Vmac Underhood 40 Installation Manual
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Vmac Underhood 40 Installation Manual

For 2015-2019 ford transit
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Installation Manual for VMAC
System
V400009
2015 – 2019 Ford Transit
3.5 L EcoBoost
www.vmacair.com

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Summary of Contents for Vmac Underhood 40

  • Page 1 Installation Manual for VMAC System V400009 2015 – 2019 Ford Transit 3.5 L EcoBoost www.vmacair.com...

  • Page 3: Table Of Contents

    Accessory Products from VMAC ........
  • Page 4 Copyright © 2020 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: System Identification, Warranty Registration And Warning Labels

    ☐ 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 The System Identification Plate must be attached to the vehicle at the time of installation.
  • Page 11 To alert any technicians that may service the vehicle, affix the servicing caution/contact label in the engine compartment near the hood latch in a visible location (Figure 3). Figure 3 — Advisory label VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 12: Preparing For Installation

    Preparing for Installation Ensure the VMAC Warranty Registration has been filled out and the System Identification Plate and Operating Instruction Label are installed prior to proceeding (Please see page 8 for details). ☐ Move the driver seat completely to the rear and remove the 2 front Torx fasteners (Figure 4).
  • Page 13 Remove the metal bracket, then lift the plastic tabs on the rear of the battery cover to remove the battery cover (Figure 7). Remove cover Figure 7 — Battery cover VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 14 (Figure 9). ☐ Loosen the 2 hose clamps on the intake tube (Figure 9). ☐ Remove the intake tube. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 15 Figure 11 — Remove engine lifting eye and turbo outlet ☐ Remove the hose clamp on the passenger side turbocharger outlet tube (Figure 11). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 16 Remove the turbocharger outlet tube and place it out of the way on top of the engine. The small vacuum line attached to the turbocharger tube can be left connected (Figure 11). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 17 Using a 14 mm wrench to release the tension, remove the OEM 4 rib belt and discard (Figure 15). Tensioner bolt Figure 15 — Remove 4 rib belt VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 18 (Figure 17). ☐ Remove the OEM power steering pump bracket from the engine. Retain all of the fasteners for use later. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 19 From underneath the vehicle, gently deflect the metal A/C lines toward the passenger side of the engine bay and away from the engine. Final adjustments will be performed later in the install. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 20: Installing The Compressor

    The OEM 4 rib tensioner must be installed on the VMAC bracket before installing the idler. ☐ Install the OEM 4 rib belt tensioner on the VMAC main bracket using the original OEM bolts (Figure 20). Install OEM tensioner first Figure 20 —...
  • Page 21 A/C compressor and the engine. Reinsert the A/C compressor bolts until the threads are just engaged and the A/C compressor is still supported (Figure 22). Install spacers Figure 22 — A/C compressor spacers VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 22 ☐ Withdraw the bottom A/C compressor bolt and while holding the A/C compressor away from its engine mounting points, insert the VMAC main bracket between the A/C compressor and the engine (Figure 23). Figure 23 — Installing the main bracket ☐...
  • Page 23 Ensure the OEM fasteners are used in the locations indicated below. ☐ Mount the power steering pump on the VMAC main bracket using the supplied M8 × 1.25 × 50 mm fastener and the 2 OEM fasteners retained earlier (Figure 26).
  • Page 24 The following steps will be easier to complete with an assistant. ☐ Install the supplied 4 rib VMAC Compressor belt so that it is centered on the compressor clutch, and tension the belt (Figure 28). Figure 28 — VMAC belt routing...
  • Page 25 Figure 29 — Align belt on clutch ☐ Reinstall the OEM 6 rib belt and tension it (Figure 30). Figure 30 — 6 rib belt routing VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 26: 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 27 18 1/8 in 15 3/8 in 4 1/2 in 5/16 in or M8 mounting holes Figure 31 — Minimum WHASP Tank mounting clearances VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 28 (Figure 33). Front of vehicle Provide a minimum of 6 in of clearance for air flow Figure 33 — WHASP ventilation VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 29: Installing The Bulkhead Fittings

    To maximize compressor performance, hose lengths should be kept as short as possible; if longer hoses are required please follow the hose requirements listed on page 31 of this manual. Figure 34 — Bulkhead fittings VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 30 The holes are shown for clarity and will be drilled in the following steps (Figure 35). Front of Fuel filler vehicle neck Driver side of vehicle 6 1/2 in 3 in Figure 35 — Vehicle Chassis bottom view VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 31 Front of vehicle ø Driver side 9/16 in of vehicle ø 5/8 in ø 5/8 in ø 1 1/8 in Figure 36 — Vehicle Chassis bottom view VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 32 Apply Loctite 567 (thread sealant) when installing the 1/4 in push-to-connect fittings in the bulkhead fittings (Figure 37, Figure 38). Figure 37 — Interior view Figure 38 — Exterior View VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 33: Hose Requirements

    • 1/4 in (PTFE Tube) × 30 in. If longer hoses are required: To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial number, part number, description and quantity. See page 6 for ordering information.

  • Page 34: 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 39 — Push-to-connect fittings VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 35 Use of an air receiver tank (minimum 6 USG) is required with this application. Follow the instructions on page 62 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 36 (Figure 42). Install push-to- connect fitting Figure 42 — Install push-to-connect fitting VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 37 Install the tube into the push-to-connect bulkhead fitting (Figure 44) Figure 44 — 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 38 Connect the 90° end of the 3/4 in hose to the compressor discharge fitting on the rear of the compressor. Direct the hose toward the driver side of the vehicle. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 39 2 supplied P-clips and 5/16 in × 3/4 in sheet metal screws in the existing holes on the frame (Figure 47). P-clips Figure 47 — Hose routing along inside of driver side frame VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 40 Use cable ties, rubber coated P-clips, 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 VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 41: 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 42: Installing The Control System

    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. Finally, replace the pin in the connector, taking special care to ensure the pin is fully inserted and the locking tabs are engaged.
  • Page 43 Control Components Overview Compressor Control Module Throttle Control WHASP Interface Tank Panel Figure 53 — 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 44 Control Module (Figure 54) 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 45 “SPEED1” adjusting screw (under side) Figure 56 — VMAC Throttle Controls Mechanical Pressure Switch (Figure 57) 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 46 Figure 58 — Electrical schematic VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 47 Grey cable Grey cable Figure 59 — Wire schematic VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 48 Control as well as the orange and red wires from the Control Module, and route them underneath the headlight controls towards the driver side door (Figure 61). Figure 61 — Headlight Switch Panel VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 49 Route the loomed wires along the inside of the driver door and underneath the driver side step, towards the driver side seat support (Figure 63). Route wires under driver side step Figure 63 — Driver side step VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 50 Ensure the fuse holder s installed as close to the power source as possible. ☐ Connect the other end of the fuse holder to the positive battery terminal. (Figure 65). Connect red wire Figure 65 — Connect red wire VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 51 *On 2015 vehicles (or an alternate location for 2016+ vehicles), the blue wire is routed to the C210 connector in the cab near the glove compartment. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 52 It is critical that the pins are protected from accidental damage while unplugged from the ECM module. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 53 Control to the yellow wire with the purple stripe at pin 11. ☐ Use 1/4 in wire loom or equivalent protection to cover the wires, and secure the VMAC tachometer cable to OEM harness with a cable tie (Figure 69). Figure 69 — Loom wire ☐...
  • Page 54 Connect the blue bullet connector on the white wire to the matching connector on the compressor. A spare bullet connector is provided to allow the clutch wire to be shortened. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 55 Figure 71 — OEM Blunt cut bundle (2016+ only) ☐ Splice the long blue wire from the throttle control to the grey wire with yellow stripe (CET22). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 56 The wire will appear on the passenger side of the dashboard, above the HVAC system (Figure 73). Factory harness VMAC wire Figure 73 — Passenger dashboard VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 57 Use an 8 mm socket to remove both the left and right fasteners holding the C210 connector (Figure 75). Remove fasteners Figure 75 — Remove C210 connector VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 58 Gently pull the connector toward the driver side and remove the 10 mm bolt to separate the connector (Figure 76). Remove fastener Figure 76 — Connector C210 VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 59 Splice the long blue wire from the Throttle Control to the grey wire with the brown stripe at pin 7. ☐ Reinstall the C210 connector. ☐ Reinstall the glove compartment. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 60 ☐ 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 61: Installing The Air Filter And Power Steering Reservoir

    Figure 81 — Air filter and bracket ☐ Using the 2 × M8 bolts retained from the OEM lifting eye, mount the VMAC air filter and bracket assembly in the OEM engine lifting eye location (Figure 82). Figure 82 — Air filter ☐...
  • Page 62 ☐ Install the power steering fluid reservoir using the Torx screws through the remaining holes in the supplied bracket (Figure 83). VMAC - Vehicle Mounted Air Compressors VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 63 Figure 84 — Rotate power steering hose Rotate the power steering feed hose on the pump inlet to direct the hose away from the belt line and any moving components. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 64: 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 65: 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 70 for a list of products available for purchase through VMAC.

  • Page 66: Completing The Installation

    Completing the Installation ☐ 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 67: 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 68 The second person will actuate the compressor switch and ball valve as necessary ☐ Install the VMAC Air Test Tool (P/N: A700052) with the 40 cfm (5/32 in) orifice installed and the ball valve closed. ☐ With the engine running and the vehicle in “PARK”, release the parking brake.
  • Page 69 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 70: Performance Testing And System Adjustments

    Try turning the engine speed down and observe the performance. When testing the system or adjusting the VMAC Throttle Control, ensure the system does not exceed 3,000 engine rpm. Exceeding this speed will cause erratic system performance and in extreme cases may also cause long term damage to the compressor.
  • Page 71 Control. 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 87).

  • Page 72: 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 73 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 74 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 75 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 76 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 77 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 78: 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 80 Manufactured by ® 888-241-2289 tech@vmacair.com 877-740-3202 warranty@vmacair.com www.vmacair.com www.kb.vmacair.com 1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada...

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V400009

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