Installation Manual. System # V FORD L TRITON V8 SUPERDUTY E250 E350. Visit us at KIPP ROAD NANAIMO B.C.

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1 Installation Manual System # V FORD L TRITON V8 SUPERDUTY E250 E350 TM 1333 KIPP ROAD NANAIMO B.C. V9X 1R3 Visit us at... underhoodair TEL: (250) FAX: (250)

2 Installation Manual Document Number: Document VR70 Underhood Air Compressor: System Number V Application: Ford L TRITON V8 SUPERDUTY E250 - E350 Publication Date: November 1, 2003 Registered Trademarks: VR70 and VMAC are registered trademarks of VMAC. Loctite, Kleen 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

3 Contents GENERAL INFORMATION... 3 Introduction... 5 Terms and Symbols... 5 Installation Notes... 5 Torque Specifications... 6 Hose Coding... 6 Ordering parts... 7 Warranty... 7 System Identification Number Plate... 7 Tool Requirements... 8 Special Installation Notes... 8 PART 1 PREPARING FOR INSTALLATION Removing Components Modifying Components Preparing for Installation PART 2 INSTALLING THE SEPARATOR TANK, HOSES AND COOLER Installing the Brackets Installing the Tank Installing the Hoses Installing the Cooler Completing the Installation PART 3 INSTALLING THE BRACKET AND COMPRESSOR Installing the Bracket Installing the Compressor Connecting Compressor Hoses Installing the Inlet Control Valve Connecting Control Hoses Installing Other Components Filling the System with Oil Completing the Installation PART 4 INSTALLING THE CONTROL COMPONENTS Installing the Control Unit Safety Feature for Vehicles with Automatic Transmissions Connecting the Wiring Harness Installing the Throttle Controller Connecting the Poly Tubes Completing the Installation Testing the safety circuit Appendix A Soldering

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5 GENERAL INFORMATION SYSTEM V FORD L TRITON V8 SUPERDUTY E250 E350 UNDERHOOD AIR COMPRESSOR 3

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7 Introduction This book provides installation instructions for the VR70 Underhood Air Compressor. The information in this book should be read completely before attempting installation. Terms and Symbols This manual uses the following terms and symbols: DDC - Drive Disable Circuit ft.-lbs - Foot Pounds (torque) HHCS - Hex Head Cap Screw (also called a hex bolt) N m - Newton Meters (metric torque) OEM - Original Equipment Manufacturer SHCS - Socket Head Cap Screw (also called an Allen-head bolt) Hex - Hexagon (six sided) This symbol indicates that there is a possibility of personal injury or 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. 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 moved 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 the specifications shown below. Always use manufacturers torque values for OEM fasteners. 5

8 Torque Specifications Torque values are applicable when Loctite is 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 3/4 Foot-pounds (ft-lb) Newton meter (N m) STANDARD GRADE 8 NATIONAL FINE THREAD Size 3/8 7/16 1/2 5/8 3/4 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 Coding 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. The following table shows the color code used by VMAC to define the different hose diameters. Hose Diameter 1/4 inch 5/16 inch 1/2 inch 5/8 inch 3/4 inch 1 inch Colour-Coded Label Yellow Orange Blue Blue Green Green 6

9 Ordering parts To order parts, contact your VMAC dealer. Please quote the VMAC part number, the description and the quantity. Warranty The VMAC warranty form is located at the back of this manual. This warranty form must be completed and mailed or faxed to VMAC at the time of installation for any subsequent warranty claim to be considered valid. System Identification Number Plate The enclosed System Identification Number Plate (Figure 1) must be attached to the vehicle at the time of installation. This plate provides information which allows VMAC to assist in customer inquiries and the ordering of parts. Locate the plate as shown below. Mark and drill two 7/64 inch holes. Secure the plate with two supplied #6 pan head self-tapping screws. Figure 1 System identification number plate 7

10 Tool Requirements Document The following tools are required for compressor installation: metric socket set, 1/2 inch drive SAE socket set, 1/2 inch drive Allen key sets, metric and SAE assorted screwdriver set nut drivers, 5/16 and 3/8 inch drill, 1/2 inch, with assorted bits up to 1/2 inch hacksaw or zip wheel suitable for cutting metal crescent wrench, eighteen inch for fan removal 1-1/4 inch crows-foot wrench The following tools are required for throttle component installation: small soldering gun or soldering pen wire cutters wire strippers crimping tool digital multi-meter Special Installation Notes If you intend to use an auxiliary air receiver with this system you must observe the following installation procedure as shown below. Failure to observe this procedure will result in damage to the system. The line from the VR70 tank to the auxiliary air receiver must have a one-way check valve installed to prevent blow back from the auxiliary tank to stop moisture from entering the VR70 tank. 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 (Figure 2). One-way check valve Auxiliary Tank VR Tank Install the line as high as possible, NOT on the bottom of the auxiliary tank Figure 2 Proper line placement 8

11 PART 1 PREPARING FOR INSTALLATION SYSTEM V FORD L TRITON V8 SUPERDUTY E250 E350 TM UNDERHOOD AIR COMPRESSOR 9

12 1.1 Removing Components Document Remove the engine cover from the inside of the vehicle. 2. Disconnect the battery. 3. Disconnect the alternator wiring. 4. Drain the coolant into a suitable container. 5. Remove the fasteners holding the plastic EVR valve (Figure 1.1) in position under the top right side of the engine compartment (from inside the vehicle). 6. Remove the OEM bolt holding the front fuel rail in position and replace it with the low-profile fastener (Figure 1.2). Figure 1.1 EVR valve 10

13 Figure 1.2 Low profile fastener 7. Remove and keep the following components and their fasteners for later installation: air intake resonator rubber connecting bellows air intake ducting air cleaner support bracket plastic protective cowl from the throttle body top radiator hose alternator rear alternator bracket engine cooling fan and fan shroud together as a unit (disconnect the rock guard to fan shroud clips) OEM belt ground strap between the rain channel and the right-hand cylinder head plastic splash guard from under front of vehicle 8. Remove and keep the following components for later use if the system is removed from the vehicle: lower radiator hose (cut off the clamp from the diverter) with 8 mm stud end holding the multi-pin electrical connector to the right-hand side of the engine 11

14 1.2 Modifying Components Document Transmission Dipstick Tube 1. Remove the transmission dipstick tube. 2. Cut off the top mounting bracket (which attaches to the intake manifold) flush with the dipstick tube. 3. Grind off any sharp edges Heater Supply Hose Fitting ITEM QTY PART # DESCRIPTION /8 90 DEG hose barb connector, modified /8 hose 90 DEG connector /8 NPT plug Plastic loom 1.0 split 1. Remove the 3/4 inch heater supply hose from the manifold outlet tube. 2. Remove the fitting from the manifold using an OEM puller, a special VMAC tool or by inserting a bolt into the fitting and using vise-grip pliers. Be careful not to damage the intake manifold. 12

15 90 degree hose barb Intake Manifold Figure 1.3 Installing the fitting 3. Apply sealant and install the supplied 90 degree spigot fitting into the manifold (Figure 1.3). Make sure that it is positioned so that it will clear the compressor mounting bracket (Figure 1.4). Figure 1.4 Positioning to clear the bracket 13

16 1.2.3 Electrical Connectors Document Disconnect the two small black and gray electrical plugs near the heater core (Figure 1.5). 2. Remove the wire harness from the locating pegs on the right front of the engine. 3. Remove the multi-pin connector and the OEM mounting bracket (Figure 1.5) from its location on the right side of the engine. Discard the bracket and OEM fastener. 4. Route the wire harness with the multi-pin connector so that it will pass around the inside of the oil filler tube and down the side of the cylinder head. Move the ground cable and temperature sensor out of the way for connection later. 5. Tuck the multi-pin connector up behind the heater core hose connections. Fasten it in place with ties. Make sure that the wiring harness and electrical multi-pin connectors are as close to the heater core as possible, with the large connector positioned with the connecting bolt at the top. The large connector should be first with the two smaller connectors pushed up below it (Figure 1.6). Figure 1.5 Electrical connectors in the OEM position 14

17 Figure 1.6 Electrical connectors relocated Figure 1.7 Remove hoses from OEM retainer 15

18 Models Heater Hoses Document Remove the heater hoses from the plastic retainer clip (Figure 1.7). Make identification marks on either the upper or lower heater hose so that they can be identified and correctly connected together later in the installation process (note the white mark on the hose in Figure 1.8). 2. Cut the upper heater hose (with the OEM tee) 2 inches around the 90 degree bend toward the front passenger side of the vehicle (Figure 1.8) from the engine compartment side. Cut 2 back from bend Figure 1.8 Marking and cutting the heater hoses 3. Cut the lower heater hose 2 inches around the 90 degree bend toward the back of the vehicle (Figure 1.9). 4. Place clamps over the heater core ends of the hoses and insert the supplied plastic connectors. Tighten the clamps. 5. Move the hoses out of the way to allow room to install the compressor. 16

19 Figure 1.9 Hoses after cutting Engine Oil Fill Tube 1. Remove the engine oil fill tube. 2. Cut 1-3/4 from the engine end of the tube. 1.3 Preparing for Installation 1. Clean the right front area of the engine so that the compressor mounting bracket will sit flush on the mounting area. 2. Make sure that there is no casting flashing on the engine that will prevent the bracket from sitting flat. If there is, it must be ground smooth. 3. Clean the frame on the passenger side of the vehicle to make sure that the tank brackets will sit flush on the mounting area. 17

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21 PART 2 INSTALLING THE SEPARATOR TANK, HOSES AND COOLER SYSTEM V FORD L TRITON V8 SUPERDUTY E250 E350 TM UNDERHOOD AIR COMPRESSOR 19

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23 ITEM QTY PART # DESCRIPTION Mounting bracket, 6 C-clamp Tube clamp, 1/4 insulated Tank L- bracket Tank cable strap 2.5a Upper tank mount clip 2.5b Lower tank mount clip Cable spacer Main tank body Connector, brass 3/8 NPT to 1/2 SAE Nipple, threaded 3/ VR70 oil filter Retaining ring O-ring, Viton 1 15/16 ID Pyrex window O-ring, Viton 1 3/8 ID Ring window O-ring, Viton 1 3/8 ID Compression spring Coalescing filter element Rear tank cap seal Thimble screen Compression spring Blowdown cap Relief valve, 200 psi O-ring, 4 3/4 ID x 1/8 wide, Viton Connector, steel 3/4 NPT x 3/4 JIC 21

24 2.1 Installing the Brackets Document Thread the 3/16 and 1/4 inch steel tube and hose assemblies into the matching fittings on the back of the tank, but do not tighten them. 2. Fit the C-clamps to the tank with the front clamp 2 inches from the front of the tank and the rear clamp 16 inches back from the back edge of the front C-clamp (Figure 2.1). 17-1/4 2 Front 18-1/2 Figure 2.1 Clamp positioning 3. Tighten the pinch-bolts just enough to hold the clamps in position on the tank so that the tank can be leveled after it is installed. 4. Place the tank mounting L-brackets on the C-clamps and install 5/16 x 1/2 inch hex head bolts (with flat washers) into the bottom holes in each bracket (Figure 2.2). 5. Install the two small insulated double tube stainless clamps over the steel tubes (Figure 2.2), position them over the top C-clamp slotted holes and install the top 5/16 x 1/2 inch bolts (with flat washers). Cable Clamp L-Bracket Upper Frame Clip Tube Clamp Cable Guides 5/16 bolt with 1/2 Flat Washer Spacer (if required) Washer, Tightening nut and Locknut Lower Frame Clip Figure 2.2 Mounting assembly 6. Position the L-brackets approximately half-way in the C-clamp slots and tighten the top and bottom cap screws enough so that the brackets will not move. 7. Tighten the tube fittings on the back of the tank. 22

25 2.2 Installing the Tank 1. Remove the nuts and washers from the threaded ends of the cable clamps. 2. Insert the tank retaining cables through the upper frame rail clips (Figure 2.3). 3. Place the front clip and cable clamp on the top of the frame rail from the inside, with the cable over the frame, approximately 12 inches back from the transmission cross-member. 4. Position the rear tank frame rail clip and cable clamp approximately 18 1/2 inches back from the front clip. 5. Place the tank in position alongside the vehicle frame, with the brackets on the tank facing the frame. Align the tank so that the two attached lines are at the top and the sight glass is facing forward. 6. Route the flexible hose portions of the 5/16 and 1/4 inch hose and tube assembly from the tank over the cab mount. From inside the wheel well, route them outside of the hydraulic brake hoses, then up the right-hand side of the engine toward the front of the vehicle. 7. Move the tank into position against the frame, with the bent portion of the mounting bracket on the tank over the top of the frame rail (Figure 2.3). 8. Position the front cable so that it fits into the grooves on the top and bottom of the mounting bracket on the tank. 9. Insert the threaded end of the cable clamp into the bottom frame clip (Figure 2.3). 10. Place a thick 5/16 inch washer over the threaded end and then install a 5/16 inch nut to hold the assembly in place. Repeat this procedure with the rear clamp. Some frame rails may require the use of the spacer shown in Figure

26 3/4 connection 1/2 connection Front and rear cable clips with nuts Figure 2.3 Attaching the tank to the frame 11. Position the tank so that the fittings on the front and back of the tank have sufficient clearance and the cable clips are aligned with the mount brackets. Tighten the nuts on the cable clamps. 12. Thread a second 5/16 inch nut over each of the first nuts to act as a lock and tighten them. 13. Remove the filter from the front of the tank. 24

27 2.3 Installing the Hoses

28 ITEM QTY PART # DESCRIPTION /2 x 62 crimped hose w/90 DEG (oil return hose) /2 x 98 crimped hose w/90 DEG (oil return hose) /4 x 72 crimped hose w/45 DEG (main air discharge hose) /16 crimped hose w/tube assembly 142 long (scavenge hose) Document /4 crimped hose w/tube assembly 125 long (pressure control hose) 1. Route the straight end of the 3/4 inch hose down from the inside of the engine compartment, over the body mount and along the same route as the other lines from the tank. 2. Connect the straight end of the 3/4 inch hose to the fitting on the tank and tighten. 3. Loosen the four 5/16 inch bolts holding the tank to the mounting brackets and raise the tank as high as possible. Tighten the bolts. 4. Connect the straight end of the longest 1/2 inch hose to the lower fitting on the front of the tank, but do not tighten the fitting. 5. Route the 1/2 inch hose up over the cab mount (making sure that it is clear of sharp edges on the mount) and along the frame rail to the front of the vehicle. 26

29 2.4 Installing the Cooler ITEM QTY PART # DESCRIPTION Cooler Rad hose, cooler to engine Rad hose, radiator to cooler Hose clamp HS Anti-roll bar spacers 1. Remove the four bolts from the two sway-bar mount brackets at the front of the frame. 2. Insert the supplied spacers between the mount brackets and the frame, install the replacement bolts through the brackets and spacers, thread them into the frame and tighten them (Figure 2.4). 3. Fit the cooler assembly into position under and in front of the radiator, with the two radiator hose spigots pointing to the rear of the vehicle (Figure 2.5). 27

30 4. Place flat washers on two 5/16 inch bolts and insert them from the back of the radiator support, through the two OEM holes. Figure 2.4 Sway-bar spacers Mounting Bolt and Nut Figure 2.5 Cooler in position 5. Install the cooler assembly onto the protruding bolts, install flat washers, spring washers and 5/16 inch nuts and tighten them. 28

31 6. Place hose clamps on the supplied lower radiator hose and install it between the passenger-side cooler hose fitting and the lower radiator fitting. Tighten the clamps. 7. Place hose clamps on the supplied cooler-to-diverter hose and install it between the driver-side cooler hose fitting and the diverter. Tighten the clamps. 8. Connect the 90 degree fitting on the long 1/2 inch hose from the tank to the passenger-side fitting on the cooler and tighten the fittings at both ends. 9. Connect the 90 degree end of the short 1/2 inch hose to the remaining fitting on the cooler. Route this hose around the steering box, up the inner fender on the driver s side and across the engine for connection to the compressor. Align the fitting at the cooler to clear all obstructions and tighten it. 2.5 Completing the Installation 1. Apply a thin coating of lubricant and install the filter on the tank. Tighten it by hand until the gasket contacts the base, then tighten an additional 3/4 turn. 2. Locate any areas where the hoses may rub or abrade on vehicle parts and protect them with the supplied plastic loom. Wrap heat insulation around hoses that are near to the exhaust manifold. 3. Fasten the lines together with plastic ties and secure them to the frame rail or other suitable location, with ties. Lines must be installed in the correct locations or the system will not function properly. Fittings must be tightened securely and checked for leaks. A hazardous situation can develop from oil spray, such as potential fire, explosion, injury or death. Correct tank alignment is very important. Improper installation can result in damage to the equipment, injury or death. 29

32 30 Document

33 PART 3 INSTALLING THE BRACKET AND COMPRESSOR SYSTEM V FORD L TRITON V8 SUPERDUTY E250 E350 TM UNDERHOOD AIR COMPRESSOR 31

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35 ITEM QTY PART # DESCRIPTION Main bracket Tensioner rib plain idler Idler bolt spacer /2 x 1 1/4 NC G8 flange lock hex bolt rib idler Nut with double serrated washer, M8 x Stud M8 x 1.25 x 38mm /8 washer SAE Nut, Nylok, M10 x VR 70 crank shaft pulley Washer 3/8 SAE mm x 70mm G 10.9 bolt, hex VR70 belt 3.1 Installing the Bracket 1. Unpack the compressor mounting bracket. 2. Remove the fasteners holding the back and ribbed idlers to the bracket. 3. Remove the back idler wheel from the auto belt tensioner on the compressor bracket. 4. Place the cast bracket in position on the right front of the engine (Figure 3.1). Make sure that nothing interferes with the placement of the bracket. Install all fasteners before tightening and ensure that the bracket is aligned properly. 33

36 Figure 3.1 Cast bracket installed 5. Apply Loctite to two 10 x 35 mm socket-head bolts and install them into the center section and under the alternator mount area. 6. Apply Loctite and install the 10 x 100 socket-head bolt in the front upper area of the engine. 7. Apply Loctite to the 8 x 25 mm socket-heat bolt and install it into the front timing cover just above the OEM belt tensioner. Torque all fasteners to specifications. 8. Position the back idler wheel on the tensioner, apply Loctite to the fastener, install it and torque it to specifications. 9. Install the idlers, apply Loctite to the fasteners and torque them to specifications. 10. Route the 5/16 and 1/4 inch hoses from the tank up to the top of the engine. 34

37 3.2 Installing the Compressor

38 ITEM QTY PART # DESCRIPTION P VR70 compressor Inlet valve, integrated regulator, short degree elbow, brass NPT-Poly, 1/8-1/ Connector, NPT-Poly, 1/8-1/ /8 Strap clamp Dipstick retaining bracket degree elbow, 1/4 tube-1/8 pipe /2 JIC male 3/4-16 o-ring /2 AOP x 7.5 long hose c/w 90 & 45 degree Plug, steel, 1/2 male JIC Nut, Nylok, NC, 1/ Washer, flat, SAE 1/ Filter cover /4 NC threaded rod, 2.62 long Nut, hex, NC, 1/ Paper filter element degree elbow, brass NPT-tube, 1/8-5/ O-ring, Viton 3 1/8 ID Connector, male, 3/4-16 o-ring Washer 3/4 o-ring O-ring 5/8 ID x 1/16 wide, Viton P Clutch, complete Temperature probe cable assembly Elbow, steel swivel 45 degree, 3/4 JIC 36

39 ITEM QTY PART # DESCRIPTION /8 x 9 heater hose /8 x 28 heater hose Hose clamp MH Plastic connector 5/8 heater hose 1. Remove the four socket-head bolts holding the inlet control valve on the compressor (note that there are two long bolts and two short bolts) and remove the control valve, complete with all attached components (Figure 3.2). Remove the large O-ring and store it carefully to prevent damage. Also remove the air filter and cover to allow better access during assembly. 37

40 Figure 3.2 Inlet control valve removed 2. Immediately install the supplied red protective cover into the opening of the compressor body to keep contamination out of the compressor. Contamination may result in compressor damage. 3. Apply Loctite to the other end of the studs and carefully lower the compressor onto the bracket (Figure 3.3). The transmission dipstick tube should be floating loose over the passenger side of the engine. Figure 3.3 Compressor in position 38

41 4. Make sure that the cruise control and throttle cables are routed under the compressor body and are not trapped between the compressor and the bracket or other objects (Figure 3.4). Figure 3.4 Proper placement of cables 5. Install two 8 mm serrated nuts onto the two front studs. 6. Install the third 8 mm serrated nut onto the back stud. This is a very tight location and will require patience to put the nut into position. Rotating the electrical connector on the injector will help provide better access. You may find that the access is easier from inside the vehicle. 7. Using a short wrench, tighten the nuts. 3.3 Connecting Compressor Hoses 1. Route the 1/2 inch hose across the top-front of the engine and connect it to the fitting on the side of the compressor. Tighten the fitting. 2. Route the 3/4 inch hose up the back of the engine and connect it to the fitting on the back of the compressor. Tighten the fitting. Use a 1-1/4 inch crows-foot wrench attachment. 3. Check the location and routing of hoses to make sure they do not contact any sharp or hot objects. Also make sure that they do not interfere with the operation of the throttle or any other moving parts. 4. Fasten the lines in place with stainless ties. 5. Protect any potential damage areas with plastic loom. 39

42 3.4 Installing the Inlet Control Valve Document Loosen the fitting of the compressor remote fill extension hose on the top of the inlet control valve so it can be moved. 2. Clean around the top of the compressor, then carefully remove the red plastic protective cover so that no contaminants enter the compressor. 3. Ensure the O-ring is still correctly seated into the compressor body, then install the inlet control valve in place and align it with the compressor body so that the air filter faces toward the center of the engine. 4. Apply Loctite to the two rear socket-head bolts (the shorter bolts) and install then into the two rear holes on the control valve, threading them into the compressor body. 5. Place the transmission dipstick support bracket (with attached spacers) over the two front holes of the inlet control valve. Make sure the main harness is routed over the top of the bracket (Figure 3.5). Figure 3.5 Main harness routing 6. Apply Loctite to the long socket-head bolts and install them into the support bracket and control valve, threading them into the compressor body (Figure 3.6). 7. Tighten the four bolts equally and torque them to specifications. 40

43 Support Bracket 3.5 Connecting Control Hoses Figure 3.6 Support bracket 1. Route the 5/16 and 1/4 inch hoses up the back of the engine. 2. Connect the 1/4 inch hose to the 45 degree fitting on the back of the inlet control valve and tighten the fitting. 3. Connect the 5/16 inch hose to the 90 degree fitting on the front of the inlet control valve and tighten the fitting. 4. Check the routing of hoses to make sure that they do not interfere with moving parts and that they will not contact sharp or hot objects. Protect them as required with plastic loom and fasten them in place with ties. Apply heat protection in areas where the hoses are close to or may contact hot areas, such as the exhaust manifold. 3.6 Installing Other Components 1. Install the transmission dipstick tube and fasten it to the OEM location on the back of the engine. 2. Fit the supplied rubber covered P clamp around the transmission dipstick tube just behind the A/C hose bleed valve. Bend the A/C bleed valve from horizontal to the vertical position. 3. Connect the P clamp to the vertical tab on the installed dipstick tube bracket on the inlet control valve using the supplied 1/4 x 1 inch bolt, washer and nut (Figure 3.7). 41

44 Figure 3.7 Dipstick attached with P-clamp 4. Fasten the electrical connector ends together and secure them in place with nylon ties. Ensure all connectors are tied back away from the compressor body. Heat from the compressor could damage insulation. 5. Install the modified engine oil fill tube and fasten it to the hole in the front horizontal tab on the dipstick tube bracket using the supplied 1/4 x 1 inch nut and bolt. Make sure that the OEM clamps are in place on the connections. 6. Fit the small electrical sensor (removed from the front of the passenger side valve cover) to the lower threaded hole on the long tab of the dipstick bracket. Use the supplied 5/16 NC x 3/4 inch bolt. Also connect the engine ground here. 7. Fit the supplied 9 x 5/8 inch heater hose to the connector previously fitted into the upper OEM heater hose (with the OEM tee) and route that hose around the front of the inlet valve (Figure 3.8). 8. Route the OEM upper heater hose (with the OEM tee) down the left side of the compressor under the inlet valve. Connect the end from the tee to the hose barb fitting installed earlier under the compressor oil return hose. 42

45 9 hose with connectors Figure 3.8 First upper hose connection 9. Install a second supplied connector into the 9 inch length hose and connect up the other end of the upper heater hose to this connector (Figure 3.9). Figure 3.9 Final upper hose connection 10. Route the lower heater hose (with the OEM tee at the rear of the engine) around the driver side of the engine throttle body clear of throttle linkage. Install a plastic connector into the cut end. 43

46 11. Fit the supplied 28 x 5/8 inch heater hose to the other end of the lower heater hose connector and route the hose over the inlet valve to the connector installed earlier at the heater core end. 12. Reposition the compressor oil-fill extension tube so that it faces forward and is positioned below the wiring harness along the drip rail (Figure 3.10). Secure it with a plastic tie. Figure 3.10 Compressor fill tube 13. Install the alternator on the compressor bracket and torque the fasteners to specifications. 14. Connect the wiring to the alternator. 15. Clean the inside of the OEM crankshaft pulley and place the VR70 pulley in place, aligning the holes. 16. Apply Loctite to the three 10 x 70 hex head cap screws and thread them into the crankshaft. Torque them to specifications. 17. Install the OEM belt. 18. Install the VR70 belt (Figure 3.11). 44

47 VR7000 Compressor VR7000 Tensioner VR7000 Back Idler VR7000 Ribbed Idler Crank Pulley Figure 3.11 VR belt routing 19. Check all fasteners and fittings to ensure that they are properly tightened. Check the routing and security of all hoses. 20. Replace all OEM parts that were removed in preparation for installation, except throttle body cover, air cleaner and the ducting components. 3.7 Filling the System with Oil 1. Make sure that the vehicle is level. 2. Remove the oil filler plug from the compressor oil fill extension tube. 3. Pour the supplied compressor oil into the filler hole using a funnel. 4. Turn the compressor clutch clockwise with a ratchet and socket using the bolt in the center of the clutch as you pour the oil. 5. Regularly check the sight glass at the front of the tank to ensure that the correct oil level is attained. Remember to check the oil level again after operating the system for the first time. 6. Insert the filler plug into the extension tube and tighten it securely. Overfilling the system will result in damage to the compressor, extreme oil loss and a hazardous situation. 45

48 3.8 Completing the Installation Document Refill the cooling system with the manufacturer recommended coolant to the correct level. 2. Make sure to eliminate all air from the cooling system to prevent overheating. 3. Check all cooling system connections for leaks. 4. Check the coolant level again after the vehicle reaches operating temperature to make sure that it is correct. 5. Make sure all vehicle systems operate correctly before operating the compressor. 46

49 PART 4 INSTALLING THE CONTROL COMPONENTS SYSTEM V FORD L Triton V8 SUPERDUTY E250 E350 TM UNDERHOOD AIR COMPRESSOR 47

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51 ITEM QTY PART # DESCRIPTION Throttle control, mechanical Throttle bracket Connector, 90 degree modified elbow 1/4 poly tube-1/8 NPT /4 poly tube, black /4 poly tube, red /4 tube 1/8 NPT orifice Cable swivel Brace hook Nylon washer Cable nipple Throttle pull Button head screw E-clip Switch box Low profile control panel Interface cable Drive disable circuit 4.1 Installing the Control Unit 1. Remove the driver-side step liner and the kick panel behind the park brake pedal. 2. Locate the control unit against the side of the seat base and mark the two mounting hole locations for the mount bracket. 3. Drill two 7/64 inch holes in the seat base at the marks. 4. Mount the control unit using two #6 x 3/4 inch self-tapping screws (Figure 4.1). 49

52 Figure 4.1 Mounting the control unit 5. Route the wires down toward the step well and along the bottom, behind the kick panel and up under the dash. Use tape to hold the wires in position. 6. Install the driver-side stepliner and kick panel back into position over the wires. 7. Remove the trim panel from the front of the dash on the driver s side. 4.2 Safety Feature for Vehicles with Automatic Transmissions WARNING FAILURE TO PROPERLY INSTALL AND VERIFY FUNCTION OF THIS SAFETY INTERCONNECT FEATURE CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH If the vehicle has an automatic transmission, the Throttle Control MUST be connected so as to be inoperable unless the transmission is in park or neutral. If this important safety interconnect is not already provided VMAC DDC Drive Disable Circuit Part Number will accomplish this. 50

53 1. Remove the two screws mounting the DataLink connector to the under-dash cross-brace (Figure 4.2). 2. Remove the six screws holding the under-dash cross-brace in place and remove the cross-brace (Figure 4.2). Figure 4.2 DataLink connector and brace 3. Apply the park brake and shift the transmission into the lowest gear. Using Blue Loctite 242 on the setscrew, mount the magnetic actuator to the transmission arm under the dash (Figure 4.3). Make sure not to pinch or damage the orange shift indicator harness during installation. Do not damage or pinch the orange cable Mount close to the end of the arm Apply Loctite, tighten with 3/32 hex wrench To mount magnet bracket, shift into low gear with park brake applied. Figure 4.3 Magnetic actuator 51

54 4. Drill a 15/64 inch hole as shown in Figure 4.4. Using a 1/2 inch socket wrench, install the screw for the magnetic switch bracket in the hole to tap threads in the hole. Remove the screw. Use the screw to pre-tap the hole before installing the switch bracket. Figure 4.4 Hole for magnetic switch 5. Mount the switch bracket to the frame under the dash (Figure 4.5). Note the location of the rectangular washer (the hole is offset to provide more clearance). Figure 4.5 Bracket mounted 6. 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. 52

55 7. Shift the transmission back into park, being careful not to hit the switch. 8. 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 4.6). Tighten the screw with a screwdriver. Shift the transmission into park Slide the switch over until the magnet and switch almost touch, then tighten the screw Figure 4.6 Adjustment with the magnet 9. 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. Once the DDC is mounted, it must be tested as outlined above. Failure to properly install and verify the operation of the safety interconnect can result in injury or death due to inadvertent vehicle movement during operation. 10. Leave the two black wires for connection later. 11. Install the under-dash cross-brace and the DataLink connector. 12. Mount the switching box up under the dash and out of the way. 4.3 Connecting the Wiring Harness 1. Use the wiring diagram in Figure 4.7 as a guide for connections. 2. Connect the white connector on the interface cable to the matching one on the switching box. 53

56 THROTTLE CONTROL HOURS 1/10 Document Connect the green Ground wire from the interface cable to a good chassis ground, such as a mounting screw on the under-dash cross-brace. 4. Route the white Clutch and red Throttle Control wires through the firewall into the engine compartment. 5. Route the white wire to the compressor and connect it to the matching connector on the clutch. 6. Route the red wire to the back of the engine inside the cab for connection to the throttle control. FIREWALL BULKHEAD CLUTCH INLET VALVE CONTROL PANEL COMPRESSOR CURTIS TEMPERATURE PROBE SWITCHING BOX 7 PIN CONNECTOR (GREEN) CLUTCH THROTTLE CONTROL 4 PIN CONNECTOR (GREEN) RED RED WHITE INTERFACE CONNECTOR WHT 16GA WHT 16GA WHT GROUND GRN RED AUTOMATIC TRANSMISSIONS ONLY DDC BLK BLK PARK BRAKE BLACK WIRE INTERFACE CABLE OR THROTTLE OEM FUSE PANEL IGNITION OFF: NO VOLTAGE IGNITION SWITCHED 12 VOLTS XXXX XXXX XXXX WIRE LABEL LEGEND CHASSIS GROUND SOLDER & SEAL TO GREEN WIRE WITH RED STRIPE STD. TRANS. ONLY NO DDC PARK BRAKE SWITCH/DDC IGNITION ON: BATTERY VOLTAGE HOT side of fuse #13 is a possible location. PARK BRAKE BLK Figure 4.7 Wiring connections 54

57 7. Route the red Key-switched 12 Volts wire with the inline fuse to the fuse panel under the dash. Connect it to the fuse tap and install it on the hot side of any fuse that is controlled by the ignition switch fuse (Figure 4.8). Fuse #13 is one possibility. Fuse tap connection Figure 4.8 Fuse box connection 8. Connect the harness from the control panel to the short harness on the switching box. 9. Route the long gray harness from the switching box through the firewall to the compressor and connect it to the matching connector on the harness from the bottom of the compressor For Manual Transmission Vehicles 1. Route the black wire labeled PARK BRAKE SWITCH/DDC from the interface cable to the park brake switch. 2. Locate the green wire with the red stripe at the park brake switch. 3. Pull the loom back from the park brake wire and splice the black wire to the green/red wire For Automatic Transmission Vehicles 1. Connect the black wire labeled INTERFACE CABLE to the black wire labeled PARK BRAKE SWITCH/DDC on the interface cable. 2. Solder the black wire labeled PARK BRAKE to the green/red park brake switch wire. 55

58 4.4 Installing the Throttle Controller Document Position the throttle controller assembly on the back of the driver side cylinder head (Figure 4.9). 2. Place split lock washers on each of two 10 x 25 mm bolts, apply Loctite and install them in the cylinder head. Torque them to specifications. 3. Route the throttle cable up the back of the engine to the throttle bracket With Cruise Control Figure 4.9 Throttle controller 1. Remove the cruise control and throttle control cables from the throttle body and from the OEM bracket. Remove the throttle bracket. 2. Drill a 13/32 size hole in the OEM throttle cable bracket on the throttle body, next to the OEM cable anchor point (Figure 4.10). 3. Install the bracket and install and connect the OEM throttle cable. 56

59 OEM Return Spring Connection 13/32 Diameter Hole OEM Throttle Location OEM Cruise Location OEM Bracket Bracket viewed from the front Figure 4.10 Bracket modifications 4. Insert the VR throttle cable through this hole and secure it with the cable nuts and washers. 5. Loosen the Allen-head screw that secures the tab to the throttle pull bracket (Figure 4.11). 6. Hook the tab onto the OEM throttle body assembly, clipping the throttle pull to the throttle arm over the cruise control cable connection shoulder with the small slot in the throttle pull bracket at the top and tucked under the spring tab. 2. Slip into the throttle pull bracket 1. Loosen the screw 5. Tighten the screw 4. Hook onto the tab on the front of the throttle body quadrant 3. Slip over the cruise control cable connection shoulder Figure 4.11 Throttle bracket 7. When correctly aligned, tighten the Allen-head screw. 57

60 8. Clamp the cable collar onto the cable, leaving approximately 1/4 inch of slack in the cable (Figure 4.12). 9. Install the cruise control cable in the bracket and attach it to the OEM throttle body assembly. Spring Tab Allen-head Screw Cruise Control Quadrant Tab 1/4 clearance Without Cruise Control Figure 4.12 VR cable connection at throttle 1. Insert the VR throttle cable through the hole for the cruise control cable and secure it with the cable nuts and washers. 2. Loosen the Allen-head screw that secures the tab to the throttle pull bracket and hook the tab onto the OEM throttle assembly, clipping the throttle pull to the throttle arm over the cruise control cable connection shoulder with the small slot in the throttle pull bracket at the top and tucked under the spring tab. 3. When correctly aligned, tighten the Allen-head screw. 4. Clamp the cable collar onto the cable, leaving approximately 1/4 inch clearance between the cable collar and the linkage (Figure 4.12). 4.5 Connecting the Poly Tubes 1. Insert the black poly tube from the inlet control valve to the 90 degree elbow on the bottom of the throttle controller. Make sure it is pushed in all the way to make a secure connection. 58

61 2. Insert the red poly tube from the throttle controller to the 45 degree fitting on the back side of the inlet control valve. Make sure it is pushed in all the way to make a secure connection. 3. Make sure that the tubes are protected and secured. 4. Install the VR air cleaner. 4.6 Completing the Installation Check all under dash and engine compartment wiring to ensure that it will not contact any hot or moving components and will not interfere with the operation of the vehicle. Secure all wiring with nylon ties and supplied loom as required. 1. Install all remaining OEM components, including the air cleaner, throttle body cover and all ducting. Tighten all clamps. Install and tighten the battery terminal connections. 2. Connect the ground strap and the temperature sensor to the lower bolt hole at the dipstick bracket using the supplied 5/16 x 3/4 inch bolt. 3. Check all fittings, fasteners and fluid levels before operating the system. 4.7 Testing the safety circuit Use the following procedure to test the operation of the DDC safety circuit: 1. For safety, place the vehicle in a safe operating position, and block the vehicle wheels. Ensure that there are no other people around the vehicle. 2. Sit in the driver s seat, with the transmission in Park and the park brake fully engaged. 3. Start the vehicle engine and wait for the idle to stabilize. Engine operating temperature should be in the normal operating range. 4. Test the operation of the VR system. Momentarily activate the system by turning it On then Off quickly, the engine should start to idle up, and the clutch should engage. 5. Firmly apply the vehicle s foot brake and hold it down. 6. Release the park brake and momentarily activate the system as before. The engine should not idle up and the clutch should not engage. 7. Apply the park brake and firmly apply the vehicle s foot brake and hold it down. 8. For Automatic Transmissions Place the gear selector in any position other than Park. 59

62 9. Momentarily activate the system as before. The engine should not idle up and the clutch should not engage. 10. Place the transmission in Park and shutdown the vehicle s engine. If the vehicle fails the test, check your wiring to make sure that all connections are correct and secure, and the spacing between the magnet and the switch is correct. If you require additional assistance, please contact your nearest VMAC dealer. This system has been adjusted to basic settings at the factory. You may need to make adjustments so that the operation of the system better suits your requirements. See the Owner s Manual for adjustment procedures and precautions. 60

63 Appendix A Soldering 1. Cut the OEM wire and strip approximately 1/2 inch from each end and from the VR70 wire. 2. Slide the provided heat shrink onto one OEM wire and one VR wire. Twist all three wires together. 3. Heat all 3 wires at the joint with a soldering gun or pen, then apply the provided solder. Ensure the solder flows into the joint to bond the wires together. 4. Once the joint has cooled, slide the heat shrink over the joint and heat it with a heat gun. Make sure the shrink is heated until the liner melts and makes a good seal. 61

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