Vmac UNDERHOOD 40 Installation Manual
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Vmac UNDERHOOD 40 Installation Manual

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Installation Manual for VMAC
System
V400018
2020 + Ford Transit Connect
2.0 L Gas (I4)
www.vmacair.com
www.vmacair.com

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Summary of Contents for Vmac UNDERHOOD 40

  • Page 1 Installation Manual for VMAC System V400018 2020 + Ford Transit Connect 2.0 L Gas (I4) www.vmacair.com www.vmacair.com...

  • Page 3: Table Of Contents

    Accessory Products from VMAC ........
  • Page 4 Copyright © 2021 VMAC Global Technology Inc. All Rights Reserved. These materials are provided by VMAC for informational purposes only, without representation or warranty of any kind, and VMAC shall not be liable for errors or omissions with respect to the materials. The only warranties for VMAC...

  • Page 5: Safety

    VMAC will not be held responsible for any liability, consequential damages, injuries, loss or damage to individuals or to equipment as a result of the failure of anyone to properly adhere to the procedures set out in this manual or standard safety practices.

  • Page 6: Warranty

    1 October, 2015. Warranty Registration The VMAC warranty registration form is located near the back of this manual. This warranty registration form must be completed and sent to VMAC at the time of installation for any subsequent warranty claim to be considered valid.
  • Page 7 2. VMAC will provide direction for repair or replacement of the failed components. 3. If requested, failed parts must be returned to VMAC for evaluation. 4. Dealers may login to the VMAC website to view the "VMAC Labour Time Guide" (under “Agreements”) to see the allowable warranty labour times.

  • Page 8: General Information

    Please contact VMAC for replacement hoses and further information. Ordering Parts To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial number, part number, description and quantity. Locate the nearest dealer online at www.vmacair.com/dealer-locator or call 1-877-912-6605.
  • Page 9 All fasteners must be torqued to specifications. Use manufacturers’ torque values for OEM fasteners. The torque values supplied in Table 1 are intended for VMAC supplied components, or for use as a guide in the absence of a torque value provided by an OEM.

  • Page 10: Preparing For Installation

    Due to the variety of possible WHASP tank installation locations, VMAC cannot specify a mounting location for the WHASP tank. This VMAC kit includes 50 in of hose to run from the bulkhead fittings to the WHASP tank. If your application requires longer hoses, refer to “Hose Requirements”...
  • Page 11 ☐ Disconnect the barbed clip securing the coolant hose to the intake manifold (Figure 2). ☐ Disconnect the coolant hose from the degas bottle (Figure 2) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 12 ☐ Using a clean container to catch the remaining coolant, disconnect the lower degas hose (Figure 4). Disconnect Figure 4 — Disconnect lower degas hose assembly VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 13 Position the degas bottle in place in the engine bay, and press firmly down until the degas bottle clicks into place. ☐ Re-connect both hoses at the “Y” and at the degas bottle. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 14 (Figure 8). Figure 8 — Mount back idler VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 15: Installing The Main Bracket, Compressor, And Drive Belts

    Using the OEM fasteners, install the OEM tensioner onto the tensioner bracket (Figure 10) OEM fasteners Figure 10 — Install tensioner onto bracket ☐ Torque the tensioner fasteners to specification. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 16 ☐ Using the supplied fasteners, install the idler (removed from the tensioner earlier) onto the VMAC main bracket (Figure 11). M8×1.25×25 Fender washer Figure 11 — Install idler ☐ Using the (×3) supplied M8 fasteners, mount the compressor and pressure switch bracket onto the main bracket and torque to specification (Figure 12).
  • Page 17 ☐ Install the VMAC belt on the inside track of the crank pulley. Two clutch ribs should be visible on each side of the belt (Figure 13). Two ribs visible on each side Figure 13 — VMAC belt routing ☐...
  • Page 18 ☐ Using the supplied fasteners and P-clip, mount the pressure switch on the bracket (Figure 16). Figure 16 — Install pressure switch VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 19: Installing The Bulkhead Fittings

    WHASP Tank. Also ensure that there are no wires, hoses, or other components on the other side of the panel that may be damaged when drilling holes. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 20 Figure 18 — Remove plastic step ☐ Remove the plastic step to provide access to the sub floor (Figure 19). Figure 19 — Access the sub floor VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 21 Install the bulkhead fittings in the floor tunnel. These instructions are continued on the next page (Figure 21). Center tunnel Locate the bulkhead fittings in the floor tunnel Figure 21 — Floor tunnel VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 22 Front of ø 9/16 in vehicle ø 5/8 in Passenger side of vehicle ø 5/8 in ø 1 1/8 in Figure 22 — Vehicle chassis (bottom view) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 23 While it is necessary to provide a secure transition from the sub floor to the cargo bay, individual layout designs preclude VMAC from recommending specific bulkhead fixtures. VMAC suggests routing the hoses into the cargo area via bulkhead fittings (not supplied). If...

  • Page 24: Hose Requirements

    They can be shortened or replaced as necessary, or hose extenders can be used. In the event that the hoses are too long, VMAC recommends shortening these hoses as a preferred alternative to coiling up and securing the excess.

  • Page 25: Connecting The Hoses

    Slide the collet out once proper tubing cutters as side cutters the tube is fully inserted will deform the tube. O-ring Figure 25 — Push-to-connect fittings VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 26 ☐ Route the 3/8 in hose and 1/4 PTFE up to the compressor, following the same routing as the 3/4 in hose. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 27 Connect the 1/4 in PTFE scavenge tubes between the compressor, pressure switch, and Tee union (Figure 28). 12 in 1.5 in Figure 28 — Connect PTFE tubes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 28 3/8 in and 3/4 in hose to protect them from any sharp areas or abrasion (Figure 30 and Figure 31). Apply protective loom Figure 30 — Hose routing VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 29 Additional p-clips and self-tapping screws are provided to further secure the hoses between the crossmember and the bulkhead fittings. Attach these to the vehicle floor as required. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 30 VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 31: Installing The Waste Heat Air Separator Package (Whasp) Tank

    Illustrated Parts List (IPL). If the WHASP Tank or bulkhead fitting location requires longer hoses, contact a local VMAC dealer. See page 6 for ordering information . VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289...
  • Page 32 18 1/8 in 15 3/8 in 4 1/2 in 5/16 in or M8 mounting holes Figure 32 — Minimum WHASP Tank mounting clearances VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 33 (Figure 34). Front of vehicle Provide a minimum of 6 in of clearance for air flow Figure 34 — WHASP ventilation VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 34 Use of an air receiver tank (minimum 6 USG) is required with this application. Follow the instructions on page 51 of this manual to prevent damage to the system. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 35 (Figure 37). Install push-to- connect fitting Figure 37 — Install push-to-connect fitting VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 36 Install the tube into the push-to-connect bulkhead fitting (Figure 39) Figure 39 — Tubing Installation Remote Blowdown Muffler assembly ☐ Secure the tube with the supplied cable ties. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 37: Adding Oil To The System

    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.

  • Page 38: Installing The Control System

    Do not use a test light to probe for power on vehicle circuits, the increased current draw of the test light may damage components. • VMAC recommends using only sealed crimp and solder butt connectors for all electrical connections. •...
  • Page 39 Control Components Overview Compressor Control Module Throttle Control WHASP Interface Tank Panel Figure 41 — General component overview (Actual installation locations may vary) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 40 Control Module (Figure 42) The Control Module serves as the primary input/output interface between the vehicle and the various VMAC components (compressor, Throttle Control, WHASP Tank, Control Interface, etc.). Power, 12 V Clutch, Throttle WHASP Compressor (switched), and Control, and...
  • Page 41 Figure 44 — VMAC digital throttle control Mechanical Pressure Switch (Figure 69) The mechanical pressure switch is mounted on the side of the WHASP Tank and limits the maximum pressure to a safe amount by disengaging the clutch once system pressure is achieved.
  • Page 42 Figure 46 — Electrical schematic VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 43 Bullet connectors Figure 47 — Wire schematic VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 44 Move both of the seats forward and remove the (×4) Torx screws located at the front and rear of the console beside both the driver and passenger seats (Figure 49). Remove Torx screw Figure 49 — Remove centre console VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 45 (on the passenger side) to allow enough room to pull the boot up the shifter (Figure 51). Disconnect harness Disconnect harness Figure 51 — Remove gear selector insert VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 46 (Figure 52). Figure 52 — Remove dashboard insert ☐ Remove the fasteners securing the lower dashboard (Figure 53). Remove dashboard insert Figure 53 — Remove dashboard insert VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 47 (shown removed) Figure 55 — Remove lower dashboard ☐ Remove the kick plate to the left of the foot pedals. ☐ Remove the doorsill trim panel. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 48 Remove the fasteners securing the OBD II port to the dashboard; this provides easier access to the wires at the back. ☐ Peel back the tape on the harness a few inches. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 49 Throttle Control to the white/brown wire at pin 10 on the harness. Plug the connector back into the gear selector (Figure 58). Disconnect harness Figure 58 — Park interlock wire VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 50 ☐ Connect the bullet connector on the black wire running from the throttle control to the matching bullet connector on the control module harness. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 51 Connect the ring terminal on the green wire with yellow stripe to a good ground. ☐ Route the grey 18 AWG wire to the WHASP Tank. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 52 ☐ Ensure all wires and harnesses are protected with loom and routed away from sharp, hot, or moving components and away from high traffic areas. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 53: Air Receiver Tank

    This is normal operation. Prior to performing any service work on the system, discharge any stored air in the air receiver tank. The VMAC WHASP Tank has a built-in check valve. Use of an additional check valve is not required and may cause erratic performance.

  • Page 54: Recommended Accessories

    Recommended Accessories While the compressor system will function without the following accessories, VMAC strongly recommends their use for optimal performance. See the “Accessory Product” section of this manual on page 61 for a list of products available for purchase through VMAC.

  • Page 55: Completing The Installation

    Completing the Installation ☐ Check all VMAC and OEM wiring to ensure that it will not contact any hot, sharp or moving components and will not interfere with the operation of the vehicle. Secure all wiring with rubber coated P-clips, cable ties and loom as required.
  • Page 56 Figure 68 — Operating Instruction label ☐ Check all VMAC and OEM wiring to ensure it will not contact any hot, sharp or moving components and will not interfere with the operation of the vehicle. Secure all wiring with rubber coated P-clips, cable ties and loom as required.

  • Page 57: Testing The Installation

    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 VMAC Technical Support 1-888-241-2289 or 250-740-3200. Safety Test Ensure the following has been completed: ☐...
  • Page 58 Add oil as necessary to bring the level to the “FULL” line in the sight glass and check for leaks. ☐ Install the VMAC Air Test Tool (P/N: A700052) with the 40 cfm (5/32 in) orifice installed and the ball valve closed. ☐...
  • Page 59 Ensure the following has been completed: ☐ Operate the system with an air tool (or the VMAC Air Test Tool with the appropriate orifice installed) for at least 1/2 hour (1 hour preferred). The WHASP Tank cooling fan is thermostatically controlled, and may start or stop without warning.

  • Page 60: Performance Testing And System Adjustments

    Adjustments System operation can be tested using the tools that will be operated by the system or by using the VMAC Test Tool (A700052) with the 40 cfm (5/32 in) orifice in the outlet to simulate tool use (Figure 51).

  • Page 61: Digital Throttle Control Operation And Adjustments

    The throttle control is configured at the factory for optimum performance at maximum cfm. In applications where maximum cfm is not required, or noise is a concern, the throttle control can be adjusted to reduce the maximum VMAC rpm. Safety features...
  • Page 62 The cfm produced by the system is directly related to engine speed; this system delivers 40 cfm at 2,900 rpm. Maximum VMAC rpm can be adjusted between 2,000 rpm and 3,200 rpm (in 50 rpm increments) via the ““ or “” buttons in the “MAX RPM” column.

  • Page 63: Accessory Products From Vmac

    Compressor Service Kits 200 Hour or 6 Month Service Kit - Part number: A700263 Includes 4 L VMAC high performance compressor oil, oil filter, air filter, and next service due decal. 400 Hour or 1-Year Service Kit - Part number: A700264...
  • Page 64 Air receiver tanks are used for lowering compressor duty cycle and removing water from compressed air; recommended for optimum operation of all VMAC Gas Driven, Diesel Driven, Hydraulic, and UNDERHOOD40 air compressors. Manufactured to FMVSS 121 standard; includes fittings, 160 psi pressure relief valve, and tank drain.
  • Page 65 Interface Harness Extension Part number: A700265 This interface harness extension provides an additional 10 ft of cable which allows for greater flexibility in locating the Interface Panel. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 66 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 67 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 68 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 69 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 70: Warranty Registration

    Warranty Registration This form must be fully completed and returned to VMAC at the time the vehicle is put into service. Warranty may be void if this form is not received by VMAC within 3 months of receiving the vehicle, or 200 hours of operation, whichever occurs first.
  • Page 72 Manufactured by ® 888-241-2289 tech@vmacair.com 877-740-3202 warranty@vmacair.com www.vmacair.com kb.vmacair.com 1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada...

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Underhood v400018

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