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- Page 1 DOCUMENT 19622 Installation Manual For The System #9039 UNDERHOOD AIR COMPRESSOR 1996-2000 GMC C2500 & C3500 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, C2500 and C3500 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 AIR TANK AND LINES ............9 1.1 P ..................11 REPARING FOR INSTALLATION 1.2 I ................ -
Page 5: General Information
DOCUMENT 19622 General Information System #9039 1996-1999 GMC C2500 & C3500 5.0L (305) & 5.7L (350) UNDERHOOD AIR COMPRESSOR... -
Page 7: Introduction
DOCUMENT 19622 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 C2500 & C3500 with a 5.0L (305) or a 5.7L (350) -
Page 8: Installation Notes
DOCUMENT 19622 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 10 DOCUMENT 19622 Special installation notes If you intend to use an auxiliary air receiver with this system you must observe the following installation procedure (Figure 2) . Failure to observe this procedure will result in damage to the system. The line from the VR7000 tank to the auxiliary air receiver must have a one-way check valve installed to prevent blowback from the auxiliary tank and to prevent moisture from entering the VR7000 tank.
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Page 11: Part 1: Installing The Air Tank And Lines
DOCUMENT 19622 Part 1 Installing the Air Tank and Lines System #9039 1996-1999 GMC C2500 & C3500 5.0L (305) & 5.7L (350) UNDERHOOD AIR COMPRESSOR... -
Page 13: Preparing For Installation
DOCUMENT 19622 Part 1: Installing the Air Tank and Lines 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: Installing The Brackets And Tank
DOCUMENT 19622 Bracket Holding Heater Hoses, Air Conditioning Line And Alternator Cable OEM Heater Hose With Metal S-shaped Pipes On Vehicles With A/C, Fit The Supplied Aluminum Idler To The Cast AluminumBracket At This Location On Vehicles With Or Withoutout A/C Discard The Idler Which Is Attached Here OEM Alternator Bracket Figure 1.1... - Page 15 DOCUMENT 19622 Fit the two (2) supplied “P” clips over the 1/4 and 5/16 inch steel lines and postion them to align with the upper fixing slots on both C-clamps. Attach the L-shaped tank brackets to the C-clamps on the tank using the supplied 5/16 x 1/2 inch cap screws.
- Page 16 DOCUMENT 19622 Slide the flat washers onto the threaded ends of each wire cable and install one of the 5/16 inch nuts on each cable. Do not tighten until all the hoses are installed. Slide the tank rearward on the frame to provide clearance for attaching the remaining lines. Figure 1.4 Figure1.5 Figure 1.6...
- Page 17 DOCUMENT 19622 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 1.7 Figure 1.8...
- Page 18 DOCUMENT 19622 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 16. Connect the 45 degree fitting end on the 3/4 inch main air hose to the upper fitting on the front of the tank.
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Page 19: Part 2: Installing The Compressor And Cooler
DOCUMENT 19622 Part 2 Installing the Compressor, Oil Cooler System #9039 1996-1999 GMC C2500 & C3500 5.0L (305) & 5.7L (350) UNDERHOOD AIR COMPRESSOR... -
Page 21: Installing The Bracket And The Compressor
DOCUMENT 19622 1.2 Installing the bracket and compressor Re-route the OEM wire harness for the crank position sensor as shown in figure 2.1 Check the mounting surface to make sure that it is clean and free of debris. If the VR7000 bracket does not mount flush with the cylinder head, the pulleys will not line up correctly. -
Page 22: Installing The Crank Pulley
DOCUMENT 19622 Slide the compressor towards the engine so that the 1/2 inch oil return fitting in the side of the compressor is protruding through the aperture cut in the side of the mounting bracket. Feed the straight end fitting of the shorter of the two flexi 1/2 inch oil return hoses down between the mounting bracket under the alternator fixing point. -
Page 23: Installing The Oil Cooler
DOCUMENT 19622 2.3 Installing the oil cooler Remove the upper mounting plate that is tied to the cooler. Place in position on the upper side of the cross member immediatly under the radiator. Measure from the center hole (close to the rear edge and in the center of the crossmember) 1 1/2 inches towards the drivers side and scribe a line. - Page 24 DOCUMENT 19622 Figure 2.6 Figure 2.7 Fit supplied HS32 hose clamp to the loose end of the radiator hose which is fixed to the oil cooler. Attach the hose to the engine at the water pump. Loosen the hose clamp on the cooler and rotate the hose to remove any kinks and tighten both the hose clamps.
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Page 25: Connecting The Hoses
DOCUMENT 19622 Figure 2.8 2.4 Connecting the hoses Connect the straight end of the 3/4 inch main air discharge hose to the 3/4 fitting on the rear of the compressor. Route the 90 degree end of the1/2 inch oil return hose from the tank, over the chassis rail and down under the crank pulley and connect to the passengers side of the oil cooler. - Page 26 DOCUMENT 19622 Alternator Air Conditioning VR7000 Air Compressor Idler Water VR7000 Idler Pump VR7000 Tensioner Tensioner Power Steering Crankshaft Crankshaft With Air Conditioning Without Air ConditioningVR 7000 Belt Routing Figure 2.9 fit the supplied 36 inches long 5/8 heater hose to replace the heater hose removed earlier. Install the lower fan shroud.
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Page 27: Part 4: Installing The Control Unit
DOCUMENT 19622 Part 3 Installing the Control Unit System #9039 1996-1999 GMC C2500 & C3500 5.0L (305) & 5.7L (350) UNDERHOOD AIR COMPRESSOR... -
Page 29: Installing The Control Unit
DOCUMENT 19622 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 30: Connecting The Wiring Harness
DOCUMENT 19622 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 31 DOCUMENT 19622 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 32 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 33: Part 4: Installing The Throttle Controller
DOCUMENT19622 Part 4 Installing the Throttle Controller System #9039 1996-1999 GMC C2500 & C3500 5.0L (305) & 5.7L (350) UNDERHOOD AIR COMPRESSOR... -
Page 35: Installing The Throttle Controller Assembly
DOCUMENT19622 A DIVISION OF MANGONEL CORPORATION Part 4: Installing the Throttle Controller 4.1 Installing the throttle controller assembly Remove the two OEM M8 hex head cap screws locating the ABS and engine control unit mounting, immediatly behind the drivers side battery box. If ABS is not fitted the the captive 8mm nuts are available. - Page 36 DOCUMENT19622 A DIVISION OF MANGONEL CORPORATION Figure 4.2 Figure 4.3...
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Page 37: Connecting The Cable
DOCUMENT19622 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 39: Illustrated Parts List
DOCUMENT 19623 Part 4 Illustrated Parts List System #9039 1996-1999 GMC C2500 & C3500 5.0L (305) & 5.7L (350) UNDERHOOD AIR COMPRESSOR... - Page 41 DOCUMENT 19623 ILLUSTRATED PARTS LIST FOR SYSTEM 9039 - 1996-1999 GMC C2500 & C3500 5.0l (305) & 5.7l(350) A S S Y . IT E M U N IT Q T Y P A R T # D E S C R IP T IO N 1 .0 4 8 2 7 4 M a in B ra c k e t A s s em b ly...
- Page 42 DOCUMENT 19623 ILLUSTRATED PARTS LIST FOR SYSTEM 9039 - 1996-1999 GMC C2500 & C3500 5.0l (305) & 5.7l(350) AS S Y . IT E M U N IT Q T Y P AR T # D E S C R IP T IO N 3044 T an k Assem b ly 92199...
- Page 43 DOCUMENT 19623 ILLUSTRATED PARTS LIST FOR SYSTEM 9039 - 1996-1999 GMC C2500 & C3500 5.0l (305) & 5.7l(350) A S S Y . I T E M U N I T Q T Y P A R T # D E S C R I P T I O N 6 .
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Page 45: 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 46 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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