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- Page 1 DOCUMENT 19144 Installation Manual For The System #9004 UNDERHOOD AIR COMPRESSOR 1996-1999 GMC CK2500 & CK3500 5.0L (305) & 5.7L (350) TEL: 250-754-6997 FAX: 250-754-6972 TOLL FREE: 800-738-8622 1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3...
- Page 2 #19130 - warranty registration Registered Trademarks: VR7000, VMAC and Throttle Commander are registered trademarks of VMAC. GMC, CK2500 and CK3500 are registered trademarks of General Motors Corporation Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.
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Page 3: Table Of Contents
Contents GENERAL INFORMATION....................3 ........................5 NTRODUCTION ......................6 NSTALLATION OTES ........................7 RDERING ARTS ..........................7 ARRANTY ....................7 HANGES AND IMPROVEMENTS PART 1: INSTALLING THE COMPRESSOR, FILTER, REGULATOR AND OIL COOLER ....................9 1.1 P ..................11 REPARING FOR INSTALLATION 1.2 I .............. -
Page 5: General Information
DOCUMENT 19144A General Information System #9004 1996-1999 GMC CK2500 & CK3500 5.0L (305) & 5.7L (350) UNDERHOOD AIR COMPRESSOR... -
Page 7: Introduction
DOCUMENT 19144A General Information Introduction This book provides installation instructions for: VMAC underhood air compressor installation kit VMAC Pneumatic Throttle Control This kit has been designed for: 1996-1999 GMC CK2500 & CK3500 with a 5.0L (305) or a 5.7L (350) -
Page 8: Installation Notes
DOCUMENT 19144A Installation Notes It is important that you complete all the installation steps before operating the system. 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 9: 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 11: Part 1: Installing The Compressor, Filter, Regulator And Oil Cooler
DOCUMENT 19145 Part 1 Installing the Compressor, Filter, Regulator Oil Cooler System #9004 1996-1999 GMC CK2500 & CK3500 5.0L (305) & 5.7L (350) UNDERHOOD AIR COMPRESSOR... -
Page 13: Preparing For Installation
DOCUMENT 19145 Part 1: Installing the Compressor, Filter, Regulator and Oil Cooler 1.1 Preparing for installation Disconnect all battery cables, then undo the battery hold down and remove the battery from the passenger side of the vehicle. Drain the coolant from the cooling system and remove the lower radiator hose. Remove and discard the rock guard from under the radiator. - Page 14 DOCUMENT 19145 The fan has right hands threads. NOTE On vehicles equipped with air conditioning, remove the OEM belt idler from the cast alternator bracket and move it to the location below the air conditioning compressor (Figure 1.2). On vehicles without air conditioning, the OEM idler on the alternator bracket is discarded with the bracket.
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Page 15: Installing The Bracket And Compressor
DOCUMENT 19145 Do not disconnect the heater return hose quick-coupler at the manifold as it may leak if removed and refitted. NOTE Remove the long stud used to locate and secure the OEM alternator mounting bracket to the cylinder head. Check the mounting surface to make sure that it is clean and free of debris. -
Page 16: Installing The Filter And Regulator Assembly
DOCUMENT 19145 Apply Loctite to the studs on the bottom of the compressor, position the compressor in place on the VR7000 bracket, install the 8 mm nuts and flat washers and torque to 25 ft-lb. 1.3 Installing the filter and regulator assembly ″... -
Page 17: Installing The Oil Cooler
DOCUMENT 19145 Install the remote filter housing and regulator back onto the VR7000 bracket using the previously removed fasteners (Figure 1.5). Tighten the fasteners. 1.4 Installing the oil cooler Remove the OEM hex head cap screws retaining the radiator to the body. Raise the radiator a few inches to gain acces to the crossmember under the radiator. -
Page 18: Completing The Installation
DOCUMENT 19145 Hose To Lower Radiator Connection Hose To Water Pump Connection Cross-Member In Front Of The Radiator Figure 1.7 1.5 Completing the installation Route the heater return hose along the lower edge of the compressor and under all compressor fittings. If necessary, secure the hose in place with nylon ties. ″... - Page 19 DOCUMENT 19145 Install the alternator on the VR7000 bracket using the OEM fasteners. Connect the wiring to the alternator and route the harness clear of belts and pulleys. If necessary, fasten the harness securely with a nylon tie. Install the drive belt for the required application (Figure 1.8): Standard alternator WAC 16229 Standard alternator WOAC...
- Page 20 DOCUMENT 19145 Fill the cooling system with the OEM recommended coolant to the correct level. Route the positive battery cable back across the fan shroud and secure it in place. When operating the engine for the first time following installation, be sure to allow the engine to reach full operating temperature and ensure that the cooling system level is correct.
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Page 21: Part 2: Installing The Air Tank And Lines
DOCUMENT 19146 Part 2 Installing the Air Tank and Lines System #9004 1996-1999 GMC CK2500 & CK3500 5.0L (305) & 5.7L (350) UNDERHOOD AIR COMPRESSOR... -
Page 23: Installing The Tank Mounts And The Tank
DOCUMENT 19146 Part 2: Installing the Air Tank and Lines 2.1 Installing the tank mounts and the tank The tank mounts supplied with this system are designed so that they can be mounted on the frame without drilling holes. The tank is secured to the frame using two L-brackets that hook over the chassis rail and are secured with wire cables and backing straps. - Page 24 DOCUMENT 19146 Wire cable L-bracket Clamp tightening bolt Tank clamp Backing strap Cable guide Mounting nuts, flat washers and lock washers Figure 2.2 Most applications come with the tank band clamps fitted to the tank. It is easier to fit the L brackets loosely to the tank band clamps and install tank and L brackets together.
- Page 25 DOCUMENT 19146 It is recommended that you leave the tank loose in the clamps until all of the lines are connected to allow you to adjust tank position during the line connection process. NOTE Figure 2.3 Figure 2.4...
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Page 26: Connecting The Air And Oil Lines
DOCUMENT 19146 Figure 2.5 2.2 Connecting the air and oil lines The lines must be installed in the correct locations or the system will not function properly. In addition, a hazardous situation may develop from oil spray, potential fire or explosion. WARNING This procedure will follow the installation of each individual line, show the location on each component and describe the complete process. - Page 27 DOCUMENT 19146 Main Air Line Fitting Scavenge Line Connected to Fitting Figure 2.6 Connect the “ x 72“ scavenge line connected earlier to the tank, to the fitting on the side of the air inlet valve (Figure 2.6). Also route this line in the same location as for the main air line and clear of the exhaust manifold.
- Page 28 DOCUMENT 19146 Connect the pressure control line from 1/4 fitting on the side of the tower on the “ x “ “ top of the tank to the fitting on the pressure regulator block (Figure 2.8). Route this line along with the other lines. Red Poly Line VR7000 Pressure Regulator Assembly...
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Page 29: Adding Oil To The System
DOCUMENT 19146 Oil Return Line To Compressor 1/2" x 33-1/2" Oil Return Line To Cooler 1/2" x 26" Figure 2.10 Check the position of the tank to ensure that it is in the correct alignment and that the hoses are not stressed and that there is sufficient access to the tank outlet. Tighten the tank clamp bolts, then tighten the mounting nuts which attach the clamps to the frame mounts. -
Page 30: Completing The Installation
DOCUMENT 19146 Remove This Plug Figure 2.11 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. WARNING Turn the compressor clutch clockwise with a ratchet and socket using the hex head cap screw at the center of the compressor clutch. -
Page 31: Part 3: Installing The Control Unit
DOCUMENT 19148 Part 3 Installing the Control Unit System #9004 1996-1999 GMC CK2500 & CK3500 5.0L (305) & 5.7L (350) UNDERHOOD AIR COMPRESSOR... -
Page 33: Installing The Control Unit
DOCUMENT 19148 Part 3: Installing the Control Unit 3.1 Installing the control unit Locate a suitable location for the control unit. One recommended location is behind the seat on the driver’s side of the vehicle (Figure 3.1). Locate and drill two (2) holes through the plastic trim panel to match the control unit brackets. -
Page 34: Connecting The Wiring Harness
DOCUMENT 19148 Connect the two interface connectors together. Route the white wire, 18 gauge red wire (without the fuse holder) 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 sealing boot where the steering column passes through the firewall. - Page 35 DOCUMENT 19148 Connect the black wire from the Drive Disable Circuit with the piggyback connector to the connector on the park brake switch. Connect the OEM wire to the piggyback connector at the park brake switch. Route the blue wire into the engine compartment along the same route as the other wires. Locatethe light green wire at cavity B in the 7 pin connector at the transmission (Figure 3.2).
- Page 36 In-line Fuse To switched power source To ground Green To OEM park brake switch and Black OEM park brake switch wire Black To female quick-connector at the Blue transmission To Matching AUTOMATIC TRANSMISSION ONLY Connector on Harness From To compressor clutch White Control Unit White...
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Page 37: Part 4: Installing The Throttle Controller
DOCUMENT19147 Part 4 Installing the Throttle Controller System #9004 1996-1999 GMC CK2500 & CK3500 5.0L (305) & 5.7L (350) UNDERHOOD AIR COMPRESSOR... -
Page 39: Installing The Throttle Controller Assembly
DOCUMENT19147 A DIVISION OF MANGONEL CORPORATION Part 4: Installing the Throttle Controller 4.1 Installing the throttle controller assembly Remove the two lower OEM nuts retaining the brake master cylinder to the power booster. Install the throttle controller mounting bracket over the lower master cylinder mounting studs (Figure 4.1). - Page 40 DOCUMENT19147 A DIVISION OF MANGONEL CORPORATION Figure 4.2 Figure 4.3...
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Page 41: Connecting The Cable
DOCUMENT19147 A DIVISION OF MANGONEL CORPORATION 4.2 Connecting the cable Remove the 6 mm OEM nut that is used to secure the OEM throttle bracket. Install the VR7000 cable bracket and replace the 6 mm OEM nut. If the vehicle is equipped with cruise control, remove the OEM cruise cable from the throttle spindle, install the VR7000 pull bracket and reinstall the OEM cruise cable. -
Page 43: Illustrated Parts List
DOCUMENT 19149 Part 5 Illustrated Parts List System #9004 1996-1999 GMC CK2500 & CK3500 5.0L (305) & 5.7L (350) UNDERHOOD AIR COMPRESSOR... - Page 45 ILLUSTRATED PARTS LIST FOR SYSTEM 9004 - 1996-1999 GMC CK2500 & CK3500 5.0L (305) & 5.7L (350) ITEM UNIT PART# DESCRIPTION 15385 Retaining ring 32033 Sight glass window 58008 O-ring, 1 15/16” ID x 3/32” wide, Viton 48105 Scavenge screen filter 17090 ¼”...
- Page 46 ILLUSTRATED PARTS LIST FOR SYSTEM 9004 - 1996-1999 GMC CK2500 & CK3500 5.0L (305) & 5.7L (350) ITEM UNIT PART# DESCRIPTION 17027 5/8” hose 17357 5/16” x 72” hose / Scavenge line 22029 Hose clamp, HS10 12220 Throttle control bracket 5039 Mechanical throttle control 50020...
- Page 47 ILLUSTRATED PARTS LIST FOR SYSTEM 9004 - 1996-1999 GMC CK2500 & CK3500 5.0L (305) & 5.7L (350) IT EM U N IT Q T Y PAR T # D ESC R IPT IO N 36053 Silencing reed 50020 1/8” N PT x ¼ ” poly tube, 90° elbow 1217 VR 7000 com pressor 49032...
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Page 49: Warranty Registration
Warranty Registration This form must be fully 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:... - Page 50 1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3 TEL: 250-754-6997 FAX: 250-754-6972 TOLL FREE: 800-738-8622...
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