Installation Manual for VMAC System V Ford SuperDuty F250-F L Power Stroke V8

Transcription

1 Installation Manual for VMAC System V Ford SuperDuty F250-F L Power Stroke V8 General Information... 4 Before You Start... 4 Part 1: Warranty and System ID... 5 Part 2: Preparing for Installation Modifying the Passenger Battery Tray Mounting the Vacuum Tank Glow Plug Modules Relocating the ICP Sensor Part 3: Installing the Tank and Hoses Installing the Brackets Installing the Tank Part 4: Installing the Cooler, Bracket and Compressor Installing the Oil Cooler Installing the Crank Pulley Installing the Main Bracket Installing the Compressor Completing the Installation Adding Oil to the System Part 5: Installing the Control Components Installing the Components Connecting the Under-hood Wiring Connecting the In-cab Wiring Completing and Testing the Installation Part 6: Finishing the Installation Before Starting the Engine Checklist After Starting the Engine Checklist Setup, Performance Testing and Adjustments Auxiliary Air Receiver Accessory Products from VMAC

2 Document # Installation Manual for VMAC System V Ford L Power Stroke Diesel Changes and Revisions Version Revision Details Revised by/date Approved Implemented L ECN SL 03 Dec 2008 PD 3 Dec Dec 2008 M ECN SAR 22 Nov 2010 NC 22 Nov Nov 2010 N ECN SH 19 Apr 2011 SM 21 Apr Apr 2011 P ECN SH 21 Aug 2013 SM 26 Aug Aug 2013 Important Information! This symbol is used to call your attention to instructions concerning your personal safety. Watch for this symbol; it points out important safety precautions, it means attention, become alert! Your personal safety is involved. Read the message that follows and be alert to the possibility of personal injury or death. Be alert; your safety is involved. While it is impossible to warn about every conceivable hazard, let good common sense be your guide. This symbol is used to call your attention to additional instructions or special emphasis on a specific procedure. 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.! All hoses, tubes, and wires that are rerouted or shifted during installation must be secure so that they do not contact excessively hot areas or sharp edges. Where possible use rubber coated P-clips. Follow the routing suggestions in this manual and cover all hoses with the supplied plastic loom. 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 that have had other changes without 2

3 additional modifications. If you have difficulty with the installation, contact VMAC. 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 Copyright 2010 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 3

4 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) Newton meter (N m) STANDARD GRADE 8 NATIONAL FINE THREAD Size 3/8 7/16 1/2 5/8 ¾ Foot-pounds (ft-lb) Newton meter (N m) METRIC CLASS 10.9 Size M8 M10 M12 M14 M16 Foot-pounds (ft-lb) Newton meter (N m) Hose Information Depending on other installed equipment, it might be necessary to move the air/oil separation tank from its intended location. The hoses used in VMAC compressor systems have a specific inner liner that is compatible with our compressor oil. Use of hoses other than those supplied or recommended by VMAC will cause compressor damage and will void your warranty. Please contact VMAC for replacement hoses and further information. 4

5 Part 1: Warranty and System ID Complete the warranty form. 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. System Identification and Operating Instructions The System Identification Number Plate must be attached to the vehicle at the time of installation (Figure 1.1). This plate provides information that allows VMAC to assist in customer inquiries and the ordering of parts. Mark and drill two 7/64-inch holes in the top of the cross member behind the passenger-side headlight. Secure the plate with the supplied self tapping screws Clean cross member beside the number plate and stick the VMAC belt routing diagram to the cross member. System ID number plate Left Front Figure 1.1 5

6 As part of the installation process, ensure that the safety and operational instruction decal is affixed in an obvious location so that it can be seen by vehicle operators. A good spot for this is usually on the inside of the door or on the panel underneath the steering wheel. (Figure 1.2) Figure 1.2 6

7 To alert any technicians that may service the vehicle, affix the servicing caution/contact label in the engine compartment near the hood latch in a visible location. Thoroughly clean the selected area before affixing the label (figure 1.3) Figure 1.3 7

8 Part 2: 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. Ensure that you have filled out the VMAC Warranty Registration. Install the System Identification Number Plate and Operational Instruction Decal. (Please see Part 1 for details). Keep all removed and unused OEM items if the truck is to be returned to original equipment. This manual contains specific installation instructions for different model years. Make sure that you read these instructions before beginning the installation and identify the sections that apply to your vehicle. Drain the cooling system, remove the upper and lower radiator hose and disconnect the coolant expansion tank hose from the top of the radiator. Disconnect the batteries and remove the passenger side battery. Remove the plastic air deflector from the upper section of the fan shroud. Keep this part if the vehicle is to be returned to stock condition. Remove the two screws securing the upper section of the fan shroud to the radiator. There are two options for removing the fan shroud (you can remove the air cleaner to make this easier): 8 a. Carefully pry the shroud upward to release the rubber seal from the groove in the stator. Push the top corner of the shroud back to clear the upper hose spigot and pull the shroud out. Be careful not to crack the shroud. b. Locate the molded lines on the fan shroud, one on each side about 6 inches (15cm) down from the top (Figure 2.1). Use a suitable tool to cut the fan shroud between these lines

9 (Figure 2.1). Do not cut the rubber seal. Remove the upper shroud section along with the rubber seal, then remove the lower fan shroud section. Rubber seal Upper shroud Cut along molded line Lower shroud Figure 2.1 Disconnect the fan clutch wiring harness from the fan stator and the fan clutch wiring plug connector. Remove the fan. Remove the rear fan stator (large plastic section with cooling fins behind the fan) and store it for future use if the vehicle is to be returned to stock condition. Remove the four bolts from the water pump pulley and replace them with the supplied low profile head bolts. Remove the OEM serpentine belt. Remove the OEM belt tensioner assembly. 9

10 Remove the intercooler tube on the passenger side and keep the 2-1/2 inch OEM clamps. Discard the intercooler tube, the connecting hose from the intercooler and the two larger T-bolt clamps. Cover the turbo outlet and the intercooler inlet to protect the system. Disconnect and remove the glow plug relay module with the mounting bracket. Detach the module from the mounting bracket, discard the bracket but keep the nuts. Unscrew the engine oil fill tube. Plug the oil filler opening to protect the engine. On automatic transmission models, remove the transmission dipstick from the passenger side valve cover and install the supplied bracket (using the OEM nut) with the spacer facing down and away from the valve cover. Attach the transmission dipstick to the lower spacer of the bracket using the supplied fasteners. Remove the wiring harness retainers from the studs at the front of the valve cover. Cut the tape back far enough so that you can reroute the harness behind the transmission dipstick tube and over the valve cover. Most of the wiring and the glow plug connectors should be behind and below the alternator. Cut off the upper threaded section of the two front valve cover bolts (just below the alternator) flush with the hex nut. Remove the steel heater return pipe with rubber O-ring. Save the O-ring and the M6 bolt. Disconnect the steel pipe from the heater hose and discard the pipe. Install the OEM O-ring onto the replacement heater hose barb connector and install it into the front of the engine where the heater hose pipe was removed (Figure 2.2). Cut a short piece of 3/4 inch hose from the supplied 8 inch piece, fit it onto the hose barb and secure it with a clamp. 10

11 Figure 2.2 Insert the long end of the supplied replacement steel heater pipe into the short 3/4" heater hose and position the short end with the tab along the alternator, pointing toward the firewall. If equipped, remove the sound proofing from the underside of the hood. Remove the plastic clips holding the flexible mud deflectors to the top and bottom of the radiator cross-member. For easier installation of the cooler, remove the bolts from the small power steering cooler in front of the radiator cross-member and leave it loose in position. You can also remove the radiator hold-downs and raise the radiator for better access. Some trucks may have a crossbeam behind the air dam and under the radiator while others may have a crossbeam that also retains the tow-hooks. This can be removed to provide easier oil cooler installation. 2.2 Modifying the Passenger Side Battery Tray Remove the passenger side battery tray. Turn the battery tray over and cut off the fender bracket along the bottom crease of the battery tray (Figure 2.3). 11

12 Figure 2.3 Install the supplied battery bracket to the inner side of the passenger fender using the two OEM M8 bolts (Figure 2.4). Install the passenger side battery tray reversed 180 degrees and fasten it in place with 5/16 x 1 inch bolts with 3/8 inch flat washers and 5/16 inch lock washers and nuts. The battery tray hold-down clamp should face to the rear of the vehicle and the tray should be on a slight angle. Slide the tray as far forward as possible. You may have to trim off some of the plastic web on the windshield washer bottle to clear the edge of the battery tray. 12

13 Battery bracket Figure 2.4 Drill an 11/32 inch diameter hole through the OEM support bracket using an existing hole in the battery tray as a guide. Install a 5/16 x 1 inch bolt with 3/8 inch flat washer and 5/16 inch lock washer and nut. Tighten all fasteners. 2.3 Mounting the Vacuum Tank If the truck does not have air conditioning, you must still relocate the vacuum tank on the plastic fender liner to clear the compressor but will not have to replace the short hose or use the mount bracket. Remove the vacuum tank from the passenger side fender and save the nuts for reinstallation. Disconnect the hoses from the vacuum tank and discard the short hose from the vacuum pump to the vacuum tank. Remove the three bolts mounting the air conditioning receiver/dryer from the heater housing. If necessary, remove the fender liner for better access. 13

14 Carefully bend the forward facing top larger air conditioning line out towards the inner fender until parallel to the fender. Twist on the vertical section while supporting the receiver/dryer canister and push inwards. This can be accomplished using a long pry bar protected where it rests between the two vertical sections of the lines (Figure 2.5). Position the cannister in front of the wiring plug Second bend pull up on the bottom of the cannister toward the front Support first bend by pushing here First bend 14 Figure 2.5 Place the clamp above the electrical connector facing forward Bend the other line by pulling upward and forward on the receiver/dryer canister to provide adequate clearance. Remove and discard the plastic shroud from the receiver/dryer. Remove the bolt and clamping components from the supplied heavy duty clamp and slide the clamp up onto the receiver drier with the open side towards the front of the vehicle, above the electrical connection. Install the clamping bolt in the clamp and through the vacuum tank bracket. Leave the clamp loose enough so that you can adjust the position (Figure 2.5). Remove the front bolt holding the vacuum pump bracket to the passenger side fender. Place the supplied vacuum tank bracket in position over the OEM vacuum pump bracket and install the OEM bolt.

15 Mount the vacuum tank bracket using the original OEM M6 nuts with the hose connections at the bottom, angled at approximately 45 degrees (Figure 2.6). If required, bend up OEM vacuum pump and OEM vacuum pump bracket approximately 20 degrees to clear the air conditioning condenser (Figure 2.7). Figure 2.6 Figure

16 Install the supplied 1/8 inch rubber hose between the vacuum pump and the vacuum tank and connect the other hoses. 2.4 Glow Plug Modules Mount the glow plug module to the supplied bracket using the two OEM M6 nuts so that the module will face toward the center of the engine when the bracket is installed. Install the assembly on the passenger side engine valve cover studs beside the engine oil fill-tube using OEM nuts. Wrap any loose OEM wires with tape and connect the glow plug relays. Make sure that the wire harness is secured behind the alternator where it will not touch the compressor or turbocharger. Install the oil fill tube. 2.5 Relocating the ICP Sensor Keep the flat on the bolt head horizontal Bend the battery tray tab up Figure 2.8 On trucks built after , remove the ICP sensor from the passenger side valve cover. 16

17 ! Check the rubber seal in the valve cover for damage and replace if necessary. Install the sensor in the supplied banjo fitting and torque to 9 foot-lbs. Install the banjo, with copper seal, into the valve cover. Attach the electrical connector, position the fitting so that the sensor points toward the turbo (towards the rear of the truck and up at about a 45 angle), and torque the banjo fitting bolt to 20 ft-lbs.! Make sure that the OEM O-ring is on the sensor and do not lose the copper sealing gasket on the supplied banjo fitting. Make sure that the ICP sensor is properly sealed and tightened to prevent oil leaks, as improper installation and sealing can void OEM warranty. Ensure that the top and bottom flats on the ICP bolt are horizontal. If required, tighten the bolt slightly to make them horizontal. 17

18 Part 3: Installing the Tank and Hoses 3.1 Installing the Brackets For F450 F550 model trucks see the special installation instructions for the rear tank mount. Remove the bolts, washers and nuts from the tank clamps. Lay the tank brackets on a flat surface with the wide flanges away from each other (Figure 3.1). The front and rear brackets are different and are stamped Front and Rear. Upper frame clip Inner tank clamp Spacer (not used on wide frames) 5/16 x 1/2 Lower frame clip Figure 3.1 Insert the cable straps through the upper frame clips and place one cable on each tank bracket with the cables in the grooves. 18

19 Place one inner tank clamp onto the front tank bracket. Apply Loctite to the 5/16 x 1/2 inch hex head bolts (with flat washers) and attach the inner clamp to the front tank bracket. Tighten all the bolts All Trucks Except F450 and F550 Place the inner tank clamp on the rear tank bracket. Apply Loctite and attach the clamp to the bracket using 5/16 x 1/2 inch hex head bolts. Tighten all the bolts. Clean the area on the frame between the two cab mounts on the passenger side and place the front bracket on the frame in front of the transmission cross-member and as far forward on the frame as possible. Place the upper frame clip on the frame rail and make sure the frame seats in the groove. Wrap the cable under the frame, insert the lower frame clip and make sure the frame is seated in the clip. Install a spacer (if necessary) a washer and a nut. Tighten the nut securely (do not over-tighten) and install a second nut as a lock. Place the rear bracket behind the transmission cross-member and as far back as possible. Attach in the same manner as the front bracket. The tank brackets must be positioned far enough apart to provide good support for the tank, but must not be positioned in any location where the tank will not be level when installed F450 and F550 Place spacers on the rear tank bracket as shown in Figure 2.2; 1/2 inch spacers on the top and bottom front holes, 5/8 inch spacer on the top rear hole and a 3/4 inch spacer on the bottom rear hole. Place the inner tank clamp on the spacers, apply Loctite and install 5/16 x 1 inch bolts with washers through the two front holes, 1/2 inch spacers and into the bracket. 19

20 Apply Loctite and install a 5/16 x 1-1/4 inch bolt with washer through the top rear hole, 5/8 spacer and into the bracket. Apply Loctite and install a 5/16 x 1-1/4 inch bolt with washer through the bottom rear hole, 3/4 inch spacer and into the bracket. Tighten all the bolts. 5/8 spacer Rear tank bracket 5/16 x 1-1/4 3/4 spacer 1/2 spacers Inner tank clamp 5/16 x 1 Figure 3.2 Clean the area on the frame between the two cab mounts on the passenger side and place the front bracket on the frame as shown in Figure 3.3. Place the upper frame clip on the frame rail and make sure the frame seats in the groove. Wrap the cable under the frame, insert the lower frame clip and make sure the frame is seated in the clip. Install a spacer (if necessary) a washer and a nut. Tighten the nut securely (do not over-tighten) and install a second nut as a lock. Place the rear bracket on the frame as shown in Figure 3.3 and attach in the same manner as the front bracket. 20

21 Tops will be about 1/4 closer together Figure Installing the Tank Install the front outer tank clamp with both bolts and washers and leave the bolts very loose. Lift the tank and slide it into the front clamp. Install the rear outer tank clamp. Position the tank for sufficient clearance at both ends and rotate the tank until the arrow molded into the rear of the tank is pointing upward. Tighten the clamp bolts. Connect the straight end of the longest 1/2 inch hose to the matching fitting on the front of the tank. Route this hose along the frame rail, over and inside the cab mounting bracket and around the steering idler arm to the front of the vehicle. Do not tighten the fitting. Connect the straight end of the 1 inch hose to the matching fitting on the front of the tank. Route this hose outside the cab mount, up behind the mud guard and fender liner towards the rear of the engine and along the passenger side valve cover. Do not tighten the fitting. 21

22 Part 4: Installing the Cooler, Bracket and Compressor 4.1 Installing the Oil Cooler Model Year Insert M10 x 90 mm bolts into the top of the two mount brackets (Figure 4.1) and place them over the cross-member that runs under the radiator, outboard of each power steering mounting bracket. M10 x 90 mm bolts with washers Mount brackets Spacers Figure 4.1 Place the cooler in position with the threaded fittings facing to the rear of the vehicle (Figure 4.2) and thread the top bolts into the top outermost holes on the cooler mount. Leave the bolts loose enough so that you can move the cooler on the cross-member. Insert bolts into the lower holes and install the spacers. Thread them into the outermost lower holes on the cooler mount. 22

23 To engine To radiator Coolant bypass hose connection 1/2 hose to compressor 1/2 hose from tank Figure 4.2 Cross-member Loosen the clamp on the hoses attached to the cooler. Connect the hose to the lower radiator spigot, adjust for best fit and tighten the clamps. On some models, the hose will interfere with the steering linkage. If necessary, cut some material off the radiator end of the hose to move the hose forward and away from the steering linkage. Install the OEM lower hose between the engine spigot and the cooler and secure it with clamps. Connect one end of the longest supplied heater hose to the spigot on the side of the cooler and secure it with a clamp. Route the hose up to the engine. Connect the 90 degree end of the 1/2 inch hose from the VR tank to the passenger side fitting on the cooler. Do not tighten the fitting. Connect the 90 degree end of the short 1/2 inch hose to the cooler and route it up the passenger side of the engine compartment. Do not tighten the fitting. 23

24 Adjust the cooler as required to provide a good fit with all hoses and tighten the mounting bolts to 2004 Model Years Install the first oil cooler mounting bracket on the lower radiator cross-member on the passenger side (Figure 4.3). Figure 4.3 Install the second bracket: for manual transmissions, on the driver s side of the power steering oil cooler bracket for automatic transmission, on the cross-member between the power steering oil cooler and the power steering oil cooler brackets. Place the cooler in position with the oil fittings to the rear of the vehicle (Figure 4.4). Line up the mounting holes in the oil cooler with the matching holes on the brackets. Apply Loctite to the M10 x 90mm bolts with 3/8 inch flat washers and install them in the matching holes. 24

25 Slide the oil cooler to the passenger side of the cross-member until the top passenger side mounting brackets is positioned where the cross-member begins to angle up. Tighten all fasteners. Figure 4.4 Measure 7-3/4 inches (20 cm) from the engine end of the lower radiator hose around the longest side of the bend. Cut the hose at this point and discard the end that attached to the engine (Figure 4.5). Install the remaining part between the cooler and the engine. Engine 7-3/4" Figure

26 Turn the steering until it reaches full right hand lock and check the clearance between the hose and the steering arm. Adjust the hose as required to clear. Install the radiator and connect the transmission cooling lines. Loosen the clamp on the remaining cooler hose, connect it to the lower radiator spigot, adjust for best fit and tighten both clamps. 4.2 Installing the Crank Pulley Clean the face of the OEM pulley, install the VR pulley, align the bolt holes and ensure that the pulley is sitting flush. Apply Loctite, install three M10 x 70mm bolts and flat washers and torque to specification. 4.3 Installing the Main Bracket Due to vehicle assembly variations, the rear right corner of the main bracket may interfere with the right hand rocker cover. Make sure that there is clearance between the bracket and rocker cover before tightening down the bracket. If necessary, grind a small amount of material off the bracket where the interference exists until adequate clearance is achieved. Remove the idlers, idler mount bracket and tensioner from the main bracket. Mount the main bracket to the right-hand side of the engine using three M10 x 55mm flange lock bolts (with Loctite) in the two upper holes and one in the lower outer-most hole. Check to make sure that the bracket is not interfering with any OEM parts. Route the A/C compressor wiring harness behind the bracket. Make sure it is not pinched by the bracket. Install the M10 x 35mm flange head bolt into the lower innermost attachment point (Figure 4.6) and torque to specifications. Install the OEM belt tensioner. 26

27 Install the OEM 8-rib belt (Figure 4.7). M10 55mm M10 35mm Figure 4.6 Figure 4.7 Install the idler mount bracket to the main bracket using three M8 x 25 mm hex head bolts and install the idler (Figure 4.8). Install the VR tensioner assembly to the main bracket. 27

28 Smooth idler Spacer 1/2 1-1/4 inch Tensioner M10 80mm M8 25mm Idler mount bracket Ribbed Idler Spacer 1/2 1-1/4 inch Figure 4.8 Tensioner pin locates here Install the remote idler brace assembly and 8-grooved idler (Figure 4.9) to the machined location on the coolant return section of the coolant manifold just above the fan pulley using an M10 x 110 mm bolt with spacer and a supplied bolt. Tighten to specifications Install the remote mounted 8-groove idler with the supplied stub and spacer to the machined stub on the front coolant manifold casting on the front of the engine, slightly down and to the driver side of the fan pulley, using an M10 x 110 mm bolt (Figure 4.10). Tighten to specifications 28

29 Remote idler brace Supplied locating bolt Idler pulley Spacer M10 x 110 mm bolt Figure 4.9 Idler stub Idler pulley Spacer M10 x 110 mm bolt Figure

30 4.4 Installing the Compressor Place the compressor in position on the main bracket. Check the air conditioning lines to make sure they do not touch the compressor and adjust as necessary to provide about one inch clearance between the compressor and the air conditioning lines. Route the straight end of the short 1/2 inch hose from the oil cooler up the front of the passenger side of the engine, clear of moving components and tie it to the passenger side post on the VR bracket supporting the idler mounting bracket. Connect the 1/2 inch hose onto the elbow fitting on the compressor and tighten the connection. Connect the 45 degree swivel fitting of the 1 inch hose to the fitting on the back of the compressor. Route the hose along the valve cover. Angle the 45 degree connector inwards to allow clearance for all OEM components. Tighten the connection using two wrenches to prevent hose twist. Make sure that no part of this hose is higher than the center of the compressor, as oil trapped in the line can flood the compressor and cause damage on startup. Remove the inlet control valve from the compressor. Immediately cover the opening to protect the compressor. Install two M8 x 110 mm socket head bolts through the passenger side compressor mounting holes and thread them into the main bracket. Remove the two OEM mounting bolts from the passenger side of the alternator. Place the supplied brace on the alternator and thread the alternator bolts back into place but leave them loose (Figure 4.11). Install the small diameter spacer under the front hole of the support brace and insert an M8 x 140 mm bolt through the brace, the spacer the front driver side compressor mount hole and thread it into the main bracket. 30

31 Install the large diameter spacer under the rear hole of the support brace and install an M10 x 50 mm bolt through the bracket and spacer. Thread it into the compressor housing. Tighten the three bolts holding the compressor to the bracket to specifications. Compressor Alternator Figure 4.11 Align the tab on the steel heater tube with the small hole in the brace bracket and insert the 1/4 inch NC bolt. Install the inlet control valve and tighten the bolts to specifications. Tighten the OEM alternator bolts and the remaining VR bolt to specifications. Insert the 3/16 and 1/4 inch tubes into the fittings on the back of the tank and cover them with high temperature loom. Route them above the front cab body mount, up inside the wheel well and inner fender towards the rear of the engine valve cover around the outside of the oil fill tube. Connect them to the matching fittings on the inlet control valve on the compressor. 31

32 Exhaust Manifold Oil Tube Dipstick Lines From Air End P-Clamp on Firewall Exhaust Figure 4.12 View from below Install the Supplied P-clamp on the firewall to hold the discharge hose and poly lines away from hot components (See Figure 4.12). The 3/16 inch line can be routed to the connection at the inlet control valve from the rear of the compressor, but if this routing may result in hose damage, rotate the fitting on the inlet control valve until it faces the front of the compressor, then route the line around the front of the inlet valve. 4.5 Completing the Installation Cut a 2 inch length of 3/4 inch heater hose then push it onto the plastic tee and the steel heater tube. Connect the OEM heater hose to the tee (Figure 4.13) and tighten all clamps. OEM hose Tee fitting 32 Short hose Figure 4.13 Long hose to cooler

33 Route the long heater hose from the oil cooler up to the top of the engine and connect it to the Tee fitting. Clamp the connection. Make sure that the hose is properly secured so that it does not contact any hot or moving parts and will clear the OEM belt. Install the compressor drive belt (Figure 4.14). Install the fan spacer washer, then install the engine fan. If you removed the fan shroud in one piece, place it in the lower positioning holes and install the top bolts. Figure 4.14 If you cut the shroud at the marked lines: place the lower half in position and locate it in the lower positioning holes install the upper half of the fan shroud and slip the shroud rubber seal onto the lower half of the shroud as it is being lowered attach the top shroud to the radiator using the original OEM bolts install the four supplied self tapping screws into the holes on each side of the shroud where it was cut. 33

34 Remove the front driver s side air intake bolt and install the fan wiring harness bracket over the adjacent stud (Figure 4.15). Install the air intake bolt through the fan wiring harness bracket and the supplied nut onto the OEM stud. Tighten all fasteners. Reposition the wiring harness to provide more wire length and insert the fan wiring harness moulded connector into the bracket and tie strap in position using two ties. Make sure that the fan wiring is well clear of the fan and other moving components.! Adequate clearance between the fan and plastic harness is important as the fan will flex forward during operation. Fasten with bolt on air intake Fan wire harness fits in this holder Fit over stud on front of intake Figure 4.15 Connect the upper radiator hose and the coolant expansion tank hose to the radiator and secure them with clamps Installing the Intercooler Tube Loosen the nut holding the positive wire on the back of the alternator. Rotate the wire so it is pointing down. Tighten the nut. Disconnect the 1/4 inch coolant hose from the engine beside the alternator. Cut 3/4 of an inch from the end of the hose and reattach. 34

35 Remove the driver s side alternator mounting bolt and install the supplied intercooler tube securing bracket under the bolt. Make sure that the elbow, the intercooler tube, the clamps and the turbocharger connections are clean and dry. Any oil on the components will cause the fittings to come apart. If the intercooler tube connections are not installed and tightened correctly, they will blow off during operation. Prior to installing the VMAC supplied intercooler tube and OEM blue silicon elbow on the engine, fit the elbow to the VMAC tube and make sure that the internal rib of the elbow fits properly into the groove on the intercooler tube. Mark the position on the intercooler tube. Also mark the location of the internal rib on the outside of the elbow so you can accurately position the clamp. Remove the staples holding the clamp on the turbocharger end of the elbow. Install the intercooler tube and adjust the elbow for best fit. Mark this position on the elbow, intercooler tube and turbocharger. Also mark the new position for the clamp. If necessary, cut about 1 inch from the end of the coolant hose on the manifold from the coolant tank (directly under the intercooler tube) to allow more clearance for the intercooler tube. Position the clamps so that the center of the clamp is directly over the internal rib. The OEM blue silicon elbow has a white line on one end to indicate clamp position. Note the location of this line in reference to the bead Fasten both clamps to the elbow using staples or small poprivets (Figure 4.16). This will ensure that the elbow will not slip out from under the clamps during high turbo pressures. If you use staples: 1. Use the existing holes in the OEM clamp or drill small holes through the clamp to match the width of a standard 1/2 inch staple. Drill three locations around the clamp. 35

36 2. Insert the staples into the clamp and press them through the blue silicon elbow using needle-nose pliers. If you have difficulty pushing the staples through, make a pilot hole using a small sharp object, such as a nail or pick. 3. Securely crimp the staple on the inside of the elbow so that it begins to embed in the material of the duct If you use pop-rivets: 1. Drill two holes in the clamp and elbow opposite the T- bolt. 2. Remove the nut and spring; open the clamp to permit access for a pop-rivet tool. 3. Insert the pop-rivets from the inside and fasten them in place. The pop-rivet head should embed slightly in the material of the duct. Install the supplied 90 degree 3-1/4 inch silicon rubber elbow to the passenger side intercooler connection and position it vertically. Loosely install the T-bolt clamps. Install staples or pop-rivets Mark the position of the elbow end on the tube Seat the rib in the groove Place the center of the clamp directly over the rib 36 Figure 4.16

37 4.4.2 Tightening Spring-loaded T-bolt Clamps Tighten the nut until all of the coils on the spring are in contact, then torque the nut to 12 N.m (106 in-lbs). Check torque again when the clamp and duct are hot. Fit the supplied rubber covered clip around the intercooler tube and attach it to the bracket using the supplied bolt and nut. Adjust the bracket as necessary to get a good fit. Install all other OEM parts removed during preparation that were not discarded for VR installation. Install the plastic Power Stroke emblem. You may have to trim the passenger side on the Power Stroke emblem to prevent it from pushing the intercooler tube up against the hood. Close the hood slowly and make sure that the intercooler tube does not hit. If you are not sure, use a block of putty on the intercooler tube to check the clearance. Tighten all hose fittings. Remove the oil filter from the tank and discard the cardboard. Fill the filter with VR compressor oil, lubricate the gasket and install the filter, tightening an additional three-quarter to one turn after the gasket contacts the base. Check all components for clearance from hot or moving parts. Check hose routing for clearance. Check all hose clamps and fittings. Secure all hoses with tie straps to prevent abrasion and damage. Protect hoses from damage by using nylon loom. 4.6 Adding Oil to the System You must use the VMAC supplied and approved! compressor oil in this system. Failure to use this special oil will result in damage to the compressor and will void your warranty. Remove the fill plug from the air inlet control valve and pour oil into the oil fill hole on the inlet control valve using a funnel. 37

38 Turn the compressor clutch clockwise with a ratchet and a 1/2 inch socket using the hex head bolt at the centre of the compressor clutch during the fill process. Allow 5 minutes for the oil to drain into the tank, then check the level at the sight glass at the front of the tank. Continue adding oil until the level is correct. Install the fill plug in the inlet control valve and tighten it securely.! Do not overfill the system. Overfilling the system with oil can flood the sight glass window and make the system appear empty. 38

39 Part 5: Installing the Control Components Clutch Inlet valve Compressor Black 3 pin connector Control Box ENGINE COMPARTMENT Green 4 pin connector White Connect to OEM white wire with light blue stripe key switched 12 volts Connect to light green wire with red stripe at the park brake switch AUTOMATIC TRANSMISSION MANUAL TRANSMISSION Connect long blue wire to yellow wire with a white stripe at the blunt-cut harness Blue Blue Throttle Controller Connect the blue wires Blue Blue Throttle Controller Do not use short blue wire with crimp connector Connect to OEM circuit 76 green wire with white stripe clean tach out Red White White To ground Green Red Black Blue To ground Blue Throttle Controller Connect to accelerator pedal OEM Connector from accelerator pedal Red White Interface Connector Connect Red White Model Year Wiring 39

40 Clutch Inlet valve Compressor Black 3 pin connector Control Box ENGINE COMPARTMENT Green 4 pin connector White Connect to OEM white wire with light blue stripe key switched 12 volts MANUAL TRANSMISSION Connect to light green wire with red stripe at the park brake switch AUTOMATIC TRANSMISSION OR To ground Red White White Green Red Black DDC To ground Black Black Connect to accelerator pedal Throttle Controller Connect to light green wire with red stripe at the park brake switch OEM Connector from accelerator pedal Connect to OEM circuit 76 light green wire with white stripe clean tach out Red White Interface Connector Connect Red White Model Year Wiring 40

41 5.1 Installing the Components Remove the driver-side plastic door frame base panel and the plastic molding ahead of the base panel. Mount the control box using the supplied sheet metal screws (Figure 5.1). Route the wire harness under the floor covering, along the inside of the door where it will be covered by the trim piece and up under the dash. Place the floor covering back into position and replace the inside left kick panel. Keep wires away from the park brake mechanism. Route wires clear of the steering column and pedals so they do not contact moving parts. Driver s Seat Control box Figure 5.1 Cut a notch in the edge of the trim piece through the saw-tooth section just inside the edge of the trim so that the wire is not cut when the trim is installed. Replace the door trim piece. Remove the trim panel from under the dash. Tie-wrap the throttle control box to the dash support bracket to the right of the steering column, behind the diagnostic connector (Figure 5.2) with the adjusting screws facing out. 41

42 Throttle pedal connector Diagnostic connector Tie-wrap to this bracket Figure Model Years with Automatic Transmission Apply the park brake and shift the transmission into the lowest forward gear. Apply Loctite to the set-screw and mount the magnetic actuator to the transmission arm under the dash (Figure 5.3).! Do not pinch or damage the orange shift indicator harness during installation. Locate the OEM hole under the dash on the support near the transmission arm (Figure 5.4). Using a 1/2 inch socket wrench, install and remove the screw for the magnetic switch bracket in the hole to tap threads in the hole. Mount the switch bracket to the frame under the dash. Note the location of the rectangular washer, the hole is offset to provide more clearance (Figure 5.5). 42

43 Mount close to the end of the arm Set screw Do not damage or pinch the orange cable Figure 5.3 Transmission arm Mounting location Figure 5.4 Slide the bracket all the way to the right. Use a screwdriver to hand-tighten the screw as a socket will push the bracket to the left. 43

44 Rectangular washer with offset hole 44 Figure 5.5 Shift the transmission back into park, being careful not to hit the switch. Slide the switch to the magnet and align the two pieces. This alignment does not need to be perfect and the magnet and switch should not quite touch (Figure 5.6). Tighten the screw with a screwdriver.! To prevent damage to the switch, check the spacing between the magnet and switch while holding the shift lever as far past the PARK position as it will go. Connect an Ohmmeter to the two black wires from the magnetic switch. In park, there should be less than 2 Ohms resistance. In all other gears, the resistance must be greater than 20 M-Ohms. If you do not have an Ohmmeter, connect 12 volts to one wire and a test light probe to the other. The light should be on in park and off in all other gears.! An improperly operating safety interconnect (DDC) can result in inadvertent truck movement during operation.

45 Slide the switch over Transmission in park Figure Connecting the Under-hood Wiring Make a slit or cut a small cross in a harness boot or other firewall plug and pass the following wires from the cab into the engine compartment: small gray harness with the green connector small gray harness with the black connector white wire with a bullet connector Route all of the wires along the engine and firewall to the compressor and connect them to the matching connectors on the compressor. Cover the wires with plastic loom and secure them to OEM harnesses and other objects with nylon ties (Figure 5.7).! Avoid the turbo and other hot or moving parts. 45

46 Secure wires with ties Firewall Firewall Keep wires away from Turbo Coolant Reservoir Turbo air ducting Figure Connecting the In-cab Wiring Unplug the cable from the foot pedal assembly and connect it to the throttle control box. Connect the throttle control box cable to the foot pedal assembly. Connect the white four-wire interface connector to the matching white plug on the harness from the control unit. Connect the green ground wires from the throttle control box and the interface connector to the dashboard ground point above the diagnostic connector (Figure 5.8). Connect the red key switched 12V wire to the OEM white wire with a light blue stripe (CCT #294) under the dash above the OEM diagnostic connector (Figure 5.8) using a butt connector. Connect the red wire from the interface connector to the red wire with the matching connector from the throttle control box. 46

47 Dash Steering column White wire with a light blue stripe OEM ground OEM diagnostic connector Figure 5.8 Solder and seal the white OEM Clean Tach out wire from the throttle control box to the light green wire with a white stripe (CTO Ford CCT #76) in the bundle of blunt cut wires near the park brake (Figure 5.9). Blunt-cut wire bundle HOOD Figure

48 Model Year Manual Transmission Solder and seal the black wire from the interface connector to the green with red stripe wire at the park brake (Figure 5.10). Cut the long blue wire to approximately 6 inches, strip and crimp it to the short blue wire with the butt connector Model Year Automatic Transmission Solder and seal the black wire from the interface connector to the green with red stripe wire at the park brake (Figure 5.10). Tie up the short blue wire at the throttle control box. Solder and seal the long blue wire from the throttle control box to the yellow wire with a white stripe in the blunt-cut bundle beside the park brake under the dash (Figure 5.9) Model Year Manual Transmission Solder and seal the black wire from the interface connector to the green with red stripe wire at the park brake (Figure 5.10) Model Year Automatic Transmission Solder and seal the black wire from the DDC to the green with red stripe wire at the park brake (Figure 5.10). Connect the remaining black wire from the DDC to the black wire from the interface connector. On some trucks the park brake switch is located on the back of the park brake assembly. 48

49 Green wire with a red stripe Figure Completing and Testing the Installation Check all wiring to ensure that it will not contact any hot or moving components and will not interfere with the operation of the truck. Secure all wiring with nylon ties and loom as required. Install and connect the batteries Safety Test Place the automatic transmission in Park or manual transmission in neutral and apply the park brake. Turn the ignition key ON but do not start the engine. Check the control box to see if there is a number showing in the hour-meter. If there is no display, there is no power to the control box. 49

50 Push the ON button on the control box. The green light should come on and you should hear the compressor clutch engage. Release the park brake. The green light should flash and PARK BRAKE will be displayed on the control box. The compressor clutch should disengage. Apply the park brake again and push the ON button. The green light should come on and the clutch should engage. On trucks up to 2005, shift the automatic transmission out of Park. The green light should flash and the compressor clutch should disengage. Place the truck in Park. Shift the transmission into Reverse. The green light should flash and the clutch should not engage. Shift the transmission back into Park and repeat this test for all other gears. On 2005 and newer trucks, the engine must be running to complete the final step in the safety test. This will be done after the pre-start checks have been completed. Turn the ignition key OFF.! If the truck fails the test, check the wiring to make sure that all the connections are correct and secure. If you require additional assistance, contact your local VMAC dealer. Call or

51 Part 6: Finishing the Installation 6.1 Before Starting the Engine Checklist Make sure that the following have been completed: Check the coolant. Check the compressor oil level. Do a final inspection to make sure that everything has been completed and tightened. Perform a final belt alignment check. Check all wiring for security and protection. 6.2 After Starting the Engine Checklist! Place the truck in a safe operating position and block the wheels. Ensure that there are no people around the truck before beginning the test. Make sure that the following have been completed: Model Year Trucks On automatic transmission trucks, with the engine running, engage the park brake; place your foot firmly on the brake pedal, shift the automatic transmission out of Park and into gear. Push the ON button on the control box. The green light will turn on and the compressor will engage, but the engine will not idle up. Push the OFF button until the green light and compressor turn off. Repeat this test in all gear selector positions to make sure that the engine does not idle up unless the selector is in Park. 51

52 6.2.2 All Trucks Operate the system with an air tool for at least 1/2 hour (1 hour preferred). Road test the truck for approximately 14 miles (20 km) Watch the underhood operation to make sure that belts rotate properly and nothing is rubbing or contacting hot parts. Check all components once the engine is turned off and the system has cooled Check the coolant after the engine reaches operating temperature. Check the compressor oil level after the engine has been shut down and the oil level has had time to stabilize. 6.3 Setup, Performance Testing and Adjustments This system has been adjusted at the factory for general operation. If your tests indicate that adjustment is necessary, refer to the owner s manual for specific instructions on how to adjust the system. You can test the system operation using the tools that will be operated by the system or you can test operations sing an orifice in the outlet to simulate tool use (Figure 6.1). Figure Install the test tool in the tank outlet fitting. 2. Make sure that the ball valve is closed. 52

53 3. Place the manual transmission in neutral or the automatic transmission in park and fully apply the park brake. 4. Allow the vehicle to run until the engine is at operating temperature. 5. Operate the air compressor system until the oil is warm. 6. Observe the pressure gauge. Pressure should be approximately 150 psi. 7. Open the ball valve on the test tool and observe the engine tachometer. Engine speed should increase to about 1,800 to 2,200 RPM. 8. Close the air valve slowly to allow the system pressure to rise. 9. Once the system pressure is at maximum, slowly open the ball valve on the test tool until the pressure on the gauge begins to drop. Engine speed should start to ramp-up when air pressure drops to approximately 140 PSI. 6.4 Auxiliary Air Receiver! If you intend to use an auxiliary air receiver with this system you must observe the following installation procedure to prevent damage to the system. The line from the VMAC tank to the auxiliary air receiver must have a one-way check valve installed (part # ) to prevent blow back from the auxiliary tank to stop moisture from entering the VMAC tank (Figure 6.2). 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 entering the line. One-way check valve Auxiliary Tank VR Tank Install the line as high as possible, NOT on the bottom of the auxiliary tank Figure