Hose Requirements ................30 Installing the Tank and Hoses ............31 Installing the Control Components ............ 48 Installing VMAC Air Filter and Power Steering Reservoir ....72 Adding Oil to the System ..............76 Completing and Testing the Installation ..........77 Setup, Performance Testing and Adjustments .........
Information is constantly changing with the addition of new models, assemblies and service techniques. If a discrepancy is noted in this manual, contact VMAC prior to initiating or proceeding with installation, service or repair. Current information may clarify the issue.
VMAC Limited Lifetime Warranty for full details. Warranty Registration The VMAC warranty form is located at the back of this manual. This warranty form must be completed and sent to VMAC at the time of installation for any subsequent warranty claim to be considered valid.
Please contact VMAC for replacement hoses and further information. Ordering Parts To order parts, contact your VMAC dealer. Your dealer will ask for the VMAC serial number, part number, description and quantity. To locate your nearest dealer, call 1-877-912-6605 or online at www.vmacair.com.
Complete the warranty form. The VMAC warranty form is located at the back of this manual, as well as online at: www.vmacair.com/warranty 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.
Page 9
Thoroughly clean the selected area before affixing the label (Figure 3). Figure 3 – Warning Label VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Figure 4 – Driver seat front □ Move the driver side seat fully forward and remove the 2 rear T40 Torx Bolts (Figure 5). Figure 5 – Driver side seat rear VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 11
Leave the seatbelt connected to the seat and lift the seat off of its mount, place the seat on the floor outside of the driver side of the van. The driver side seat is heavy, take care when lifting to prevent injury. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 12
(Figure 7). Remove Figure 7 – Battery cover □ Disconnect the negative battery cable from the battery terminal stud (Figure 8). Negative Figure 8 – Battery cables VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 13
Disconnect the PCV hose from the intake tube, there is a small grey plastic tab which has to be lifted while the connector is pulled away from the intake tube (Figure 10). Figure 10 – PCV hose VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 14
Remove intake tube (Figure 11). □ Cover the engine and air filter openings to prevent contaminants from entering into the engines intake system. Clamp Vacuum Figure 11 – Intake tube assembly VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 15
Use a 10 mm socket to remove the 2 x M8 engine hook bolts, remove engine hook (Figure 13). Figure 13 – Engine hook Raise the vehicle and support the front of the vehicle on stands. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 16
Use a 14 mm flexible head gear wrench to access the tensioner bolt. Access the tensioner bolt via the passenger side of the engine, in front of the air conditioning compressor clutch. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 17
OEM tensioner. Remove the 6 rib belt. Keep this belt as it will be re- used (Figure 15) (Figure 16). Figure 15 – Using the serpentine wrench Tensioner bolt Figure 16 – Tensioner bolt location VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 18
Loosely install the supplied 4 rib belt on the crank pulley. □ Route and tension the original 6 rib belt (Figure 17). Figure 17 – 6 Rib belt routing VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 19
The top bolt can be difficult to access due to the air conditioning lines; a 10 mm flexible head gear wrench can make removal easier (Figure 18). Connector Top Bolt Figure 18 – Air Conditioning compressor bolts VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Install the supplied M8 x 60 socket head bolt into the engine hook bolt hole (Figure 19). M8x60 M8x45 M8x45 M8x45 Figure 19 – Main Bracket and Fasteners □ Torque fasteners to specification. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 21
□ Mount the OEM air conditioning compressor to the VMAC main bracket. Re-use the 3 OEM bolts (Figure 20). When installing the A/C compressor, ensure the clutch wire is routed so that it will not be pinched, or damaged by any sharp edges or hot components.
Page 22
The top bolt is difficult to access due to the location of the air conditioning lines. Push the compressor against the main bracket so the top bolt can be accessed through the machined opening in the top of the VMAC bracket. Use a 10 mm open ended wrench to tighten the bolt. Once the bolt is threaded in far enough a 10 mm flexible head gear wrench can be used to fully tighten the bolt (Figure 21).
Installing the Compressor □ Use Loctite 242 (blue) and install the 3 supplied M8 x 45 socket head bolts to secure the VMAC compressor onto main bracket (Figure 22). Figure 22 – Compressor fasteners VMAC – Vehicle Mounted Air Compressors...
Page 24
□ Install the supplied 4 rib belt so that it is centered on the compressor clutch and tension the belt (Figure 23). Figure 23 – Belt routing VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 25
Figure 24 – Belt alignment To ensure the belt is properly aligned on the clutch pulley, confirm there are 2 grooves visible on each side of the belt (Figure 24). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Use good judgement before installation; before drilling any holes confirm that there are no wires, hoses or components on the other side of the panel that may be damaged. A pilot drill hole may be required. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 27
The holes are shown for clarity and will be drilled in the following steps (Figure 26). Front of vehicle Filler Neck Location Driver side of vehicle 6 1/2 in 3 in 3 in Figure 26 – Vehicle Chassis bottom view VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 28
Driver side mark - 3/8 in. Install a 3/8 in rubber grommet (Not supplied). Front of vehicle 9/16 in 5/8 in 5/8 in 3/8 in 3 in 1 1/8 in Driver side of vehicle 3 in Figure 27 – Bottom View VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 29
Use thread sealant and install the 1/4 in fittings in the top and bottom of the bushing (Figure 28) (Figure 29). Figure 28 – Top view Figure 29 – Bottom View VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 30
Remove the locking nut from the remote muffler assembly (Figure 30). Figure 30 – Bulkhead blowdown assembly □ Insert the bulkhead fitting through the hole in the floor (Figure 31). Figure 31 – Installing the fitting VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 31
□ Install the lock-nut and serrated washer from underneath the vehicle (Figure 32). Figure 32 – Installing the fitting VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
3/8 in x 28 in • 1/4 in x 25 in VMAC Compressor oil will degrade rubber lined hoses, use only hoses with an AQP elastomer type liner. Contact VMAC Tech Support at 1-888-241-2289 for further information. Do not attempt to shorten the supplied hose unless there is access to the necessary equipment to do so properly.
When routing hoses, ensure cap-plugs are installed so that contaminants do not get in the line. Take care when routing hoses, as a hose failure may damage the compressor. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 34
Route the 3/4 in x 150 in, 3/8 in x 150 in hoses, and 1/4 in x 150 in PTFE hose downwards from the rear of the compressor, in front of the passenger side engine mount (Figure 34). Figure 34 – Hose routing from compressor VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 35
(Figure 35) (Figure 36). Figure 35 – Hose routing on sub-frame M6 x 14 M6 washer M6 nut Figure 36 – P-clip, washer, and nut VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 36
Continue routing the hoses up to the driver side frame rail; run the hoses above the suspension and steering components (Figure 37). Figure 37 – Hose routing from sub-frame to driver side frame VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 37
(Figure 38) (Figure 39. Figure 38 – Hose routing along inside of driver side frame 5/16 in x 3/4 in Sheet Metal Screw Figure 39 – P-clip and fastener VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 38
Route the hoses above the fuel filler hose, and around to the rear of the fuel filler housing (Figure 40) (Figure 41). Figure 40 – Hose routing continued Figure 41 – Hose routing above fuel filler hose VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 39
Secure the hose with the supplied with P-clip and 5/16 in x 3/4 in sheet metal screw in location shown (Figure 41) (Figure 42). 5/16 in x 3/4 in Sheet Metal Screw Figure 42 – Rear P-clip and fastener VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 40
Ensure all hoses are routed securely, away from hot and moving parts, hydraulic lines, and vehicle wiring. Use cable ties and suitable hose protection as required. If the vehicle is 4WD ensure the hoses are protected from the front driveshaft. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 41
Ideal ventilation will provide good airflow through the unit with no restrictions. Cool ambient air ducted to the cooler, and the installation of an exhaust fan to remove hot air is recommended. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 42
Allow for extra space on the filter side of the WHASP tank, for access to change filters, compressor oil, as well as to check the level of oil in the compressor system. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 43
12 in Fan out Clearance for servicing 18 1/8 in 15 3/8 in 4 x M8 or 5/16 in Rectangular Mount Pattern Figure 46– Minimum WHASP Tank mounting clearances VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 44
They can be shortened or replaced as necessary, or hose extenders can be used. • VMAC recommends shortening these hoses as a preferred alternative to coiling up and securing the excess. Shorter hose length will maximize system performance.
Page 45
#12 Male JIC (Main discharge from Compressor) #6 Male JIC (Oil return to compressor) 1/4 in Scavenge (To compressor) #8 Male JIC (To downstream equipment) Figure 47 – WHASP Tank VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 46
Contamination of the assembly may cause erratic performance. □ Separate the PTFE tube from both fittings. □ Loom the 1/4 in hose with supplied 1/4 in plastic split loom. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 47
(Figure 49). Figure 49 – Fitting installation □ Connect the 1/4 in PTFE tube into the push-to-connect fitting installed in the WHASP tank (Figure 50). Figure 50 – Tubing Installation VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 48
Do not use side cutters as this will deform the hose. □ Install the hose into the push-to-connect fittings (Figure 51). Figure 51 – Remote Blowdown Muffler assembly □ Secure the hose with supplied cable ties. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 49
This page intentionally left blank VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 52
To confirm a good ground, use an ohm meter to measure the resistance between the ground point and the battery negative therminal. Resistance should be less than 1 Ω. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 53
Loom the black wire from the throttle control with 1/4 in split loom or equivalent protection, and route underneath the headlight controls towards the driver side door (Figure 54). Figure 54 – Headlight Switch Panel VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 54
(Figure 55). □ Route the wire underneath the driver side step, towards the driver side seat support (Figure 55). Figure 55 – Driver side step VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 55
Figure 56 – Driver side seat support □ Route the wire between the seat support and battery box, towards the park brake (Figure 57). Figure 57 – Battery Box Overview VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 56
Strip the wire at the desired location and solder the VMAC wire into place. Slide the shrink tube up to the soldered joint and seal it.
Page 57
Figure 60 – Firewall wiring grommet □ Undo the 2 bolts holding the coolant overflow bottle, and move it out of the way (Figure 61). Figure 61 – Coolant overflow bottle VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 58
□ The second plug from the front of the Power Train Control Module is C175E, lift the grey tab and pull the connector up to remove it (Figure 62). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 59
□ Solder and seal the short blue wire from the tach module cable to pin 63, the green wire with the white stripe. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 60
Use 1/4 in wire loom or equivalent protection to cover the wires, and secure with a cable tie to the OEM harness (Figure 65). Figure 65 – Wire loom VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 61
Figure 66 – Glove box □ Route the long blue wire from the VMAC throttle, above the driver side fuse box, along the factory wire harness located at the rear of the dashboard, to the passenger side of the dash (Figure 67).
Page 62
Remove the access panel at the back of cup holder directly to the right of the glove box, connector C210 is located behind this panel (Figure 69). Figure 69 – Connector C210 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 63
(Figure 70). Figure 70 – C210 Left bolt □ Use 8 mm socket to remove the right bolt holding connector C210 (Figure 71). Figure 71 – C210 Right bolt VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 64
□ Gently pull the connector over towards the driver side and undo the 10 mm bolt to separate the connector (Figure 72). Figure 72 – Connector C210 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 65
Solder and seal the long blue wire from the throttle control to pin 7, the grey wire with the brown stripe (Figure 75). Figure 75 – Long Blue wire VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 66
The control panel is not weather-proof. It should be installed either inside the cab or inside a cabinet on the service body (if equipped). Keep the rear of the control panel protected from tools and equipment. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 67
To confirm a good ground, use an ohm meter to measure the resistance between the ground point and the battery negative therminal. Resistance should be less than 1 Ω. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 68
Run the yellow 18 AWG wire from the WHASP tank to the throttle control under the dash and connect it to the matching yellow wire (Figure 79). Throttle Control Throttle Activation Clutch Figure 79 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 69
The battery and switched power are located underneath the driver side seat. □ Route the red 14AWG wire from the control panel to the relay harness location under the driver side seat (Figure 83 on page 69). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 71
Mount the relay harness using the supplied M5 x 14 pan head screw, M5 flat washer, and M5 Nylok nut (Figure 82) (Figure 83) (Figure 84). Figure 83 – Relay harness mounted Figure 84 – Relay harness washer and nut VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 72
Figure 85 – Black fused wire □ Connect the green wire with the yellow stripe from the relay module to battery negative (Figure 86). Figure 86 – Ground wire VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 73
Solder and seal the short red wire on the relay module to the red 14AWG wire from the control panel (Figure 52 on page 48) (Figure 80 on page 67). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Steering Reservoir □ Remove the 2 OEM bolts and front engine brace. □ Install VMAC air filter bracket, re-use the OEM bolts (Figure 89). Figure 89 – VMAC air filter bracket VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289...
Page 75
Ensure clamps are tight, and that the hose, and clamps will not contact any components (Figure 90). Figure 90 – VMAC air filter hose Figure 91 – Power steering reservoir VMAC – Vehicle Mounted Air Compressors...
Page 76
Use Loctite 242 (blue), install the supplied power steering bracket on top of the compressor with the 3 supplied M6 x 8 button head screws. Do not overtighten (Figure 92). Figure 92 – VMAC power steering bracket VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289...
Page 77
Install the OEM power steering reservoir onto the supplied bracket with the 2 x M6 x 14 bolts, 4 x M6 flat washers, and 2 x M6 Nylok nuts (Figure 93). Figure 93 – Power steering reservoir fasteners VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Adding Oil to the System The VMAC supplied and approved compressor oil must be used in this system. Failure to use this special oil will result in damage to the compressor and will void warranty. Do not overfill the system. Overfilling the system with oil can flood the sight glass window and make the system appear empty.
If the vehicle fails the test, ensure the wiring to all of the connections are correct and secure. If additional assistance is required, contact your local VMAC dealer or call 1-888-241- 2289 or 250-740-3200. Completing and Testing the Installation ...
Page 80
The second person will actuate the compressor switch and ball valve as necessary. Install the VMAC Air Test Tool (P/N: A700052) with the 30 cfm (1/8 in) orifice installed and the ball valve closed. With the engine running and the vehicle in “PARK”, release the parking brake.
Page 81
Reapply the park brake. The engine speed should increase as soon as the park brake is engaged. Close the ball valve, allow the system to build to full pressure and the engine speed to return to VMAC base idle. Turn the compressor off and shut down the engine. ...
30 cfm (1/8 in) orifice in the outlet to simulate tool use. (Figure 95) Figure 95 – VMAC A700052 test tool Install the VMAC test tool at the system outlet with the 30cfm orifice (1/8 in) Ensure the ball valve is closed.
Page 83
Throttle Control Adjustment Locate the VMAC throttle controller. It is typically installed under the dash, near the throttle pedal. Example installation only, actual installation may not be exactly as shown. Figure 96 – Throttle control Adjustment is made by turning the set screw with a small flathead screwdriver.
Page 84
□ Check the compressor oil level after the engine has been shut down and the oil level has had time to stabilize VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
(not in the bottom of the tank) to prevent water from filling the line. Failure to observe these requirements will result in damage to the system. The VMAC WHASP tank has a built-in check valve. Use of an additional check valve may cause erratic performance.
The addition of a receiver tank will also reduce the frequency of clutch and system cycling. For information on installing a receiver tank see page 83 of this manual. Receiver tanks are available for purchase through VMAC. See page 85 of this manual for more information. Pressure Gauge While not critical to system performance, a pressure gauge is important for fine tuning the system and simplifies any potential troubleshooting.
Accessory Products These accessory products for your underhood compressor system are available from VMAC. For more information or to order these products, call 1- 800-738-8622 or email sales@vmacair.com. Eliminator Aftercooler Part number: A800070 Removes up to 80% of moisture from compressed air. Quick installation, automatic drain and compact design.
Warranty Registration This form must be fully completed and returned to VMAC at the time of installation. Warranty may be void if this form is not received by VMAC within 30 days of installation. VMAC’s Warranty policy and registration can be viewed online at: www.vmacair.com/warranty...
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