Vmac V900047 Installation guide

Installation Manual

For The

System #V900047

UNDERHOOD AIR COMPRESSOR

1999-2000 FORD SUPER DUTY F250-F550

7.3 L 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 1900585

Installation Manual Document 1900585

VR70 Underhood Air Compressor

System Number V900047

Application: 1999-2000 Ford Super Duty F250-F550 7.3 L Power Stroke Diesel

Publication Date: February 2000

Origination Documents: #1900585 - introduction

#1900585a - General information

#1900586 - Installing the compressor and oil cooler

#1900587 - Installing the air tank and lines

#1950088 - Installing the control components

#1900588a- Installing the throttle commander

#1900589 - illustrated parts list

#1900130 - warranty registration

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

Registered Trademarks:

VR70, 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.

Contents

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

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

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

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

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

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

PART 1: INSTALLING THE COMPRESSOR AND OIL COOLER ...........................9

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

1.2 INSTALLING THE OIL COOLER ......................................................................................14

1.3 INSTALLING AND MOUNTING COMPONENTS .......................................................................15

1.4 INSTALLING THE COMPRESSOR ....................................................................................17

PART 2: INSTALLING THE AIR TANK, FILTER AND LINES ...............................19

2.1 INSTALLING THE TANK BRACKETS AND TANK ....................................................................21

2.2 INSTALLING THE REMOTE OIL FILTER ..............................................................................25

2.3 CONNECTING THE AIR AND OIL LINES ............................................................................27

2.4 ADDING OIL TO THE SYSTEM ......................................................................................30

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

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

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

PART 4: INSTALLING THE THROTTLE COMMANDER .......................................35

4.1 INSTALLING THE THROTTLE COMMANDER ........................................................................37

4.2 ATTACHING THE WHITE WIRE ......................................................................................38

4.3 CONNECTING THE WIRING .........................................................................................40

4.4 COMPLETING THE INSTALLATION ..................................................................................43

ILLUSTRATED PARTS LIST ..................................................................................45

WARRANTY REGISTRATION .................................................................................51

1

2

General Information

System #V900047

1999-2000 FORD

SUPER DUTY F250-F550

7.3 L POWER STROKE DIESEL

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 1900585a

4

General Information

Introduction

This book provides installation instructions for:

VMAC underhood air compressor installation kit

VMAC Throttle Commander

This kit has been designed for:

1999-2000 Ford Super Duty F250 - F550 7.3 L Power Stroke Diesel

Installation steps

The installation procedure in this manual has four main steps:

Part 1: Installing the Compressor

Part 2: Installing the Regulator, Filter, 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.

5

DOCUMENT 1900585a

Installation Notes

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).Always use manufacturers

torque values for OEM fasteners

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

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

Ordering Parts

To order parts, contact VMAC at:

Telephone: 250-754-6997

Facsimilie: 250-754-6972

Office Hours 8:00 AM to 4.30PM Pacific Time

Please quote the VMAC part number, the description and the quantity.

6

DOCUMENT 1900585a

WARNING

✁

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

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 (S/N) must be attached to the vehicle at the time

of installation.

Locate the S/N plate on the drivers side frame member in front of the battery. Drill the two hole

locations using a 7/64” drill bit. Place the S/N plate in position and fix in place with the two #6 pan

head self tapping screws provided.

IMPORTANT

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

ordering of parts. It is important that this S/N plate is affixed to the vehicle.

Changes and improvements

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

7

DOCUMENT 1900585a

8

DOCUMENT 1900585a

Part 1

Installing

the Compressor and Oil

Cooler

System #V900047

1999-2000 FORD

SUPER DUTY F250-F550

7.3 L POWER STROKE DIESEL

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 1900586

10

Part 1: Installing the Compressor and Oil Cooler

1.1 Preparing for installation

1. Disconnect the batteries and remove the battery from the driver’s side box.

2. Drain the coolant from the radiator.

3. Remove the OEM fasteners from the coolant expansion bottle and move it out of the way.

Do not disconnect the hoses from the bottle (Figure 1.1).

4. Loosen the clamps holding the left intercooler tube at the air intake on the engine and at the

intercooler beside the radiator and remove the intercooler tube.

11

Figure 1.1

5. Remove and discard the plastic cover and attaching nuts from the center top area of the

engine (Figure 1.1).

6. Remove the OEM belt

7. Remove the cooling fan and the fan shroud.

NOTE

Removing the cooling fan will provide additional clearance for removing and installing

components.

Remove This Cover

Remove Coolant Expansion Tank

DOCUMENT 1900586

12

8. Disconnect the air inlet horn from the front of the air cleaner and battery box. Leave this

part in place. This is optional for ease of removal and installation. Remove the air cleaner

box and the battery box from the driver’s side of the vehicle (Figure 1.2).

Figure 1.2

9. Remove the alternator from its mount and lay it back on top of the engine. Keep the OEM

fasteners for alternator installation.

10. Remove the power steering pump pulley (noting the position of the pulley on the shaft), then

remove the power steering pump from the bracket. Keep the OEM fasteners for the power

steering pump installation. You will require the correct puller to remove the power steering

pump pulley.

11. Remove the power steering return hose from the power steering pump. Remove and

discard the metal portion of the hose.

12. Fasten the pump out of the way or lay it on the frame. Do not allow it to hang from the

pressure hose.

13. Remove and discard the OEM alternator and power steering pump mounting bracket and

the OEM bracket fasteners (Figure 1.3).

14. 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 1.3).

15. Remove and discard the upper and lower radiator hoses.

Remove The Air Cleaner And Battery Boxes

DOCUMENT 1900586

13

Figure 1.3

16. Exchange the forward right bolt and rear left stud on the aluminum cover at the top front of

the engine (Figure 1.4).

Figure 1.4

Exchange these two fasteners

Front

OEM Alternator And

Power Steerin

g

Pump

Mounting BracketOEM

Fasteners

Cylinder Head

Mounting Area

En

g

ine Block Mount

FRONT

LEFT SIDE

OF ENGINE

Peen Back This Area Of The Cover

DOCUMENT 1900586

14

17. Remove and discard the 12 mm bolt from lower alternator bracket (lower right side of the

engine) and the 12 mm cap screw (lower left side of the engine) which retain the ground

straps (Figure 1.5).

18. Remove and discard the positive battery cable locating bracket from the same area.

Figure 1.5

19. Clean the front of the engine block thoroughly to ensure that there is no contamination in the

areas where the cooling tank and mounting bracket will fit. If the mounting area is dirty, the

bracket will not mount flush, resulting in fouling of the pulley or belt.

1.2 Installing the oil cooler

1. Install the oil cooler on the engine. Insert the supplied M12 x 30 mm hex head cap screws

and 12 mm serrated washer through the ground strap fittings on the drivers side and fasten

the oil cooler in place. Fit the supplied M12x 80 hex head cap screw with the 7/16 flat

washer through the cooler mount strap and the ground strap on the passengers side. Fit to

the lower alternator bracket where the bolt was removed from previosly, tighten both bolts.

Torque the fasteners to specifications.

Figure 1.6

12 mm bolt securin

g

lower alternator bracket

to the engine and holding ground strap

and transmission cooling lines

12 mm hex head cap screw

holding ground strap

DOCUMENT 1900586

M12 x 30 HHCS

M12 x 0 HH C S

To en

g

ine block

To radiator

15

2. Place hose clamps on both hoses. Connect the right side cooler hose to the bottom radiator

outlet (Figure 1.7) and the left side hose to the engine block connection. Tighten all the hose

clamps securely.

3. Fit two (2) 4” lengths of 1/2” rubber hose around the transmission line for protection where

they pass the cooler bracket. Use ties to hold the rubber in position on the lines

Figure 1.7

1.3 Installing and mounting components

1. Install the crankshaft pulley using three (3) supplied M10 x 20 mm socket head cap screws.

Torque them to specifications.

2. Install four (4) 3/8” flat washers on the four (4) supplied M10 x 30 mm hex head cap

screws for the compressor mounting bracket. Apply Loctite to the fasteners.

3. Install the supplied VR70 mounting bracket using the four (4) M10 x 30 mm hex head cap

screws (Figure 1.8). Torque them to specifications.

4. Install the power steering pump to the compressor mounting brackets using the OEM

fasteners.

5. Install the power steering pump pulley. The outer edge of the power steering pump pulley

must be flush with the end of the pump shaft.

DOCUMENT 1900586

Lower radiator hose

Hose to

engine

block

1/2 oil line fittings

16

Figure 1.8

6. Install the alternator onto the compressor mounting bracket using the OEM fasteners.

NOTE

7. Insert the supplied hose barb into the power steering rubber return hose which is attached

to the brake booster.

8. Install the supplied 3/8” x 11” power steering return hose on the other end of the hose barb.

9. Install one of the OEM hose clamps on the end which will attach to the power steering

pump fitting. Install the hose on the pump.

10. Re-align the power steering hoses to clear the steering column.

The alternator must be mounted 180 degrees (upside-down) from the original mounting

position. Rotate the alternator 180 degrees in a counterclockwise direction.

Four (4) M10 x 30

Hex Head Cap Screws

DOCUMENT 1900586

17

1.4 Installing the compressor

1. Apply Loctite to the burred-ends of the three (3) 8 mm studs and thread them in the holes

in the bottom of the compressor. Tighten them securely using two (2) jam nuts.

2. Install the compressor to the mounting bracket using three (3) supplied 8 mm nuts and 5/16

inch flat washers. Use Loctite on these fasteners and torque them to specifications.

3. Remove the M12 x 80 mm hex head cap screw which retains the compressor belt

tensioner. Apply Loctite, install the fastener and torque it to specifications.

4. Remove the 1/2” x 1-1/4” NC hex head cap screw which retains the idler. Apply Loctite,

install the fastener and torque it to specifications.

5. Install the OEM belt. Be sure to use the correct routing.

Figure 1.9

6. Install the VR70 belt. Be sure to use the correct routing (Figure 1.10).

Figure 1.10

VR70

Crankshaft

Pulley

VR70

Tensioner

VR70 Air

Compressor

VR70

Idler

VR70

Drive Belt

DOCUMENT 1900586

Crankshaft pulley

Power steering

Water pump

Alternator

Idler

Tensioner

Air conditioning

Belt Idler Pulley

Generator

7. Install the fan and the fan shroud.

8. Install clamps on the supplied upper radiator hose and fit it on the engine and radiator

fittings.

9. Rotate the hose on the thermostat housing and radiator fitting until the hose clears both the

compressor belt and the fan shroud. Tighten the clamps.

Figure 1.11

18

DOCUMENT 1900586

10. Install the intercooler tube and tighten the clamps. Be sure that the tube clears the back of

the compressor and power steering pump and the bead inside the rubber OEM bellows sits

in the groove properly before tightening the clamps (Figure 1.11).

If the locating rib on the inside of the flexible tube does not seat correctly in the groove on

the intercooler tube, it is possible that the connection will come undone, allowing unfiltered

air into the engine. This can result in engine damage.

NOTE

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Vmac V900047 Installation guide

Vmac V900047 Installation guide

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