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Vmac VR7000 9037 Installation Manual

Underhood air compressor 1999-2000 ford super duty f250-f550 7.3 l power stroke diesel
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DOCUMENT 19351
Installation Manual
For The
System #9037
UNDERHOOD AIR COMPRESSOR
1999-2000 FORD SUPER DUTY F250-F550
7.3 L POWER STROKE DIESEL
TEL: 250-754-6997
FAX: 250-754-6972
1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3
TOLL FREE: 800-738-8622

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Summary of Contents for Vmac VR7000 9037

  • Page 1 DOCUMENT 19351 Installation Manual For The System #9037 UNDERHOOD AIR COMPRESSOR 1999-2000 FORD SUPER DUTY F250-F550 7.3 L POWER STROKE DIESEL TEL: 250-754-6997 FAX: 250-754-6972 1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3 TOLL FREE: 800-738-8622...
  • Page 2 #19356 - illustrated parts list #19130 - warranty registration Registered Trademarks: VR7000, VMAC and Throttle Commander are registered trademarks of VMAC. Ford, Super Duty, F250-F550, Power Stroke Diesel are registered trademarks of Ford Motor Company Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.

  • Page 3: General Information

    DOCUMENT 19351a General Information System #9037 1999-2000 FORD SUPER DUTY F250-F550 7.3 L POWER STROKE DIESEL UNDERHOOD AIR COMPRESSOR...

  • Page 4: Installation Steps

    DOCUMENT 19351a General Information Introduction This book provides installation instructions for: VMAC underhood air compressor installation kit VMAC Throttle Commander This kit has been designed for: 1999-2000 Ford Super Duty F250 - F550 7.3 L Power Stroke Diesel Installation steps...

  • Page 5: Installation Notes

    DOCUMENT 19351a Installation Notes It is important that you complete all the installation steps before operating the system. Refer to the Owner’s Manual before operating the system for the first time. Follow all safety precautions for underhood mechanical work. Use Loctite 242 or equivalent on all engine-mounted fasteners. All hoses, tubes and wires which are re-routed or shifted during installation must be secured so that they do not contact excessively hot areas or sharp edges.

  • Page 6: Ordering Parts

    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.

  • Page 7: Changes And Improvements

    DOCUMENT 19351a Changes and improvements These products and documents are subject to changes or improvements without notice.
  • Page 8 DOCUMENT 19352 Part 1 Installing the Compressor and Oil Cooler System #9037 1999-2000 FORD SUPER DUTY F250-F550 7.3 L POWER STROKE DIESEL UNDERHOOD AIR COMPRESSOR...

  • Page 9: Preparing For Installation

    DOCUMENT 19352 Part 1: Installing the Compressor and Oil Cooler 1.1 Preparing for installation Disconnect the batteries and remove the battery from the driver’s side box. Drain the coolant from the radiator. Remove the OEM fasteners from the coolant expansion bottle and move it out of the way. Do not disconnect the hoses from the bottle (Figure 1.1).
  • Page 10 DOCUMENT 19352 Disconnect the air inlet horn from the front of the air cleaner and battery box. Leave this part in place. This is optional for ease of removal and installation. Remove the air cleaner box and the battery box from the driver’s side of the vehicle (Figure 1.2). Remove The Air Cleaner And Battery Boxes Figure 1.2 Remove the alternator from its mount and lay it back on top of the engine.
  • Page 11 DOCUMENT 19352 Peen Back This Area Of The Cover LEFT SIDE OF ENGINE Cylinder Head Mounting Area Engine Block Mount OEM Alternator And Power Steering Pump Mounting Bracket Fasteners Figure 1.3 Exchange the forward right bolt and rear left stud on the aluminum cover at the top front of the engine (Figure 1.4).

  • Page 12: Installing The Oil Cooler

    DOCUMENT 19352 Remove and discard the two (2) battery 12 mm studs and nuts which retain the ground straps on the lower left and right sides of the engine block (Figure 1.5). Remove and discard the positive battery cable locating bracket from the same area. OEM Ground Strap Locations On Engine Figure 1.5...
  • Page 13 DOCUMENT 19352 Connect the lower cooler hose to the bottom radiator outlet (Figure 1.7). Tighten all the hose clamps securely. Fit two (2) 4” lengths of 1/2” rubber hose around the transmission line where they pass the cooler bracket. Use ties to hold the rubber in position on the lines To Engine Block Connection HS28 Clamps...
  • Page 14 DOCUMENT 19352 Four (4) M10 x 30 Hex Head Cap Screws Figure 1.8 Install the alternator onto the compressor mounting bracket using the OEM fasteners. The alternator must be mounted 180 degrees (upside-down) from the original mounting position. Rotate the alternator 180 degrees in a counterclockwise direction. NOTE Insert the supplied hose barb into the power steering rubber return hose which is attached to the brake booster.

  • Page 15: Installing The Compressor

    DOCUMENT 19352 1.4 Installing the compressor Apply Loctite to the three (3) 8 mm studs and install them in the bottom of the compressor. Install the compressor to the mounting bracket using three (3) supplied 8 mm nuts and 5/16” flat washers.
  • Page 16 DOCUMENT 19352 Install the fan and the fan shroud. Install clamps on the supplied upper radiator hose and fit it on the engine and radiator fittings. Rotate the hose on the thermostat housing and radiator fitting until the hose clears both the compressor belt and the fan shroud.
  • Page 17 DOCUMENT 19352 Install the intercooler tube and tighten the clamps. Be sure that the tube clears the back of the compressor and power steering pump and the bead inside the rubber OEM bellows sits in the groove properly before tightening the clamps. If your vehicle was manufactured before December 7, 1998, use the original intercooler tube, but reverse direction, installing the end which was removed from the radiator in the intake.
  • Page 18 DOCUMENT 19353 Part 2 Installing the Air Tank, Filter and Lines System #9037 1999-2000 FORD SUPER DUTY F250-F550 7.3 L POWER STROKE DIESEL UNDERHOOD AIR COMPRESSOR...
  • Page 19 DOCUMENT 19353 Part 2: Installing the Air Tank, Filter and Lines 2.1 Installing the tank brackets and tank The tank is mounted on the frame on the driver’s side of the vehicle, positioned so that it will clear the body mounts, as shown in Figure 2.1. Figure 2.2 provides tank mount component identification.
  • Page 20 DOCUMENT 19353 Install the two L-shaped tank brackets to the C-clamps on the tank. The short arm of the L should be at the top of the tank, facing away from the tank. Install the four (4) 5/16” x 1/2” hex head cap screws loosely with flat washers under each cap screw.
  • Page 21 DOCUMENT 19353 Front cab mount F250 & F350 standard cab 2x4 and 4x4 Front cab mount F250 & F350 super cab 2x4 and 4x4 Front cab mount 11.75 1.25 Transfer case 16.25 17.25 F450 & F550 standard cab 2x4 and 4x4 Front cab mount 19.25 16.25...
  • Page 22 DOCUMENT 19353 Mounting the L-brackets Backing straps on inside of the frame Strap through the cable guide Front tank mount positioning Front tank mount Rear tank mount Figure 2.4 Check the alignment of the tank to make sure that the tower with the two lines attached is at the top and that the tank is aligned correctly (Figure 2.5).
  • Page 23 DOCUMENT 19353 This alignment is extremely important. Improper installation can result in an extremely hazardous situation which could cause severe personal injury or could damage the equipment. WARNING Remove each of the hex head cap screws holding the C-clamp to the L-bracket and apply Loctite.
  • Page 24 DOCUMENT 19353 Figure 2.6 Figure 2.7 Figure 2.8...
  • Page 25 DOCUMENT 19353 2.3 Connecting the air and oil lines The lines must be installed in the correct locations or the system will not function prop- erly. In addition, a hazardous situation may develop from oil spray, potential fire or explosion. WARNING Figure 2.5 shows the location of the lines at the tank.
  • Page 26 DOCUMENT 19353 Scavenge Line Main Air Line Pressure Control Line Figure 2.10 Holes for Securing Lines Scavenge and Pressure Control Line Routing with Protective Covers Oil Return and Main Air Line Routing with Protective Covers Figure 2.11 Connect one end of the 1/2” x 15” oil return line to the tank at location 4 (Figure 2.5) and the other end to the uppermost fitting on the remote filter (Figure 2.9).
  • Page 27 DOCUMENT 19353 Connect the remaining end on the 1/4” x 91” pressure control line previously connected to the tank fitting at location 2 (Figure 2.5) to the 45 degree fitting on the front of the air inlet valve at the compressor (Figure 2.9). Route this line above the front cab body mount, between the air cleaner box and intercooler tube and around the outside of the steering column.

  • Page 28: Adding Oil To The System

    DOCUMENT 19353 2.4 Adding oil to the system Make sure that the vehicle is level. Remove the oil filler plug from the air inlet control valve (Figure 2.13). Pour six (6) litres (1.6 US Gal.) of the supplied compressor oil into the filler hole using a funnel.

  • Page 29: Installing The Control Unit

    DOCUMENT 19354 Part 3 Installing the Control Unit System #9037 1999-2000 FORD SUPER DUTY F250-F550 7.3 L POWER STROKE DIESEL UNDERHOOD AIR COMPRESSOR...
  • Page 30 DOCUMENT 19354 Part 3: Installing the Control Unit 3.1 Installing the control unit Remove the driver-side plastic door frame base panel and the plastic moulding ahead of the base panel (Figure 3.1). Driver’s Seat Remove This Inside Left Kick Remove This Panel Door-frame Base Panel Figure 3.1...
  • Page 31 DOCUMENT 19354 Route the wire harness under the floor covering, along the inside of the door where it will be covered by the trim piece and up under the dash. Place the floor covering back into position. Replace the door trim piece. Cut a notch in the edge of the trim piece for the wire (Figure 4.3).
  • Page 32 DOCUMENT 19355 Part 4 Installing the Throttle Commander System #9037 1999-2000 FORD SUPER DUTY F250-F550 7.3 L POWER STROKE DIESEL UNDERHOOD AIR COMPRESSOR...
  • Page 33 DOCUMENT 19355 Part 4: Installing the Throttle Commander 4.1 Installing the Throttle Commander Fasten the Throttle Commander under the dash, to the right of the steering column with the adjusting screws pointing downward (Figure 4.1). The mounting bracket acts as a ground for the control unit.
  • Page 34 DOCUMENT 19355 Green CMP Sensor Wire Cover Shown Here For Reference Purposes Only Figure 4.2 4.2 Attaching the white wire Cut the green wire. Strip approximately 3/8” insulation from each cut end (Figure 4.3). Figure 4.3...
  • Page 35 DOCUMENT 19355 Slip on the supplied meltable liner shrink tube (Figure 4.4). Figure 4.4 Strip 1″ of insulation from the end of the white wire and twist it onto the free ends of the green wire (Figure 4.5). Figure 4.5 Solder the connection using the supplied 60/40 rosin core solder.

  • Page 36: Connecting The Wiring

    DOCUMENT 19355 Figure 4.7 Push the green wire and the splice back into the OEM plastic loom. Slide the supplied 16″ ID loom on the white wire forward and insert the end into the slit in the OEM plastic loom. Secure the connection with the supplied nylon wire (Figure 4.8). Figure4.8 4.3 Connecting the wiring Feed the large white wire with the blue bullet connector through the steering column boot,...
  • Page 37 DOCUMENT 19355 Remove the OEM connector from the park brake slight switch on the park brake assembly. Attach the black wire from the Throttle Commander to the spade connector on the park brake light switch. Attach the OEM park brake light switch wire to the piggy-back connector on the end of the black VR7000 wire at the park brake light switch.
  • Page 38 DOCUMENT 19355 Speed control connection OEM diagnostic connector to vehicle harness removed from under dash Light Blue & Pink for clarity Figure 4.10...

  • Page 39: Illustrated Parts List

    DOCUMENT 19356 Part 5 Illustrated Parts List System #9037 1999-2000 FORD SUPER DUTY F250-F550 7.3 L POWER STROKE DIESEL UNDERHOOD AIR COMPRESSOR...
  • Page 41 DOCUMENT 19356 ILLUSTRATED PARTS LIST SYSTEM 9037 - 1999-2000 FORD SUPER DUTY F250 - F550 7.3 POWER STROKE DIESEL ITEM UNIT PART# DESCRIPTION 15029 ¼” NC Nylok Nut 15374 ¼” NC x 3” Threaded Rod 15221 ¼” NC Nut 36045 Filter Cover 36037 Paper Filter Element...
  • Page 42 DOCUMENT 19356 ILLUSTRATED PARTS LIST SYSTEM 9037 - 1999-2000 FORD SUPER DUTY F250 - F550 7.3 POWER STROKE DIESEL IT E M U N IT Q T Y P A R T # D E S C R IP T IO N 1 7 3 7 9 H o s e , C o o le r to W a te r P u m p 2 2 0 4 3...
  • Page 43 Warranty Registration This form must be completed and returned to VMAC at the time of installation. Warranty will be void if this form is not received by VMAC within 30 days by mail or fax. Installer Information Company Name: Installer Name: City: State/Prov.

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