inch (16 mm) core plug.

4. Remove the OEM coolant temperature

sending unit at the front of the inlet

manifold next to the thermostat housing.

5. Apply Loctite 592 sealant and install the

supplied heater hose adapter block into

the port of the removed OEM coolant

temperature transmitter.

6. Tighten the adapter and make sure that

final alignment has the 1/2 inch hose

barb facing approximately 45 degrees

to the passenger side from the engine

center line.

7. Apply Loctite 592 to the hose barb

and install it in the adapter block.

Tighten the fitting.

8. Route the heater hose along the intake

manifold (between the intake runners

for cylinder 1 and 3) to the hose barb.

Install the hose on the hose barb at the

adapter block and make sure that the

OEM hose clamp is in place.

9. Apply Loctite 592 sealant and install the

OEM temperature sensor into the fitting

in the hose adapter block. Connect the

electrical harness to the sensor.

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Vmac V900044 Installation guide

Vmac V900044 Installation guide

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