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Installation Manual Document Number: 1930010 Document #1930010 VR70 Underhood Air Compressor: System Number V900040 Application: DODGE 1998.5-2002, 5.9L Cummins 24 Valve Diesel, with Air Conditioning) Publication Date: Revised by T. W. Mitchner, 17 July 2003 Previous Document Number 1900675 Previous Document Number 1900660 Registered Trademarks: V70 and VMAC are registered trademarks of VMAC. Dodge is a registered trademarks of Daimler-Chrysler AG. Cummins is a registered trademarks of Cummins Inc. 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 2002 The contents of this manual may not be reproduced in any form without the express written permission of VMAC Printed in Canada 2
CONTENTS GENERAL INFORMATION... 5 INTRODUCTION... 7 INSTALLATION STEPS... 7 TERMS AND SYMBOLS... 7 INSTALLATION NOTES... 7 ORDERING PARTS...9 WARRANTY... 9 SYSTEM IDENTIFICATION PLATE... 9 SPECIAL INSTALLATION NOTES... 10 CHANGES AND IMPROVEMENTS... 10 PART 1: PREPARING FOR INSTALLATION... 11 1.1 PREPARING FOR INSTALLATION... 13 1.2 INSTALLING THE BRACKET... 15 1.3 INSTALLING THE COOLER HOSES AND COMPRESSOR... 17 1.4 INSTALLING THE THROTTLE CONTROLER ASSEMBLY... 21 PART 2: INSTALLING THE OIL COOLER, AIR TANK AND LINES... 23 2.1 INSTALLING THE OIL COOLER... 25 2.2 INSTALLING THE TANK MOUNTS... 25 2.3 CONNECTING THE LINES... 28 PART 3: INSTALLING THE CONTROL UNIT... 33 3.1 INSTALLING THE CONTROL UNIT... 34 3.2 CONNECTING THE WIRING HARNESS... 35 3.2.1 2003 MANUAL TRANSMISSION... 35 3.2.2 2002 AUTOMATIC TRANSMISSION... 36 3.2.2.1 TESTING THE DRIVE DISABLE CIRCUIT (DDC)... 37 APPENDIX A...38 PART 4: INSTALLING THE THROTTLE CONTROLLER... 45 4.1 INSTALLING THE CABLE... 43 4.2 ADDING OIL TO THE SYSTEM... 46 4.3 COMPLETING THE INSTALLATION... 47 PART 5: ILLUSTRATED PARTS LIST... 49 MAIN BRACKET ASSEMBLY... 51 COMPRESSOR ASSEMBLY... 51 TANK ASSEMBLY... 52 HOSE KIT... 52 THROTTLE CONTROL ASSEMBLY... 52 TANK BRACKET ASSEMBLY... 53 OIL COOLER ASSEMBLY... 53 ELECTRICAL ASSEMBLY... 53 MISCELLANEOUS... 53 WARRANTY REGISTRATION 3
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General Information System # V900040 DODGE 1998.5-2002 5.9L CUMMINS 24 VALVE DIESEL with Air Conditioning TM UNDERHOOD AIR COMPRESSOR 5
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GENERAL INFORMATION Introduction This book provides installation instructions for the VR70 Underhood Air Compressor. The information in this book should be read completely before attempting installation. Installation Steps The installation procedures are divided into the following main steps: Part 1: Preparing for installation Part 2: Installing the tank and lines Part 3: Installing the cooler and main bracket Part 4: Installing the throttle controller Part 5: Installing the control components Part 6: Illustrated parts list Terms and Symbols This manual uses the following terms and symbols: 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 if the indicated warning is not followed. This symbol indicates that there is a possibility of damage to the equipment if the warning is not followed. This symbol indicates that there is additional information or special emphasis on a specific procedure. Installation Notes 1. It is important that you complete all the installation steps before operating the system. 2. Follow all safety precautions for underhood mechanical work. 3. Use Loctite 242 or equivalent on all engine-mounted fasteners. 4. 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. 7
5. These installation instructions are intended as a general guide. In some instances, due to variations in vehicle manufacture or if prior modifications have been made to the vehicle, it may be necessary to carry out grinding, bending or rearranging operations for correct fit. These operations MUST follow sound, standard shop practices. 6. Left and right definitions in this manual are determined when sitting in the driver s seat, facing forward. 7. All fasteners must be of the correct size and torqued according to the specifications shown below. Always use manufacturers torque values for OEM fasteners. 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 (ft-lb) 9 18 35 55 80 110 170 280 Newton meter (N m) 12 24 47 74 108 149 230 379 STANDARD GRADE 8 NATIONAL FINE THREAD Size 3/8 7/16 1/2 5/8 3/4 Foot-pounds (ft-lb) 40 60 90 180 320 Newton meter (N m) 54 81 122 244 434 METRIC CLASS 10.9 Size M8 M10 M12 M14 M16 Foot-pounds 19 41 69 104 174 Newton meter 25 55 93 141 236 Table 1 The fastener values are applicable when Loctite is applied unless otherwise specified. 8. 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. Example: A410055 is a 55 inch hose extender kit. Hose Diameter Colour Coded Label Part Number Prefix 1/4 inch Yellow 173 5/16 inch Orange 174 1/2 inch Blue 175 5/8 inch Blue 176 3/4 inch Green 177 Table 2 - Above illustrates the colour code used by VMAC to define the different hose diameters. 8
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 must be attached to the vehicle at the time of installation. Locate the plate as shown in Figure A. Drill the two hole locations using a 7/64 inch drill bit. Attach the plate with the two supplied #6 pan head self tapping screws. Figure A 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. 9
Special Installation Notes Document #1930010 If you intend to use an auxiliary air receiver with this system you must observe the following installation procedure (Figure B). Failure to observe this procedure will result in damage to the system. 1. The line from the VR70 tank to the auxiliary air receiver must have a one-way check valve installed to prevent blow back from the auxiliary tank to stop 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 entering the line. Figure B Changes and Improvements These products and documents are subject to changes or improvements without notice. 10
PART 1 Preparing for Installation System # V900040 DODGE 1998.5-2002 5.9L CUMMINS 24 VALVE DIESEL with Air Conditioning TM UNDERHOOD AIR COMPRESSOR 11
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1 Preparing for installation 1.1 Preparing for installation 1. Disconnect the batteries. 2. Remove the air cleaner to turbo inlet ducting and immediately cover the inlet to the turbocharger. 3. Remove the OEM drive belt. 4. Disconnect the wiring from the alternator. Also disconnect the wiring plug beside the passenger-side battery (Figure 1.1) and remove the retaining clip from the battery tray. Figure 1.1 Wiring plug beside the battery 5. Remove the alternator top support bracket, the alternator and the alternator tie mount from the engine. 6. Remove the battery positive cable from the top of the radiator. 7. Drain the coolant. 8. Remove the top radiator hose. 9. Remove the coolant expansion tank and the windshield washer reservoir from the fan shroud. 10. Remove the lower radiator hose. 13
11. Remove the coolant return hose from the transmission cooler at the square block tee connector (Figure 1.2). Document #1930010 Heater return hose Transmission heat exchanger supply pipe Engine Block OEM M10 hex head bolts two hidden Transmission heat exchanger return pipe Figure 1.2 Location of hoses, fittings and fasteners 12. Loosen the securing clamp which retains the two 1/2 inch steel coolant lines near the exhaust manifold. 13. Remove the heater return hose from the square block tee connector. 14. Remove the fan belt tensioner, the engine cooling fan and the fan shroud. 15. Remove and discard the lifting lug from the engine. 16. Remove the electric horns from the top-side of the fender panel. 17. Remove the hex head cap screws from the OEM crankshaft pulley. 18. Remove and discard the transmission heat exchanger supply pipe and hose from the front of the transmission cooler to the cylinder head outlet (Figure1.3) labelled E in Figure 1.4. 19. Remove the T-connector in the bottom hose housing (Figure 1.2). 20. Remove the three M12 hex head cap screws and the three M10 hex head cap screws retaining the OEM mounting unit to the engine block. 21. Remove and discard the entire assembly from the engine block (Figure 1.3). 22. Remove the three M10 OEM cap screws from lower radiator hose outlet and the three M12 hex head cap screws retaining the air conditioning mount to the engine block. 23. Remove and discard the entire assembly from the engine block. 14
On automatic transmission vehicles, remove and discard this hose and metal line. On manual transmission vehicles, remove the blanking plug from this location. T-connector with heater coolant return and transmission heat exchanger return lines Figure 1.3 Location of hoses and fittings 1.2 Installing the bracket 1. Automatic Transmission Remove the OEM hose barb fitting from the cylinder head which held the OEM steel coolant line for the transmission cooler. This may have an internal hex. Apply Loctite PST to the supplied 1/2 NPT 5/8 inch hose barb and thread it into the supplied brass 45 degree elbow, then thread the assembly into the OEM hose barb location in the cylinder head. Angle it downwards about 20 degrees (Figure 1.4). Manual Transmission Remove the plug in the side of cylinder head just below the front lifting lug location, then install the supplied 45 degree brass fitting and hose as for the automatic transmission. Figure 1.4 Angle of fitting 15
2. Connect the supplied 40 5/8 inch heater hose to the 45 degree fitting in the cylinder head, install the supplied hose clamp and tighten. Route this hose down behind the engine oil filter. Cooling line fitting (note angle) Socket head bolt Heater hose connection Figure 1.5 Hose connections and fittings 3. Check the machined surface on the engine block and clean it before attempting to mount the VR70 bracket. 4. Remove the belt tensioner, idlers and the lower front AC stub from the VR70 bracket to make installation easier. 5. Apply Loctite PST and install the T-connector (removed earlier) into the rear of the VR70 bracket in the OEM orientation. 6. Insert the OEM rubber seal into the groove on the side of the engine. Lift the bracket into position and install the three OEM M12 hex bolts loosely through the lower section of the bracket and into the engine. The roll pins on the VR70 bracket are used to align the bracket with the front edge of the engine block. They do not fit into any holes. 7. Install the three M10 socket head screws into the holes around the radiator hose fitting. Make sure that the rubber seal is still in position, then torque all fasteners to specifications. 8. Install the OEM belt tensioner to the VR70 bracket using the OEM cap screw. Then install the VR70 belt tensioner and both VR70 idlers removed before fitting the bracket (Figure 1.6). Use Loctite and torque both fasteners to specifications. 9. Place the OEM A/C compressor in position and install the small stub to the lower front mounting point using the M8 20 hex head bolt. Thread the four A/C cap screws into place and torque to specifications 10. Install the OEM lower rad hose and clamp. You may have to bend it slightly to provide clearance for the belt tensioner. 16
Tensioners Figure 1.6 Installing the tensioners 1.3 Installing the cooler hoses and compressor 1. On automatic transmission models, connect the supplied 5/8 50 inch heater hose to the front end fitting on the OEM transmission cooler (located on the side of the engine under the exhaust manifold). Install a hose clamp and tighten. Route the hose forward and down beside the engine oil filter. 2. On manual transmission models (Figure 1.8), cut the OEM heater return hose approximately 1 inch before the bend. Insert the supplied plastic T and secure it with the supplied hose clamps. Route the hose clear of the exhaust manifold and tie it to the air conditioning line, then route it forward and down under the radiator and clear of all hot or moving parts. Cutting the hose Installing the L-shaped bracket Figure 1.7 3. Place the L-shaped bracket for the upper alternator support on the side and front of the cylinder head. Apply Loctite and install the two supplied M8 x 25mm socket head bolts to the front and supplied M10 x 25mm bolts to the side (Figure 1.7). 17
Figure 1.8 Connection for manual transmission models 4. Place the compressor on the mounting bracket. Apply Loctite, thread the two M8 nuts with washers on the two front studs and tighten. Apply Loctite and thread the supplied M8 bolt with washer into the remaining hole at the rear of the compressor. 5. Attach the shortest 1/2 inch braided oil return line to the 90 degree fitting on the engine side of the compressor and tighten the fitting. 6. Fit the alternator to the boss welded on top of the VR70 mounting bracket using the OEM bolt and nut. 7. Refit the OEM upper support bracket for the alternator to the installed L bracket using OEM bolts. Tighten all bolts. 8. Reconnect the wiring to the alternator. 9. Install the VR70 pulley to the OEM pulley after cleaning out all dirt and debris using the OEM bolts. 10. Install the replacement OEM drive belt (Figure 1.10). 11. Install the VR70 belt (Figure 1.10). 18
Figure 1.9 Compressor and alternator installed on the engine VR70 belt routing OEM belt routing Figure 1.10 OEM and VR70 belt routing 19
12. Modify the fan shroud as shown in Figure 1.11 Use an angle grinder or similar tool. Cut away the three ribs and the angled section on the passenger side of the shroud. Figure 1.11 Fan shroud modifications 13. On 2000 models, install and tighten the supplied fan spacer. Lower the fan shroud and fan into place together. Fit the fan and tighten. 14. Push the air conditioning line on the passenger side of the vehicle so that it tucks up under the lip of the inner fender (Figure 1.12). Install the VR70 replacement bracket for the coolant expansion tank to the two fan shroud retaining cap screws on the passenger side of the vehicle, then install the expansion tank. Fit the 3/8 11-3/4 inch long hose and two clips to the expansion tank and radiator. 20 Figure 1.12 Expansion tank bracket installation
15. Install the horns together on the opposite (lower) side of the fender panel using the single center hole. Pass the horn wires through the large hole at the front of the panel. Figure 1.13 shows the location looking upward from under the vehicle. 16. Install the top radiator hose. Tighten the hose clamps. 17. Install the windshield washer bottle. Figure 1.13 Location of horn and wires 1.4 Installing the throttle controller assembly 1. Mount the throttle controller assembly to the front of the cylinder head (Figure 1.14). 2. Route the throttle controller cable along the engine toward the firewall. Tuck it under the windshield wiper motor shelf and behind all wiring so that the cable sweeps in a large U-shape back toward the engine injector pump at the front of the engine. Route the cable carefully to ensure that the cable does not foul other linkages. Secure the cable with ties or clips as required. 21
Figure 1.14 Installation of pneumatic throttle controller 22
Part 2 Installing the Oil Cooler, Air Tank and Lines System # V900040 DODGE 1998.5-2002 5.9L CUMMINS 24 VALVE DIESEL with Air Conditioning TM UNDERHOOD AIR COMPRESSOR 23
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2 INSTALLING THE OIL COOLER, AIR TANK AND LINES 2.1 Installing the oil cooler 1. Install the oil cooler bracket to the cross-beam under the vehicle radiator using the existing holes. Use two 3/8 inch flange-lock bolts, washers and Nylok nuts through the two outer holes. 2. Insert the supplied strap nut (piece of strap steel, threaded, with a bend on one end) through the hole in the crossmember. Install a 3/8 inch flange-lock bolts through the cooler bracket and thread it into the strap nut. Tighten all the fasteners securely. Cooler mounting location Figure 2.1 Mounting location for the oil cooler 2.2 Installing the tank mounts 1. Remove the 1/4 inch bolts from the C -clamps, expand the clamps and slide them over the front of the tank. Position the clamps at the front and rear of the tank just behind the front and rear end cap welds. Rotate the clamps so that the flat ends face to the right side of the tank when viewed from the front. Insert the 1/4 inch bolts through the C - clamps from the top, squeeze the clamps together and fit the 1/4 nuts. Tighten the pinch bolts just enough so that you can rotate the clamps for alignment purposes. 2. Select the two tank mount brackets and fit the widest bracket to the front C-clamp using the two supplied 5/16 1/2 NC bolts, push the tank mount bracket up as far as it will go in the C- clamp slotted holes and tighten the bolts. Use Loctite. 3. Fit the rear narrow tank mount bracket to the rear C-clamp using two 5/16 1/2 NC bolts. 25
Figure 2.3 Front tank mounting bracket assembly 4. Select the tank mount backing strap with the spacing tabs welded on one side. 5. Thread one tank strap cable through the upper hole above the long welded tab from the flat side of the backing strap. Hang the cable over the passengers side of the frame rail from the inboard side as close as possible to the front cab mount. 6. Place the second tank mount cable through the flat backing strap and hang it over the frame approximately 2 feet back from the front cable. 7. Raise the tank with the attached mounting brackets and hook the extended flat ends over the top of the passenger side frame rail. Support the tank in this position and align the tank front to rear so the front mount bracket fits up behind the front cab mount. 8. Slip the front cable over the top of the front tank mount bracket so the cable sits in the slot and wraps down around the flat surface of the mount bracket, through the lower slot with the kicked up lower tab. Insert the threaded end of the cable through the lower hole in the backing strap and install the supplied 5/16 inch nut. Repeat this procedure for the rear mount. 9. Rotate the tank so that the UP arrow on the rear of the tank points directly up. Also make sure the tank sits parallel with the ground when the truck is and normal working load. THIS IS VERY IMPORTANT FOR PROPER OPERATION 10. Tighten all bolts and cable nuts and add the two 5/16 lock nuts to the cables and lock the two nuts together. 26
Figure 2.4 Location of tank mount bracket assembly Figure 2.5 Position of tank brackets 27
Figure 2.6 Location of the front tank mounts 2.3 Connecting the lines 1. Connect the 45 degree end of the 3/4 inch line to the compressor. Route the line around the outside of the cab mount and connect the other end of the line to the fitting on the back of the connector. 2. Connect the swivel nut on the steel line coupled to the 1/4 inch braided pressure control line, to the upper location on the rear of the tank, run the steel line down the outside of the tank, up around the outside of the cab mount to the 1/4 inch 90 degree fitting pointing downwards on the compressor inlet control valve. 3. Connect the swivel on the steel line coupled to the 5/16 inch braided scavenge line, into the lower location at the rear of the tank. Route the line along the tank following the same route as the 1/4 line up to the 5/16 inch 90 degree fitting on the opposite side of the inlet control valve. 4. Connect the 90 degree end of the 1/2 inch oil return line to the tank and to the passenger-side fitting on the oil cooler. Route these hoses over the top of the cab mount. 28
Figure 2.6 Lines connected to the tank Figure 2.7 Lines connected to the compressor 5. Connect the 1/2 inch cooler to compressor line from the compressor, to the driver-side fitting of the cooler. Route all lines over the cab mount and along the frame, fastening them to the frame with nylon ties or stainless clamps. Route the line to the cooler and secure it so that it does not contact any moving parts. Ensure that the lines to the compressor are secured so that they do not contact the exhaust system or turbocharger. 6. Tighten all fittings securely. 7. Position the U-bracket on the C-clamp to locate the 5/16 and 1/4 inch steel lines with the P- clamp fitted over the two steel lines. Align the U-bracket with the steel lines and secure the P- clamp with the supplied small socket head cap screws and nuts. Tighten the C-clamp pinch bolt. 29
8. Apply a thin film of oil to the rubber gasket on the oil filter and thread it onto the front of the tank. 7. Slide a hose clamp over the end of the 5/8 50 inch rubber hose connected to either the T-fitting installed in the heater return hose (manual transmission) or to the transmission cooler (automatic transmission). Cut the hose to length as required and connect this hose to the driver-side hose fitting on the oil cooler (Figure 2.8). Tighten the hose clamp. Oil line to compressor Hose to transmission cooler or T fitting inthe heater hose Oil line to compressor Oil line from tank Figure 2.8 Connections at the cooler 8. Slide a hose clamp over one end of the 5/8 32 inch rubber hose. Connect the hose to the fitting on the cylinder head and tighten the hose clamp. 9. Route the hose around the oil filter and under the vehicle. Slide a hose clamp over the end of the hose and connect the hose to the passenger-side hose fitting on the oil cooler (Figure 2.8). Tighten the hose clamp. 10. Fill the cooling system with OEM recommended coolant to the correct level. 30
Part 3 Installing the Control Unit System # V900040 DODGE 1998.5-2002 5.9L CUMMINS 24 VALVE DIESEL with Air Conditioning TM UNDERHOOD AIR COMPRESSOR 31
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3 INSTALLING THE CONTROL UNIT Figure 3.1 V900040 System wiring diagram 33
3.1 Installing the control unit Document #1930010 1. Remove the plastic trim panel from the door sill and the kick panel on the driver s side. 2. Locate a suitable mounting location for the control unit on the floor of the cab next to the driver s side of the seat. Remove the control unit from the mounting bracket and using the bracket as a template, mark and drill two 3/16 holes through the cab floor (Figure 3.2) 3. Fasten the bracket to the floor of the cab using the two supplied #14 hex head self-tapping screws, then fasten the controller back onto the bracket. Figure 3.2 Location for the control unit 5. Route the wire harness from the control unit along the door sill, under the trim panel, behind the kick panel and up under the dash. 6. Attach the switching box to the wire harness on the left of the steering column using nylon ties. Refer to Figure 3.1 for system wiring diagram. 7. Connect the two interface connectors together. Route the white wire, 18 gauge red wire (without the fuse holder) from the interface cable and the wire for the compressor temperature sensor from the electronic control unit through a suitable opening in the firewall. If necessary, you can cut a small slit in the rubber plug to the left of the steering column. 8. Make sure that the underhood harness cannot become pinched or damaged. Fasten the harness out of the way with nylon ties if necessary. 34
3.2 Connecting the wiring harnesses 1. Connect the compressor sensor wire harness to the matching connector on the harness from the control unit. Use Figure 3.1 to assist in locating the wire connections 2. Attach the green wire with the ring connector to a good ground. 3. Route the white wire with the bullet connector across the firewall and along the engine, then connect it to the compressor clutch. 4. Route the red wire with the spade connector along the firewall and the engine, then connect it to the throttle controller. 5. Secure all underhood wire harnesses with ties as necessary to retain them securely and to prevent interference with moving parts or hot areas of the engine. 6. Locate a fuse in the fuse panel that will provide power only when the ignition switch is in the ON position. Be sure to connect to the power side of the OEM fuse. 7. Route the red wire with the in-line fuse out of the way under the dash to the fuse box. Insert the special connector into the fuse fitting at the fuse box, then attach the spade connector from the red wire. Tape if necessary to avoid shorting. 3.2.1 Manual transmissions Figure 3.3 Manual transmission DDC wiring 1. Remove the OEM connector from the switch at the park brake. 2. Connect the Transmission Park Brake jumper to the black DDC interface cable wire and tape the connection. 35
3. Route the black wire with the piggyback connector from the Transmission Park Brake jumper to the park brake switch and attach it to the switch. 4. Connect the OEM wire to the piggyback connector. 3.2.1 Automatic transmission Figure 3.4 Automatic transmission DDC wiring 1. Remove the OEM connector from the switch at the park brake. 2. Install the Drive Disable Circuit (DDC) under the dash using nylon ties Figure 2.4 shows the DDC connections. 3. Connect the black wire from the interface connector to the matching black wire at the DDC. Tape the connection. 4. Connect the yellow wire with the bullet connector from the DDC to the matching connector at the interface connector. 5. Connect the black wire with the piggyback connector from the DDC to the OEM connector on the park brake switch. 6. Connect the OEM park brake wire to the piggyback connector. 7. Locate the three (3) connectors to the power-train control module on the engine side of the firewall on the passenger side of the vehicle (Figure 3.5). 36
C3 C2 C1 Windshield C1 Air Cleaner Figure 3.5 Models with three connectors 8. On vehicles with three (3) connectors, locate the black/white wire connected to terminal 6 on connector C1. 9. Feed the blue wire from the DDC along the same route with the rest of the wires from the interface connector. 10. Solder the blue wire to the black with white stripe wire as shown in Appendix A. 3.2.2.1 Testing the Drive Disable Circuit (DDC) Use the following procedure to test the operation of the DDC safety circuit: 1. Block the wheels, apply park brake, and place transmission in park P. 2. Turn key on but DO NOT START ENGINE. 3. Turn on the control panel, the green lamp should turn on. 4. Release the park brake, the green lamp should turn off. 5. Reapply the park brake, the green lamp should turn back on. 6. Place the gear selector in drive. The green light should turn off. 7. Turn off the control panel. Turn on the control panel, green lamp should NOT turn on. 8. Shift back to Park. The green lamp should turn on. 9. Turn off the control panel and turn off the key. 37
APPENDIX A - SOLDERING INSTRUCTIONS Document #1930010 1. Cut the OEM wire, and strip approximately. 1/2 from each end and from the VR wire (Figure A1). Figure A1 2. Slide the heat shrink provided onto one OEM wire and the VR wire. Twist the 3 wires together (Figure A2). 38 Figure A2
3. Heat all 3 wires at the joint with a soldering gun/pen, then apply the provided solder. Ensure the solder flows into the joint to bond the wires together (Figure A3). 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 till the meltable liner melts and makes a good seal (Figure A4). Figure A4 39
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Part 4 Installing the Throttle Controller System # V900040 DODGE 1998.5-2002 5.9L CUMMINS 24 VALVE DIESEL with Air Conditioning TM UNDERHOOD AIR COMPRESSOR 41
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INSTALLING THE THROTTLE CONTROLLER 4.1 Installing the cable 1. Mark and drill a 3/8 inch hole in the rear of the OEM throttle bracket (Figure 4.1). Figure 4.1 Location for drilling the hole 2. Fit the throttle cable through the hole, slip on a serrated washer and thread on the securing nut (Figure 4.2). Figure 4.2 Throttle component locations 3. Remove the OEM cruise cable retaining clip from the inner end of the throttle spindle and remove the OEM cruise cable. 4. Insert the wide end of the VR70 throttle pull bracket over the spring and over the spindle. Fit the O-clamp over the spindle to secure the VR70 pull bracket against the throttle arm and crimp both ends of the O-clamp. 43
Figure 4.3 Pull bracket and cable installation 5. Connect the red and black poly-lines between the throttle controller and the compressor as shown in Figure 4.4. 6. Route the line to avoid hot areas and any moving parts. Fasten the line with ties as required to keep it secure. 7. Install the cable nipple on the throttle cable. 8. Pull the throttle cable snug and slide the nipple up the cable until it contacts the pull bracket, but not so tight that the throttle is prevented from returning to base idle. 9. Tighten the setscrew on the cable nipple, leaving a 1/4 gap between the pull bracket swivel and the cable nipple. 10. Cut out a section of the throttle arm plastic cover to allow for movement of the throttle pull. 44
Red Poly-line Black Poly-line Figure 4.4 Poly-line connections Figure 4.5 Trimming the cover 45
4.2 Adding oil to the system 1. Make sure that the vehicle is level. 2. Remove the filler plug on the air inlet control valve. 3. Pour six litres (1.6 US Gal.) of the supplied compressor oil into compressor fill hole (Figure 4.6). 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 cap screw at the center of the compressor clutch. Oil filler plug Figure 4.6 5. Allow a few minutes for the all of the oil to flow into the tank, then check the level through the sight glass. It is important not to overfill the system. 6. Install the fill plug in the inlet control valve and tighten it securely 46
4.3 Completing the installation 1. Replace the plastic throttle body cover. Make sure that the VR70 throttle controller cable does not hit against the cover. 2. Refit the plastic air intake trunking to between the air cleaner and the throttle. 3. Connect all electrical plugs removed during installation. 4. Check all lines to ensure that they are properly routed, secured and that all fittings are tightened. 5. Check all cap screws mounting the bracket and components to the engine to ensure that they are properly torqued. 6. Check all belts to ensure that they are installed properly and that the pulleys, idlers and tensioners are correctly aligned. 7. Check all hoses and hose clamps to ensure that they are connected correctly and that the hose clamps have been tightened. 8. Check the oil level in the oil/air tank to ensure that it is at the correct level. Make sure that the system has settled for at least 10 minutes after operation before checking. 9. Check the coolant level in the engine to make sure that it is correct. Remember to run the engine to operating temperature and check the coolant level to make sure that it has not changed. 10. READ THE OWNER S MANUAL BEFIRE OPERATING THE SYSTEM. 47
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PART 5 ILLUSTRATED PARTS LIST System # V900040 DODGE 1998.5-2002 5.9L CUMMINS 24 VALVE DIESEL with Air Conditioning TM UNDERHOOD AIR COMPRESSOR 49
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ILLUSTRATED PARTS LIST SYSTEM V900040 DOGGE 1998.5-2002 5.9L CUMMINS 24 VALVE DIESEL with Air Conditioning ASSY.ITEM UNIT QTY PART# DESCRIPTION 1.0 Main Bracket Assembly 1.1 ea 1 1100134 Main bracket 1.2 ea 2 1300007 Idler, 6-rib smooth 1.3 ea 2 1400051 Spacer, Idler bolt 1.4 ea 2 1510161 Bolt, hex head 1/2 1-1/4 inch NC G8 flange lock 1.5 ea 1 1800137 Pulley VR crankshaft 1.6 ea 4 OEM Bolt 1.7 ea 1 1520147 Bolt, hex head M8 1.25 20mm 1.8 ea 1 3300023 Adjuster Dayco 89211 + fittings 1.9 ea 2 1560508 Nut, hex 8mm 1.25 with double serrated washer 1.10 ea 1 1400140 Stub, air conditioning 1.11 ea 2 1500399 Stud, 8mm 38mm 1.12 ea 1 1520203 Bolt, hex head 8mm 25mm full thread 1.13 ea 3 1570058 Washer, split lock 5/16 inch 1.14 ea 1 1560406 Nut, 12mm Nylok 1.15 ea 1 1570048 Washer, 7/16 inch SAE, plated 1.16 ea 1 3400016 Fan spacer 1.17 ea 1 1620248 OEM belt, 8-rib 1.18 ea 1 1650350 VR70 belt 1.19 ea 1 1300008 Idler, 6-rib grooved 1.20 ea 1 1400129 Spacer, idler.080 1.21 ea 1 1520419 Bolt, hex head G10.9 M12. 1.75 80mm 1.22 ea 1 OEM Bolt 1.23 ea 1 OEM Dished Washer ASSY.ITEM UNIT QTY PART# DESCRIPTION 2.0 P120049 Compressor Assembly 2.1 ea 1 P120002 VR70 compressor 2.2 ea 1 9200212 Inlet valve 2.3 ea 1 1500029 Nut, hex, 1/4 inch NC Nylok 2.4 ea 1 1570038 Washer, flat, 1/4 inch SAE 2.5 ea 1 3600066 Filter cover 2.6 ea 1 1500519 Rod 1/4 inch NC threaded, 2.62 inch 2.7 ea 1 1550221 Nut, hex, 1/4 inch NC 2.8 ea 1 3600037 Filter element 2.9 ea 1 5000081 Elbow, 90 degree, 1/8 inch NPT 2.10 ea 4 1540375 Bolt, socket head M8 1.25 45mm 2.11 ea 1 5000020 Connector elbow, 1/4 inch poly tube 1/8 NPT male 2.12 ea 1 5000020 Connector elbow, 1/4 inch poly tube 1/8 NPT male 2.13 ea 1 5000064 Elbow, 90 degree 1/4 inch poly tube 1/8 NPT male 2.14 ea 1 5000018 Plug, 1/8 NPT hex socket 2.15 ea 4 1540389 Bolt, socket head M8 1.25 18mm low profile 2.16 ea 1 9200036 Inlet valve angle adaptor 2.17 ea 2 2200097 Cable clamp, 1/4 inch 2.18 ea 1 1570482 Washer 7/8 inch ID 2.19 ea 1 5830005 O-ring, Vitron 11/16 inch ID 2.20 ea 1 P200035 Clutch, complete 2.21 ea 1 3550363 Temperature probe and cable assembly 2.22 ea 1 4900002 Elbow, steel JIC/O Ring 1/2 3/4-16 51
ILLUSTRATED PARTS LIST SYSTEM V900040 DOGGE 1998.5-2002 5.9L CUMMINS 24 VALVE DIESEL with Air Conditioning ASSY ITEM UNIT QTY PART # DESCRIPTION 3.0 9200380 Tank Assembly 3.1 ea 1 9200378 Oil Separator Tank Weldment 3.2 ea 2 2200105 Mounting Bracket, 6 Dia. C/W fasteners 3.3 ea 1 3600090 Thimble Screen 3.4 ea 1 5840069 Spring, Compression, FL 1.5 OD-54 3.5 ea 1 3600054 200 PSI Relief Valve 3.6 ea 1 9200217 Blowdown Cap 3.7 ea 1 3600064 Tank Rear Cap Seal 3.8 ea 1 3600036 Coalescing Filter Element 3.9 ea 1 5840068 Compression Spring 3.10 ea 1 5830066 O-ring, Viton, 4-3/4 ID 3.11 ea 1 4900035 Nipple, Steel, Straight Thread, 3/4-16 3.12 ea 1 5000089 3/8 NPT 1/2 SAE Brass Connector 3.13 ea 1 9200039 VR70 Oil Filter 3.14 ea 1 4900036 Elbow, 45 degrees, 3/4 JIC Swivel Nut 3.15 ea 1 5830043 O-ring, Viton 1-7/8 ID x 1/8 3.16 ea 1 4900033 3/4 NPT 3/4 JIC Steel Connector 3.17 ea 1 3600096 Window, Pyrex, 2.12 dia. x.35 thick 3.18 ea 1 1400235 Ring, 2.12 OD x 1.72 ID x.15 3.19 ea 1 1500385 Retaining Ring 3.20 ea 1 3200231 Cover, Sight Glass Document #1930010 ASSY.ITEM UNIT QTY PART# DESCRIPTION 4.0 Hose Kit 4.1 ea 1 1740088 Hose, crimped 5/16 88 inch 4.2 ea 1 1730091 Hose, crimped 1/4 91 inch 4.3 ea 1 1771048 Hose crimped 3/4 48 inch 4.4 ea 1 5000079 Elbow, 45 degree, 1/2 brass 4.5 ea 1 5000006 Fitting, hose barb 1/2 NPT 5/8 inch 4.6 ea 1 2200029 Hose clamp, HS-10 4.7 ea 1 1700027 Heater hose, 150 PSI, 5/8 40 inch 4.8 ea 1 1750035 Hose, crimped 1/2 35 inch 4.9 ea 1 1700027 Heater hose, 150 PSI, 5/8 50 inch 4.10 ea 1 1752067 Hose, crimped with 90 degree elbow, 1/2 67 inch ASSY.ITEM UNIT QTY PART # DESCRIPTION 5.0 3620057 Throttle Control 5.1 ea 1 3620039 Throttle Control, mechanical 5.2 ea 1 9200147 Elbow, orifice 90 deg., 1/8 inch NPT 1/4 inch poly 5.3 ea 1 1700055 Tube, 1/4 inch black poly, 24 inch long 5.4 ea 1 1700334 Tube, 1/4 inch red poly, 23 inch long 5.5 ea 1 5000020 Elbow, 1/4 inch poly tube to 1/8 inch NPT male 5.6 ea 1 1200242 Throttle control bracket 5.7 ea 4 1570350 Washer, lock internal serrated 1/4 inch 5.8 ea 4 1510519 Bolt, flanged hex head 1/4 5/8 inch NC G8 plated 5.9 ea 1 3200070 Nipple, throttle pull cable 5.11 ea 1 3200058 Cable clamp fitting 5.12 ea 1 1200272 Throttle pull arm 5.13 ea 1 1500410 Cotter pin 52
ILLUSTRATED PARTS LIST SYSTEM V900040 DOGGE 1998.5-2002 5.9L CUMMINS 24 VALVE DIESEL with Air Conditioning ASSY.ITEM UNIT QTY PART # DESCRIPTION 6.0 Tank Brackets 6.1 ea 1 1200244 Mounting bracket (tank rear) 6.2 ea 2 2200135 Tank cable strap 6.3 ea 1 2200119 Tank strap flat bar (rear) 6.4 ea 1 1200243 Mounting bracket (tank front) 6.5 ea 1 2200125 Tank strap flat bar (front) 6.6 ea 4 1550066 Nut, 5/16 inch NC 6.7 ea 2 1570476 Washer Flat 5/16 ID 3/4 OD ASSY.ITEM UNIT QTY PART # DESCRIPTION 7.0 4800196 Oil Cooler Assembly 7.1 ea 1 9200188 Oil Cooler assembly 7.2 ea 2 5000001 Elbow, hose barb 90 degree, 1/2 NPT 5/8 inch 7.3 ea 2 2200029 Hose clamp, HS-10 ASSY.ITEM UNIT QTY PART # DESCRIPTION 8.0 Electrical 8.1 ea 1 3550389 Interface cable 8.2 ea 1 3550412 Switch box 8.3 ea 1 3550404 Low profile control panel 8.4 ea 1 3550523 Drive disable circuit ASSY.ITEM UNIT QTY PART # DESCRIPTION 9.0 Misc. 9.1 ea 1 1200246 Low profile control box bracket 9.2 ea 2 4800257 Tank hose clamp assembly 9.3 ea 1 1200109 Radiator bottle bracket 9.4 ea 2 2200001 Hose clamp MH-6 9.5 in 11.75 1700030 Hose, 300 PSI, 3/8 inch 9.6 ea 1 1200169 Alternator bracket 9.7 ea 1 5300001 Tee, nylon 5/8 inch 9.8 ea 3 2200029 Hose clamp, HS-10 ea 1 A700091 Oil, VR High Performance, 1 Litre ea 1 A700094 Oil, VR High Performance, 4 Litre 53
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