System # V INTERNATIONAL , 4400 SERIES DT466

Transcription

1 System # V INTERNATIONAL , 4400 SERIES DT466

2 Installation Manual Document Number: Document # VR70 Underhood Air Compressor System Number V Application: INTERNATIONAL , 4300, 4400 SERIES DT466 (Trucks with air brakes will require an adaptor kit.) Publication Date: Revised by S.Coker, 20th November Registered Trademarks: VR70, VMAC and Throttle Commander are registered trademarks of VMAC. International is a registered trademarks of Navistar International Corporation. Loctite, Klean N Prime, 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 2003 The contents of this manual may not be reproduced in any form without the express written permission of VMAC Printed in Canada 2

3 CONTENTS GENERAL INFORMATION... 5 INTRODUCTION... 7 TERMS & SYMBOLS... 7 INSTALLATION NOTES... 8 TORQUE SPECIFICATIONS... 8 SYSTEM IDENTIFICATION NUMBER PLATE... 9 WARRANTY ORDERING PARTS TOOL REQUIREMENTS SPECIAL NOTES PART 1: PREPARING FOR INSTALLATION PREPARATION FOR INSTALLATION PART 2: INSTALLING THE OIL/AIR SEPARATOR TANK AND LINES INSTALLING THE OIL/AIR SEPARATOR TANK BRACKETS ALTERNATE OIL/AIR SEPARATOR TANK MOUNTING LOCATIONS INSTALLING THE C-CLAMPS ATTACHING THE LINES TO THE OIL/AIR SEPARATOR TANK PART 3: INSTALLING THE COMPRESSOR AND OIL COOLER INSTALLING THE VR70 CRANK PULLEY OIL COOLER INSTALLATION INSTALLING THE MAIN BRACKET INSTALLING THE MAIN BRACKET BRACE INSTALLING THE COMPRESSOR ATTACHING THE LINES TO THE COMPRESSOR INSTALLING THE ALTERNATOR AND OEM BELT INSTALLING THE MAIN BRACKET FRONT PLATE & VR70 BELT ADDING OIL TO THE SYSTEM COMPLETING THE INSTALLATION PART 4: INSTALLING THE CONTROL COMPONENTS INSTALLING THE CONTROL UNIT CONNECTING THE WIRING INSTALLING THE THROTTLE HYDRAULIC BRAKES HYDRAULIC BRAKES AND STANDARD TRANSMISSION HYDRAULIC BRAKES AND AUTOMATIC TRANSMISSION FINAL TESTING & ASSEMBLY APPENDIX A GENERIC SOLDERING PART 5: ILLUSTRATED PARTS LIST WARRANTY REGISTRATION 3

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5 GENERAL INFORMATION SYSTEM #V INTERNATIONAL , 4400 SERIES DT466 TM UNDERHOOD AIR COMPRESSOR

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7 Introduction This book provides installation instructions for the VMAC underhood air compressor installation kit. Terms and Symbols This manual uses the following terms and symbols: DDC - Drive Disable Circuit ft-lbs - Foot Pounds (torque) HHCS - Hex Head Bolt (also called a hex bolt) N m - Newton Meters (metric torque) OEM - Original Equipment Manufacturer SHCS - Socket Head Bolt (also called an allen head bolt) Hex - Hexagon (six sided) This symbol indicates that there is a possibility of personal injury if the indicated warning is not followed. This symbol indicates that there is a possibility of damage to the equipment if the indicated warning is not followed. This symbol indicates that there is additional information or special emphasis on a specific procedure. 7

8 Installation Notes It is important that you complete all the installation steps before operating the system. Follow all safety precautions for underhood mechanical work. Use Loctite 242 or equivalent on all engine-mounted fasteners. All hoses, tubes and wires which are rerouted 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. 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. Left and right definitions in this manual are determined when sitting in the driver s seat, facing forward. All fasteners must be of the correct size and torqued according to specifications (Table 1). Torque specifications are in foot pounds (ft-lb) and are only applicable when Loctite is used. If the threads are dry, add 20% to the torque values. Torque Specifications 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 Newton meter STANDARD GRADE 8 NATIONAL FINE THREAD Size 3/8 7/16 1/2 5/8 3/4 Foot-pounds Newton meter METRIC CLASS 10.9 Size M8 M10 M12 M14 M16 Foot-pounds Newton meter Table 1 The fastener values are applicable when Loctite is applied unless otherwise specified. Table 1 Torque Specifications 8

9 Hose Diameter Color Coded Label 1/4 inch Yellow 5/16 inch Orange 1/2 inch Blue 5/8 inch Blue 3/4 inch Green 1 inch Green 1-1/4 inch Green Table 2 Hose color codes Table 2 above illustrates the color code used by VMAC to define the different hose diameters. Check that system hoses are all tight before running the system. Refer to setup procedure in the Owner s Manual before attempting to run this air system. Different frame designations will affect the tank mounting position. You may have to move the tank rearward from the standard position on your application. If you must move the tank, the lines may be too short. If this is the case, measure the hose shortfall and order a Hose Extender Kit, P/N (A410XXX). The last three digits in the P/N indicate the length of the extension, for example, A is a 55 inch hose extender kit. You would receive a kit which includes a set of each size hose 55 inches long required to relocate the tank. System Identification Number Plate The System Identification Number Plate included with the kit must be attached to the vehicle at the time of installation. Locate the plate as shown below. Mark and drill two holes using a 7/64 inch drill bit. Secure the plate in position using the supplied #6 pan head, self-tapping screws. This plate provides information, which allows Vmac to assist in customer inquiries and the ordering of parts. It is important that this plate is affixed to the vehicle. Figure 1 Identification plate mounted 9

10 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. Ordering Parts To order parts, contact your nearest VMAC dealer. Please quote the VMAC part number, the description and the quantity. Tool Requirements The following tools are required for installation: * 1/2 inch drive metric socket set * 8 to 24 mm metric wrench set * 1/2 inch drive SAE socket set * 7/16 inch to 7/8 inch SAE wrench set * Allen key sets - metric & SAE * mechanic s screwdriver set * nut drivers - 5/16 to 3/8 inch * 1/2 inch drill with assorted bits up to 1/2 inch * hacksaw or zip wheel suitable for cutting metal * OEM fan wrench tool The following tools are required for throttle component installation: * small solder gun or soldering pen * wire cutters * wire strippers * crimping tool * digital multimeter, preferably with a frequency (Hz) setting * small jeweller s screwdriver set for adjustment of the throttle control 10

11 Special Installation Notes If you intend to use an auxiliary air tank with this system you must observe the following installation procedure. Failure to observe this procedure will result in damage to the system. 1. The line from the VR70 tank to the auxiliary air tank must have a check valve installed to prevent blow-back 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. Figure 3 Auxiliary air tank piping 11

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13 PART 1 PREPARING FOR INSTALLATION SYSTEM #V INTERNATIONAL , 4400 SERIES DT466 TM UNDERHOOD AIR COMPRESSOR

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15 1.1 Preparing for Installation 1. Disconnect the batteries 2. Drain the coolant 3. Remove the four OEM bolts used to secure the passenger side fender shroud and set the shroud aside temporarily. 4. Disconnect the radiator end of the passenger side turbo/intercooler pipe and allow it to hang loose. 5. Remove the air cleaner to turbo rubber intake duct. 6. Remove the air cleaner 7. Remove the fan. Be sure to use the factory recommended fan-removing tool. 8. Lay the fan down temporarily in the fan shroud and carefully lean it against the radiator with cardboard protection between. 9. Remove the OEM eight-rib drive belt by releasing the OEM tensioner and allow the belt to hang loose. 10. Remove the alternator. 11. Remove the OEM eight-rib drive belt tensioner. 12. Unplug the cam sensor wiring and remove the bolt that secures the cam sensor and set it aside temporarily. Rotate the cam sensor clockwise to expose the M8 bolt hole underneath. 13. Remove the three M10 bolts locating the alternator-mounting bracket and remove the M8 bolt through the timing cover and alternator bracket. Discard the alternator bracket. 14. Remove the plastic OEM heater hose clamp and bracket from the front right of the cylinder head. Discard the plastic clamp but retain the mounting nut, bolt and bracket. Put the original bracket-mounting bolt back into the hole and retighten it to secure it in place. 15. Remove the two OEM bolts locating the engine-lifting lug on the side of the cylinder head and remove and discard the lifting lug. It will be necessary to zip wheel the head of the bolt after loosening to be able to remove it. 15

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17 PART 2 INSTALLING THE OIL/AIR SEPARATOR TANK AND LINES SYSTEM #V INTERNATIONAL , 4400 SERIES DT466 TM UNDERHOOD AIR COMPRESSOR

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19 2.1 Installing the oil/air separator tank brackets 1. Measure 10-1/2 inches (26 cm) back from the rear of the front spring hanger and mark the lower edge of the driver side frame rail (Figure 2.1). Figure 2.1 Bracket mounting -driver side Figure 2.2 Bracket tab facing the frame rail 2. Measure 23 inches (58 cm) back along the rail from the previous mark and mark the lower edge of the driver side frame rail (Figure 2.1). 3. Pass the threaded end of the supplied tank cable strap, through the top hole in the front tank mount bracket from the flat side of the bracket. Pull the cable right through to the stop (Figure 2.2). 4. Hang the front tank mount bracket on the inside of the driver side frame rail at the 10-1/2 inch mark, with the cable over the top of the frame rail. Wrap the cable around the outside of the frame rail and pass the threaded end back through the hole in the tank mount bracket that aligns with the under side of the frame rail. Set the notch protruding from the bracket on the inside of the frame, locating the bracket on the top edge of the lower frame rail lip. 5. Repeat the above procedure with the rear tank mount bracket and set this bracket at the rear marked position on the frame rail. 6. Square up the brackets and install the two 5/16 inch thick washers then the two 5/16 inch nuts to the threaded ends of the tank cable straps. Tighten the nuts on the cables until the tank mounting brackets are securely located. Do not over tighten the cables. 19

20 2.2 Alternate oil/air separator tank mounting locations The 2.2 section is for trucks with under deck exhaust system or trucks that cannot mount the oil/air separator tank on the driver side of the vehicle. 1. Measure 20 inches (51 cm) back from the front spring hanger along the frame rail and mark this as the position of the first bracket (Figure 2.3). 2. Measure an additional 20 inches (51 cm) back from the first mark to make a second marking for the rear tank-mounting bracket. 3. Following these measurements, install the tank brackets in the marked positions as outlined in figure 2.4 and steps 3, 4, 5, and 6 of section 2.1. Figure 2.3 Bracket mounting, passenger side Figure 2.4 Tank brackets, passenger side 2.3 Installing the C-clamps 20 The C-clamps will need to be on the opposite side of the tank when installing the tank on the passenger s side. 1. During the installation, it will help to align the clamps if the tank is set on the edge of a workbench (Figure 2.5). Remove the 1/4 3-1/2 inch pinch bolts and nuts from both the supplied tank mount C-clamps. Slide both clamps over the front of the tank with the flat side of the clamp facing the opposite side to the oil filter. Set the front clamp at 6 inches from the front of the tank. (For a driver side tank mount) set the rear clamp position 23 inches (58 cm) back from the front bracket. (For a passenger side tank mount) set the rear clamp position 20 inches (51 cm) back from the front bracket). Set the clamps so that the up arrow on the front of the tank is in the vertical position and check that the clamp holes align with the mount bracket holes. Reinstall the 1/4 3-1/2 clamp pinch bolts and nuts and tighten enough just to loosely hold the tank.

21 Figure 2.5 C-clamp mounting positions Figure 2.6 Rear view of lines 2. Insert the threaded end of the 5/16 inch scavenge tube into the fitting at the bottom rear of the tank (Figure 2.6). Route the steel tube section down the upper inside (frame rail side) of the tank. 3. Insert the threaded end of the 1/4 inch pressure control tube into the fitting at the top rear of the tank (Figure 2.6). Route the steel tube section down the upper inside (frame rail side) of the tank alongside of the scavenge tube. 4. Lift the tank into position on the inside of the driver side frame rail and support it in position. Install two of the supplied 5/16 1 inch tank mount bolts with 5/16 inch flat washers to fasten the lower tank mount clamps to the bottom holes in the frame mount brackets. Install the 5/16 Nylok nuts with flat washer and tighten hand tight. Ensure there is adequate clearance for the tank and other vehicle components. 5. Back off the front C-clamp 1/4 3-1/2 inch clamp pinch bolt and slide the U-shaped bracket that is used to mount the P-clip, under the front C-clamp with the vertical section of the bracket facing backward. Open the small insulated P-clip and fit it over the two steel tubes of the scavenge and pressure control lines. Using the supplied fastening nut and bolt, secure the clip around the two lines and tighten the nut and bolt to specification (Figure 2.7). Figure 2.7 Tubes secured with P-clip 21

22 6. Rotate the U-shape bracket to allow the steel tubes to run straight and aligned with the tank. Tighten both C-clamps. 7. Insert the two remaining 5/16 1 inch tank mount bolts through the upper holes in the tank mount C-clamps to secure the tank to the tank mount brackets. Install the last two 5/16 inch flat washers and Nylok nuts. Rotate the tank so the arrow on the front of the tank is vertical. 8. Reinstall and tighten the 1/4 3-1/2 inch pinch bolts on the C-clamps and fully tighten all four 5/16 inch tank mount bolts and nuts to specification. If the tank is not set in the correct vertical position (arrow on the rear blowdown cap pointing straight up) the oil scavenge line will not work correctly. 2.4 Attaching the lines to the oil/air separator tank 1. Normal Driver s Side Tank Mounting: Connect the straight connector of the 1/2 48 inch long oil return hose directly to the front of the tank. 2. Feed the ends of the 1/4 and 5/16 inch hoses up into the engine compartment. 3. Install the straight connector of the 3/4 inch main air discharge hose to the top fitting on the front of the tank (Figure 2.8). Route the hose up into the engine compartment with the 1/4 and 5/16 inch hoses. Figure 2.8 Front view, (oil filter removed) 4. Alternate Passenger Side Tank Mounting: Connect the female end of the 1/2 inch extension hose to the 1/2 inch fitting on the lower front of the tank and tighten securely. 5. Alternate Passenger Side Tank Mounting: Connect the straight end connector of the 1/2 inch 48 inch long hose to the male connector on the end of the 1/2 inch extension hose fitted to the tank. Tighten securely using two wrenches. 22

23 PART 3 INSTALLING THE COMPRESSOR AND OIL COOLER SYSTEM #V INTERNATIONAL , 4400 SERIES DT466 TM UNDERHOOD AIR COMPRESSOR

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25 3.1 Installing the VR70 Crank Pulley 1. Ensure that the face of the OEM pulley is clean of all dirt and debris to allow for a good fit of the VR70 crank pulley. Align the bolt holes and ensure that the pulley is sitting flat. After applying Loctite to the threads, install the six supplied M10 45mm bolts with washers to secure the pulley and torque to specification (Figure 3.1 and 3.2). 2. Thread the fan spacer onto the front of the fan pulley. Reinstall the fan and tighten the fan nut to specifications. Figure 3.1 Bolts in the OEM crank pulley Figure 3.2 VR70 crank pulley installed 25

26 3.2 Oil Cooler installation fastener pack (cooler) (hose) OEM 3/4 inch heater return hose 1 inch hose barb to 3/4 inch NPT fitting (supplied) Water pump housing OEM lower radiator hose VMAC diverter tube (supplied) OEM 90 fitting 3/4 inch hose to 3/4 NPT connector below thermostat housing Upper 1 inch spigot Cut OEM lower radiator hose approx. 1 inch from clamp 1 inch 1 inch hose VR cooler return (supplied) OEM clamp OEM lower radiator hose 1 inch hose VR cooler feed (supplied) Lower 1 inch spigot Figure Install the VMAC diverter tube as detailed in figure 3.3, cutting the OEM lower radiator hose approximately 1 inch (25mm) away from the OEM clamp. Secure the diverter and hose using the supplied HS-40 hose clamp. Some truck configurations may vary in which case the most suitable location for the diverter will be approximately 4.0 away from the radiator discharge connection. 2. Apply pipe sealant to the supplied straight 3/4 to 1 inch hose barb and install it into the top connection in the back of the water pump housing. The top connection will either be plugged or have the OEM heater return hose installed. In both instances the existing connection or plug should be removed and the supplied 3/4 to 1 inch hose barb installed as detailed in step 2. If the connection is occupied by the heater return hose this hose will need to be relocated as detailed in step 6 and figure

27 3. Install the oil cooler with the three supplied M16 30mm bolts with flat washers in the engine block just behind the straight fitting on the water pump housing (Figure 3.4). Figure 3.4 Cooler mounting locations 4. Cut a suitable length of the 1 inch hose and route it from the straight fitting in the back of the water pump housing (Figure 3.5) to the bottom spigot of the oil cooler. Water pump straight fitting Figure 3.5 Cooler mounting locations 5. Cut a 3 inch (8 cm) length of 1 inch heater hose and install it onto the top spigot of the oil cooler and clamp it in place with a supplied HS-16 hose clamp (Figure 3.3). Place an HS-16 hose clamp over the hose and install the 1 inch connection of the 1 1 3/4 inch hose-t into the hose and clamp it. 6. Cut a suitable length of the supplied 3/4 heater hose and route from the 3/4 NPT connection fitting below the thermostat housing.(figure 3.6) to the branch 3/4 inch connection of the hose-t installed in step 5 and secure using an HS10 hose clamp. 7. Cut a suitable length of 1 inch heater hose and route it from the primary coolant flow diverter (installed in step 1) to the remaining connection of the 1 1 3/4 inch hose-t. Secure the hose in place using the supplied HS-16 hose clamps (Figure 3.3). 27

28 Figure Relocate the heater return hose connection (if it was connected to the back of the water pump housing) onto the 3/4 connection of the 1 1 3/4 inch hose-t, which has to be connected into the coolant expansion supply hose (Figure 3.3). Secure the hose and Tee in place using the supplied HS-10 and HS16 hose clamps. Extend as necessary using the supplied connector and 3/4 hose. 9. Ensure all connections are tight and all hoses are clear of moving components. 3.3 Installing the main bracket 1. After removing the main bracket from its shipping container, remove the VR belt tensioner and idlers then remove the five bolts securing the VR70 front idler plate to the VR70 main bracket. It is recommended to remove the VR70 tensioner before mounting the front plate assembly to allow for easier access to the mounting bolts for proper tightening. 2. Clean all dirt and debris from the rear of the timing cover before installing the main bracket. Figure 3.7 Bolt mounting locations Figure 3.8 Moving the cam sensor bracket 28

29 3. Fit the VR70 main bracket on the right side rear edge of the engine timing cover with the compressor mounting plate facing forward (Figure 3.9). Figure 3.9 Main bracket bolt mounting locations Item Number Description of fasteners used 1 One M10 70 hex head bolt, Two 3/8 inch flat washers, One M10 Nylok nut 2 One M8 60 socket head bolt, Two 5/16 inch flat washers, One M8 Nylok nut 3 One M10 70 hex head bolt, Two 3/8 inch flat washers, One M10 Nylok nut 4 One M10 60 hex head bolt, Two 3/8 inch flat washers, One M10 Nylok nut 4. Attach the main VR70 bracket with the supplied two M10 70mm, one M10 60mm, and one M8 60mm hex head bolts (Figure 3.9 & Table above). Slide one of the supplied 3/8 inch flat washers on each of the M10 hex head bolts before inserting them into the appropriate holes at the front of the engine timing cover. Install an additional 3/8 washer on each M10 hex head bolt where it protrudes through the VR70 bracket at the rear before installing the supplied Nylok nuts. 5. Likewise, when installing the one M8 60mm socket head bolt near the cam sensor, be sure to slide one of the supplied 5/16 inch flat washers over the socket head bolt before inserting it into the hole at the front of the engine timing cover. Install an addition 5/16 inch flat washer over this M8 socket head bolt where it protrudes through the VR70 bracket at the rear before installing the supplied Nylok nut. 29

30 3.4 Installing the main bracket brace 1. Locate the hole that was created earlier by removal of the engine-lifting lug. This hole will be used to install the socket head bolt that mounts the main bracket brace to the engine cylinder head (Figure 3.10). 2. Slide a 7/16 inch washer over the supplied M12 30mm socket head bolt. Insert the socket head bolt with 7/16 inch washer through the rear hole in the main bracket brace and into the hole in the engine cylinder head as described in step 1 (Figure 3.10). Screw into the engine cylinder head but leave a bit of slack to allow for lining up with the two horizontal holes at the rear of the compressor plate on the main bracket assembly. Figure 3.10 Rear bracket brace attachment Figure 3.11 Front bracket brace attachment 3. Line up the two holes at the rear of the main bracket with the two mounting holes at the front of the main bracket brace. Insert the two supplied M8 35mm hex head bolts that will attach the bracket brace with the main bracket and screw the 8mm double serrated nuts in place. Tighten the socket head bolt in the engine cylinder head and the hex head bolts with serrated lock nuts to specification (Figure 3.11). 3.5 Installing the compressor 1. Remove the three socket head bolts that secure the VR70 compressor belt guard to the top of the compressor and set the belt guard aside temporarily. Reinstall these screws to help secure the inlet control valve during further steps in the installation. 2. Remove the packaging from under the VR70 compressor and retain the captive serrated washer nuts. Take extra care to protect the temperature probe wires during installation. 3. Lift the compressor into place on the horizontal mounting plate at the top of the VR70 main bracket. Line up the studs on the bottom of the compressor with the three holes in the mounting plate and thread the supplied captive serrated washer nuts onto the studs. Tighten the nuts to specification (Figure 3.12). 30

31 Figure 3.12 Compressor mounted 3.6 Attaching the lines to the compressor Figure 3.13 Compressor lines 1. Connect the female 90 degree fitting of the 1/2 inch oil hose to the top male fitting on the oil cooler. Connect the other end of this line to the 1/2 inch fitting on the right side of the compressor (Figure 3.13). 2. Connect the other female 90 degree 1/2 inch fitting on the oil hose coming from the oil/air separator tank to the bottom male fitting on the front of the oil cooler (Figure 3.12). 3. Connect the female 3/4 inch main air hose fitting from the oil/air separator tank to the connector on the back of the VR70 compressor (Figure 3.13). 4. Connect the female connector of the 1/4 inch pressure control line that comes from the oil/air separator tank to the right hand side of the VR70 inlet control valve (Figure 3.14). Figure 3.14 Pressure control line fitting Figure 3.15 Oil scavenge line fitting 5. Connect the 5/16 oil scavenge hose from the oil/air separator tank to the male 90 degree 5/16 inch connector on the left hand side of the inlet control valve (Figure 3.15). 31

32 6. Bundle the hoses together using the supplied nylon ties. Secure the bundled hoses to the metal bracket on the top of the engine block used in the Cooler installation section of the manual. Be sure that the hoses are routed to ensure they won t foul other engine components. Apply supplied loom to areas where the hoses may come in contact with other engine hoses or where abrasion may occur (Figure 3.16). Figure 3.16 Road draft tube detail Figure 3.17 Alternator mounted When the compressor hoses need to run on the passenger side of the vehicle, special caution should be taken to avoid contact with areas of the engine that may produce excessive heat. It is therefore recommended that the road draft tube at the back of the cylinder head near the fire wall be used as a securing point to isolate system lines from the turbo charger and the exhaust manifold. 3.7 Installing the alternator and the OEM belt 1. Reposition the cam sensor on the front of the engine timing cover to its original location and connect the wiring. Secure the cam sensor with its original OEM bolt. 2. Mount the alternator in place using the supplied 1/2 1-1/2 inch flange bolt in the top mounting boss of the main bracket (Figure 3.17). Hand tighten at this time to allow for lining up the mount at the bottom of the alternator with the lower alternator mounting boss on the main bracket. 3. Use the original OEM bolt to mount the alternator to the lower boss on the main bracket (Figure 3.17). Tighten both upper and lower bolts to specification. 4. Reconnect the OEM wiring to the alternator. 5. Install the OEM tensioner on the front of the engine timing cover using the OEM bolt (Figure 3.18). Tighten the bolt to specification. 6. Reinstall the OEM drive belt. Take tension off of the OEM tensioner and route the eight-rib OEM belt as shown in the photograph in figure 3.19 &

33 Figure 3.18 OEM tensioner remounted Figure 3.19 OEM belt refitted 3.8 Installing the main bracket front plate and VR70 belt Figure 3.20 VR70 belt routing after installation 33

34 1. Position the main bracket front plate assembly on the main bracket and insert the top 1/2 7 inch mounting bolt with 1/2 inch washer, from the front so that the threads protrude through the rear of the main bracket. Only hand tighten the 1/2 inch prevailing torque nut to allow the other bolt holes to line up with the bracket posts (Figure 3.21). Figure 3.21 VR70 tensioner and front plate bolt mounting detail 2. Install the two 1/2 6-1/2 inch bolts with 1/2 inch washers through the two left hand side bracket posts. Install a 1/2 inch prevailing torque nut and hand tighten each of the two bolts (Figure 3.21). 3. Fit the two 3/8 1 inch steady bolts to the top of the front plate just underneath the VR70 compressor mounting plate (Figure 3.21). 4. Using the appropriate wrenches, tighten all mounting bolts on the front plate assembly to specification. 5. Install the VR70 tensioner with the supplied M10 80mm bolt and tighten to specifications. 6. Install the supplied VR70 six-groove drive belt. Take tension off of the VR70 tensioner and route the six-rib VR70 belt as shown in the photograph in figure

35 Figure 3.22 VR70 belt routing after installation 3.9 Adding oil to the system 1. Make sure that the vehicle is level. 2. Remove the oil filler plug from the inlet control valve (Figure 3.23). 3. Pour the supplied compressor oil into the filler hole using a funnel. 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. 4. Turn the compressor clutch clockwise with a ratchet and socket using the hex head bolt at the center of the compressor clutch as you pour in the oil. 5. Check the sight glass window at the front of the tank regularly to ensure that the correct oil level is attained. It is important not to overfill the system. 6. Insert the filler plug in the inlet control valve and tighten to specifications. 35

36 Figure 3.23 Oil fill detail 3.10Completing the installation 1. Use the original screws that secured the compressor belt guard to install the compressor belt guard back on the compressor inlet control valve. 2. Refill the coolant in the radiator that was drained in the Preparation for installation section of the manual. 3. Reconnect the intercooler pipe to the intercooler. 4. Reconnect the trunking from the turbo charger to the air cleaner. Leave fasteners and clamps only hand tight to allow for an easier fitting of the air cleaner filter box. 5. Reinstall the air cleaner filter box and tighten all clamps and applicable fasteners. To avoid disconnection of the air cleaner boot from the air cleaner filter box, it is advised that this part of the component should not be used as a grip or a point of leverage when the box is reinstalled. 6. Reinstall the air filter and air filter retainer cap. 7. Reinstall the plastic left fender well using the four OEM M8 bolts and washers. 36

37 PART 4 INSTALLING THE CONTROL COMPONENTS SYSTEM #V INTERNATIONAL , 4400 SERIES DT466 TM UNDERHOOD AIR COMPRESSOR

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39 4.1 Installing the control unit 1. Remove the screws holding the plastic protector panel in place on the floor inside the driver s door. Remove the panel. 2. Remove the rear seat rail bolt and fasten the bracket to the floor using the bolt through the rearmost hole (Figure 4.1). Figure Cut a small slot in the rubber floor mat where the control unit will mount so that you can route the wires under the mat from the back of the unit. 39

40 4. Mount the control unit to the bracket with the four supplied sheet metal screws (Figure 4.2). Position it with the wire harness coming out from the bottom of the unit (Figure 4.3). Feed the harness through the hole in the floor mat, along the floor and up under the dash. Figure Figure 4.3

41 4.2 Connecting the wiring Figure

42 1. Connect the two interface cable connectors. A wiring diagram is shown in figure 4.4. Tape up the yellow DDC wire and tie it up under the dash. 2. Connect the green wire with the ring connector to a good ground. 3. Route the red wire with the fuse holder under the dash to the fuse panel. Locate an empty fuse connection and install the red wire using the fuse holder connector. 4. Locate a fuse in the fuse panel that will provide power only when the ignition switch is in the ON position (Figure 4.5). Figure Locate a grommet or other opening in the firewall and feed the white wire from the interface cable and the grey cable from the control panel, through to the engine compartment. Connect the white wire to the matching connector at the compressor clutch, and the grey cable to the temperature probe cable. 6. Leave the red wire under the dash near the throttle pedal for connection to the throttle control. 7. Replace the doorsill trim at the driver s door. 8. Replace the fuse panel cover. 42

43 4.3 Installing the throttle 1. Using the supplied nylon ties, mount the throttle up under the dash near the accelerator pedal. Keep the adjustment screws accessible. 2. Disconnect the OEM connector at the accelerator pedal position sensor, and connect it to the connector on the throttle. 3. Connect the black throttle connector to the accelerator pedal position sensor. 4. Route the red throttle wire to the red wire from the interface cable that was set aside in section 4.2, step 6. Connect these wires. 5. Connect the green Ground inch wire from the throttle to a good ground. 6. Route the grey Pressure sensor cable from the throttle through the firewall to the compressor, alongside the white Clutch wire and connect it to the pressure sensor on the inlet control valve. 7. Cover the wires in the engine compartment with the supplied split loom. 4.4 Hydraulic brakes 1. Locate the black and white park brake wires that route under the floor mat from the park brake and come up beside the accelerator pedal (Figure 4.6). Figure

44 4.4.1Hydraulic brakes and standard transmission Figure Disconnect the OEM connector and reconnect it to the mating connectors on the Parking Brake black interface cable wire (Figure 4.7) Hydraulic brakes and automatic transmission 1. Connect the VR black wire on the Drive Disable Circuit. (DDC) to the black wire on the interface cable. 44 Figure 4.8

45 2. Disconnect the OEM connector and reconnect it to the mating connectors on the Parking brake black DDC wire (Figure 4.8). 3. Locate the connector shown in Figure 4.9. Figure Locate the pink wire labeled L17E at pin G of the connector shown at the transmission (Figure 4.9). 5. Solder the blue DDC wire to the pink wire labeled L17E on pin G as shown in Appendix A. VMAC recommends that all wire connections be soldered for reliability. A T-Tap connector has been supplied if this is not practical. 4.5 Final testing and assembly 1. Block the wheels of the vehicle. Apply the park brake, and if it is an automatic, put the transmission in neutral. 2. With the battery reconnected, turn the ignition to the Run position. Do not start the engine. 3. Turn On the control panel. The green light should come On. 4. Release the park brake. The green light should go off. 5. Reapply the park brake. 6. If the truck is an automatic, shift into gear. The green light should go Off. 45

46 7. Shift back to Neutral. The green light should come back On. 8. Turn off the control panel. Shift the transmission into gear. 9. Turn on the control panel. The green light should not come On. 10. Shift back to Neutral. The green light should come On. 11. Turn off the control panel and ignition. 12. Secure the wires in place under the dash and make sure that none of the wires interfere with any moving parts. 46

47 Appendix A - Soldering Instructions 1. Cut the OEM wire, and strip approximately 1/2 inch (13 mm) from each end and from the VR70 wire (Figure A1). Figure A1 2. Slide the heat shrink provided onto one OEM wire and the VR wire. Twist the three wires together (Figure A2). Figure A2 3. Heat all three wires at the joint with a soldering gun/pen, then apply the provided solder. 47

48 Ensure the solder flows into the joint to bond the wires together (Figure A3). Document # Figure A3 4. Slide the heat shrink over the joint, and shrink onto the joint using a heat gun. Make sure the shrink is heated until the liner melts and makes a good seal (Figure A4). Figure A4 48

49 PART 5 ILLUSTRATED PARTS LIST SYSTEM #V INTERNATIONAL , 4400 SERIES DT466 TM UNDERHOOD AIR COMPRESSOR

50 50 Document #

51 ILLUSTRATED PARTS LIST FOR SYSTEM V INTERNATIONAL 4300, 4400 SERIES DT466 ASSY.ITEM UNIT QTY PART# DESCRIPTION Main Bracket Assembly 1.1 ea Main bracket, International 1.2 ea Front Plate 1.3 ea Washer, flat SAE, 1/2 inch 1.4 ea VR tensioner, modified 1.5 ea Bolt, hex head, NC 1/2 6 1/2 inch 1.6 ea Bolt, hex head, flanged, M ea Bolt, hex head flanged NC 1/2 inch 1 1/4 inch 1.8 ea Spacer, idler - bolt 1.9 ea Bolt, hex head, NC 1/2 inch 7 inch 1.10 ea Idler, smooth 1.11 ea Bolt, hex head flanged NC 3/8 inch 1 inch 1.12 ea VR belt, 1.13 ea Nut, prevailing torque NC, 1/2 inch 1.14 ea Spacer, fan 1.15 ea Crank pulley 1.16 ea Washer, 3/8 inch 1.17 ea Bolt, hex head M P Compressor Assembly 2.1 ea 1 P VR70 compressor 2.2 ea Cable, assembly with temperature probe 2.3 ea Elbow, Brass NPT-1/2 inch, Tube-1/2 inch 2.4 ea Stud, M mm 2.5 ea 1 P Clutch complete, 6-groove 2.6 ea O-ring, Viton, 2 3/8 inch ID 2.7 ea Blanking plate 2.8 ea O-ring, Viton, 3/4 inch ID 2.9 ea Fitting, filter blanking plate 2.10 ea Clamp, cable, 1/4 inch 2.11 ea O-ring, Viton, 3 1/8 inch ID 2.12 ea Adaptor, angle mount 2.13 ea Bolt, socket head, low profile, M ea Modified fitting 2.15 ea O-ring, Viton, 3/4 inch ID 2.16 ea Elbow, JIC, 7/ / ea Tee, street, 1/8-1/8 inch 2.18 ea Elbow, brass street, 1/8 inch 2.19 ea Sensor, pressure 2.20 ea Elbow, brass pipe-1/4 inch, tube-1/8 inch 2.21 ea Valve, inlet control 2.22 ea Bolt, socket head, M ea Bolt, socket head, M ea Elbow, brass NPT-1/8 inch, tube-5/16 inch 2.25 ea Guard, strap 2.26 ea Nut, hex NC, 1/4 inch 2.27 ea Filter element, paper 2.28 ea Rod, threaded, 1/4 inch 2.62 inch 2.29 ea Filter cover, plastic 2.30 ea Washer, flat SAE, 1/4 inch 2.31 ea Nut, Nylok NC, 1/4 inch 51

52 ILLUSTRATED PARTS LIST FOR SYSTEM V INTERNATIONAL 4300, 4400 SERIES DT466 ASSY ITEM UNIT QTY PART # DESCRIPTION Tank Assembly 3.1 ea Oil Separator Tank Weldment 3.2 ea /8 NPT 1/2 SAE Brass Connector 3.3 ea Nipple, Steel, Straight Thread, 3/ ea O-ring, Viton 1-7/8 ID x 1/8 3.5 ea VR70 Oil Filter 3.6 ea Retaining Ring 3.7 ea Ring, 2.12 OD x 1.72 ID x ea Window, Pyrex, 2.12 dia. x.35 thick 3.9 ea PSI Relief Valve 3.10 ea /4 NPT 3/4 JIC Steel Connector 3.11 ea O-ring, Viton, 4-3/4 ID 3.12 ea Compression Spring 3.13 ea Coalescing Filter Element 3.14 ea Tank Rear Cap Seal 3.15 ea Thimble Screen 3.16 ea Spring, Compression, FL 1.5 OD ea Blowdown Cap 3.18 ea Cover, Sight Glass Document # ASSY.ITEM UNIT QTY PART# DESCRIPTION 4.0 Hose Kit 4.1 ea Hose, crimped, 3/4 76 inch 4.2 ea Hose, crimped, 5/ inch 4.3 ea Hose, crimped, 1/4 111 inch 4.4 ea Hose, crimped, 1/2 48 inch 4.5 ea Hose, crimped, 1/2 32 inch 4.6 ea Hose, heater inch 4.7 ea Barb, 3/4 1 inch 4.8 ea Hose clamp, HS ea Hose clamp, HS ea T-barb, 1 1 3/4 inch 4.11 ea Hose assembly 4.12 ea Diverter tube assembly 4.13 ea Hose clamp, HS ea Elbow,Brass xtrd street 45D,3/4 NPT 4.15 ea Hose, Heater, 3/4 X 100" ( ) 4.16 ea Barb, 3/4x3/4 inch ASSY.ITEM UNIT QTY PART# DESCRIPTION Throttle Control 5.1 ea Control box 5.2 ea Throttle 5.3 ea Interface cable 5.4 ea Drive disconnect circuit (DDC) 5.5 ea Bracket, control panel 52

53 ILLUSTRATED PARTS LIST FOR SYSTEM V INTERNATIONAL 4300, 4400 SERIES DT466 ASSY.ITEM UNIT QTY PART# DESCRIPTION 6.0 Tank Bracket Assembly 6.1 ea Bracket, tank mount 6.2 ea Cable, tank strap 6.3 ea Washer, 5/16 inch ID 3/4 inch OD 6.4 ea Nut, hex NC 5/16 inch 6.5 ea Clamp mounting bracket 6.6 ea Hose support clamp assembly ASSY.ITEM UNIT QTY PART# DESCRIPTION 7.0 Cooler Assembly 7.1 ea Cooler ASSY.ITEM UNIT QTY PART# DESCRIPTION 8.0 Miscellaneous 8.1 ea Bracket brace ea 1 A Oil VR high performance, 1 litre ea 1 A Oil VR high performance, 4 litre ASSY.ITEM UNIT QTY PART# DESCRIPTION ea Plug, 3/4 pipe fitting 53