Vmac V300004 Installation Manual
Installation Manual for VMAC
System V300004
2015- 2016 Ford Transit
3.7 L Gas
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
1
Installation Manual for VMAC
System V300004
2015 - 2016 Ford Transit
3.7L Gas
Safety ...................................................................................................... 3
Warranty ................................................................................................. 4
General Information ............................................................................... 5
System Identification, Warranty and Warnings .................................. 6
Preparing for Installation ...................................................................... 8
Installing the Main Bracket ................................................................. 18
Installing the Compressor ................................................................... 21
Installing the Bulkhead Fittings .......................................................... 24
Hose Requirements ............................................................................. 30
Installing the Tank and Hoses ............................................................ 31
Installing the Control Components .................................................... 48
Installing VMAC Air Filter and Power Steering Reservoir ................ 72
Adding Oil to the System .................................................................... 76
Completing and Testing the Installation ............................................ 77
Setup, Performance Testing and Adjustments ................................. 80
Air Receiver Tank ................................................................................. 83
Recommended Accessories ............................................................... 84
Accessory Products ............................................................................ 85
Warranty Registration ......................................................................... 87
VMAC – Vehicle Mounted Air Compressors
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Document #: 1930258
Changes and Revisions
Additional Application Information
• V300004 2015- 2016 Ford Transit 3.7 L Gas
Registered Trademarks
All trademarks mentioned in this manual are the property of their
respective owners. Their use by VMAC is for identification of the
manufacturers’ products only and does not imply any affiliation or
endorsement by said companies.
Loctite®, Loctite® 242 and are registered trademarks of Henkel AG &
Company KGaA.
Ford® is registered trademark of Ford Motor Company.
Torx® is a registered trademark of Acument Intellectual Properties, LLC
Important Information
The information in this manual is intended for certified VMAC installers
who have been trained in installation procedures and for people with
mechanical trade certification who have the tools and equipment to
properly and safely perform the installation. Do not attempt this
installation if you do not have the appropriate mechanical training,
knowledge and experience.
Follow all safety precautions for mechanical work. Any grinding, bending
or restructuring operations for correct fit in modified vehicles must follow
standard shop practices.
Notice
Copyright © 2016 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 products and services are those set forth in the
express warranty statements accompanying such products and services,
if any, and nothing herein shall be construed as constituting an
additional warranty. You may print or copy for your personal use any
whole page or pages in this document. All other use, copying or
reproduction in both print and electronic form of any part of this
document without the written consent of VMAC is prohibited. The
information contained herein may be changed without prior notice.
Printed in Canada
Revision
Revision Details
Revised
by
Checked by
Implemented
Eng.
Tech.
Qual.
Mech.
Elec.
C
ECN 16-071, ECN 16-078
MSP
KRM
AJH
GB
AMG
10 Nov 2016
D
ECN 16-140 – Park interlock update
MSP
N/A
AJH
GB
AMG
28 Nov. 2016
E
ECN 17-094 – Improved safety testing
MSP
N/A
AJH
GB
SM
28 June 2017
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Safety
Important Safety Notice
The information contained in this manual is based on sound engineering
principles, research, extensive field experience and technical
information. Information is constantly changing with the addition of new
models, assemblies and service techniques. If a discrepancy is noted in
this manual, contact VMAC prior to initiating or proceeding with
installation, service or repair. Current information may clarify the issue.
Any person with knowledge of such discrepancies who performs service
and repair assumes all risks.
Only proven service procedures are recommended. Anyone who departs
from the specific instructions provided in this manual must first assure
that their safety and that of others is not being compromised and that
there will be no adverse effects on performance or the operational safety
of the equipment.
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 any person to properly adhere to the procedures
set out in this manual or standard safety practices. Safety should be
your first consideration in performing service operations. If you have any
questions concerning the procedures in this manual or require any more
information on details that are not included in this manual, please
contact VMAC before beginning repairs.
Safety Messages
This manual contains various warnings, cautions and notices that must
be observed to reduce the risk of personal injury during installation,
service or repair and the possibility that improper installation, service or
repair may damage the equipment or render it unsafe.
This symbol is used to call your attention to instructions
concerning your personal safety. Watch for this symbol; it points
out important safety precautions, it means, “Attention, become
alert! Your personal safety is involved”. Read the message that
follows and be alert to the possibility of personal injury or death.
Be alert; your safety is involved. While it is impossible to warn
about every conceivable hazard, let good common sense be
your guide.
This symbol is used to call your attention to instructions on a
specific procedure that if not followed may damage or reduce
the useful life of the compressor.
This symbol is used to call your attention to additional
instructions or special emphasis on a specific procedure.
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Warranty
Standard Product Warranty
For complete warranty information, including both our standard Product
Warranty and Limited Lifetime Warranty requirements, please refer to
our current published warranty located at:
www.vmacair.com/warranty
If you do not have access to a computer, please contact us and we will
be happy to send you our warranty.
VMAC’s warranty is subject to change without notice.
Limited Lifetime Warranty
Effective 1 October 2015 - The Compressor Assembly (excluding Inlet
and Clutch, where applicable) is warranted against manufacturer defects
in materials and workmanship for the lifetime of the Compressor
Assembly. Restrictions apply – refer to VMAC Warranty Policy and
VMAC Limited Lifetime Warranty for full details.
Warranty Registration
The VMAC warranty form is located at the back of this manual. This
warranty form must be completed and sent to VMAC at the time of
installation for any subsequent warranty claim to be considered valid.
There are 4 ways warranty forms can be submitted to VMAC:
Online
http://vmacair.com/support/warranty/
Email
tech@vmacair.com
Fax
(250) 740-3201
Mail
VMAC - Vehicle Mounted Air Compressors
1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
5
General Information
Before You Start
Read this manual before attempting installation so that you can
familiarize yourself with the components and how they fit on the vehicle.
Identify variations for different engine models and different situations that
are listed in the manual. Open the package, unpack the components and
identify them.
Torque Specifications
All fasteners must be torqued to specifications. Use manufacturers’
torque values for OEM fasteners. Apply Loctite 242 (Blue) or
equivalent on all engine-mounted fasteners. Torque values are with
Loctite applied unless otherwise specified.
STANDARD GRADE 8 NATIONAL COARSE THREAD
Size
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
Foot-pounds (ft•lb)
9
18
35
55
80
110
170
280
Newton meter (N•m)
12
24
47
74
108
149
230
379
STANDARD GRADE 8 NATIONAL FINE THREAD
Size
3/8
7/16
1/2
5/8
3/4
Foot-pounds (ft•lb)
40
60
90
180
320
Newton meter (N•m)
54
81
122
244
434
METRIC CLASS 10.9
Size
M6
M8
M10
M12
M14
M16
Foot-pounds (ft-lb)
4.5
19
41
69
104
174
Newton meter
(N•m)
6
25
55
93
141
236
Special Tools Required
• 15 mm Serpentine belt wrench
• 10 mm flex-head gear wrench
• Torx Drive set
• VMAC test tool P/N: A700052
• 14 mm flex-head gear wrench
Hose Information
Depending on other installed equipment, it might be necessary to move
the air/oil separation tank from its intended location. The hoses used in
VMAC compressor systems have a specific inner liner that is compatible
with VMAC compressor oil. Use of hoses other than those supplied or
recommended by VMAC may cause compressor damage and may void
your warranty. Please contact VMAC for replacement hoses and further
information.
Ordering Parts
To order parts, contact your VMAC dealer. Your dealer will ask for the
VMAC serial number, part number, description and quantity. To locate
your nearest dealer, call 1-877-912-6605 or online at www.vmacair.com.
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System Identification, Warranty and
Warnings
Preparation for installation is very important. Missing a step or an item can
cause problems in the installation or damage to components.
Check off each item as it is completed so that you do not miss any
preparation steps.
□ Check through the illustrated parts list, ensure that no components are
missing and that they are in the correct quantity. If any components are
missing, have the system ID ready and call VMAC Technical Support at
(888) 241-2289.
□ 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
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.
The System Identification Number Plate must be attached to the
vehicle at the time of installation. This plate provides
information that allows VMAC to assist in parts and repairs.
□ Mark and drill 2 x 7/64 in holes in an appropriate location, close to the
compressor. Secure the plate with supplied self-tapping screws
(Figure 1).
Figure 1 – System Identification Plate
□ Install the VMAC belt routing diagram in a suitable location under the
hood.
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□ As part of the installation process, ensure that the safety and operational
instruction decal is affixed in an obvious location so that it can be seen by
vehicle operators. A good spot for this is usually on the inside of the door
or on the panel underneath the steering wheel (Figure 2).
Figure 2 – Operating Instruction Label
□ 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. Thoroughly clean the selected area before affixing the
label (Figure 3).
Figure 3 – Warning Label
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Preparing for Installation
In the Cab:
□ Move the driver side seat fully to the rear and remove the 2 front T40 Torx
Bolts (Figure 4).
Figure 4 – Driver seat front
□ Move the driver side seat fully forward and remove the 2 rear T40 Torx
Bolts (Figure 5).
Figure 5 – Driver side seat rear
T40
T40
T40
T40
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□ Use an 8 mm socket to remove the seat electrical connector (Figure 6).
Figure 6 – Seat electrical connector
□ The seat electrical harness is hooked to a stud on the bottom of the seat.
Ensure the harness is unhooked and the wire is allowed to hang loose
under the seat.
□ Leave the seatbelt connected to the seat and lift the seat off of its mount,
place the seat on the floor outside of the driver side of the van.
The driver side seat is heavy, take care when lifting to prevent
injury.
Remove
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□ Use an 8 mm socket to remove the 2 bolts underneath the piece of carpet
at the rear of the battery cover retaining plate. Remove the metal bracket,
then lift the plastic tabs on the rear of the battery cover to remove the
battery cover (Figure 7).
Figure 7 – Battery cover
□ Disconnect the negative battery cable from the battery terminal stud
(Figure 8).
Figure 8 – Battery cables
Remove
Negative
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In the Engine Bay:
□ Disconnect the vacuum hose from the intake tube, press the 2 locking
tabs simultaneously and pull the connector back (Figure 9).
Figure 9 – Vacuum hose
□ Disconnect the PCV hose from the intake tube, there is a small grey
plastic tab which has to be lifted while the connector is pulled away from
the intake tube (Figure 10).
Figure 10 – PCV hose
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□ Loosen the 2 hose clamps on the intake tube ( Figure 11).
□ Remove intake tube (Figure 11).
□ Cover the engine and air filter openings to prevent contaminants from
entering into the engines intake system.
Figure 11 – Intake tube assembly
Clamp
PCV
Vacuum
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□ Remove the 2 x T30 Torx button head screws holding the power steering
reservoir to the radiator support and use a cable tie to secure the reservoir
to the windshield washer fill tube (Figure 12).
Figure 12 – Washer reservoir
□ Use a 10 mm socket to remove the 2 x M8 engine hook bolts, remove
engine hook (Figure 13).
Figure 13 – Engine hook
Raise the vehicle and support the front of the vehicle on stands.
Washer Fill
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□ Remove the 4 rib OEM drive belt, discard belt (Figure 14).
Figure 14 – Accessing the tensioner bolt
Use a 14 mm flexible head gear wrench to access the tensioner
bolt. Access the tensioner bolt via the passenger side of the
engine, in front of the air conditioning compressor clutch.
Tensioner
bolt
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□ From the bottom of the vehicle, use a 15 mm serpentine belt wrench on
the OEM tensioner. Remove the 6 rib belt. Keep this belt as it will be reused (Figure 15) (Figure 16).
Figure 15 – Using the serpentine wrench
Figure 16 – Tensioner bolt location
Tensioner
bolt
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□ Loosely install the supplied 4 rib belt on the crank pulley.
□ Route and tension the original 6 rib belt (Figure 17).
Figure 17 – 6 Rib belt routing
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The air conditioning system is always pressurized with
refrigerant. Do not remove or damage the air
conditioning lines as a refrigerant leak can cause
serious injury.
□ Disconnect the electrical connector from the air conditioning compressor
clutch. Ensure that the wiring is not attached to the compressor housing
as the weight of the compressor may damage the harness (Figure 18).
□ Remove the air conditioning compressor from the engine; it is held on by 3
x M8 bolts with 10 mm bolt heads. Lower the compressor until it rests on
the sub-frame (Figure 18).
The top bolt can be difficult to access due to the air
conditioning lines; a 10 mm flexible head gear wrench can make
removal easier (Figure 18).
Figure 18 – Air Conditioning compressor bolts
Connector
Top Bolt
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Installing the Main Bracket
Do not use an impact tool to tighten fasteners. Use a torque
wrench and follow the recommended torque values. Use
Loctite 242 (blue) on all fasteners.
□ The main bracket (4800701) is held onto the engine with 4 fasteners. Use
Loctite 242 (blue) on all fasteners (Figure 19).
□ Install the 3 supplied M8 x 45 socket head bolts finger tight through the
main bracket, into the existing air conditioning compressor bolt holes
(Figure 19).
□ Install the supplied M8 x 60 socket head bolt into the engine hook bolt
hole (Figure 19).
Figure 19 – Main Bracket and Fasteners
□ Torque fasteners to specification.
M8x45
M8x60
M8x45
M8x45
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□ Mount the OEM air conditioning compressor to the VMAC main bracket.
Re-use the 3 OEM bolts (Figure 20).
When installing the A/C compressor, ensure the clutch wire is
routed so that it will not be pinched, or damaged by any sharp
edges or hot components.
□ Loosely install the rear and bottom bolts; use them to hold the compressor
in position.
Figure 20 – Main Bracket and OEM A/C Fasteners
Air conditioning lines not shown for clarity.
Rear OEM
Bolt
Top OEM
Bolt
Bottom OEM
Bolt
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□ The top bolt is difficult to access due to the location of the air conditioning
lines. Push the compressor against the main bracket so the top bolt can
be accessed through the machined opening in the top of the VMAC
bracket. Use a 10 mm open ended wrench to tighten the bolt. Once the
bolt is threaded in far enough a 10 mm flexible head gear wrench can be
used to fully tighten the bolt (Figure 21).
Figure 21 – Top A/C compressor bolt
□ Reconnect A/C clutch electrical connector.
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Installing the Compressor
□ Use Loctite 242 (blue) and install the 3 supplied M8 x 45 socket head bolts
to secure the VMAC compressor onto main bracket (Figure 22).
Figure 22 – Compressor fasteners
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□ Install the supplied 4 rib belt so that it is centered on the compressor
clutch and tension the belt (Figure 23).
Figure 23 – Belt routing
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Figure 24 – Belt alignment
To ensure the belt is properly aligned on the clutch pulley,
confirm there are 2 grooves visible on each side of the belt
(Figure 24).
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Installing the Bulkhead Fittings
4 bulkhead fittings are supplied with the system.
3 Bulkhead fittings are supplied for passing the system discharge, oil, and
scavenge hoses into the body of the vehicle (shown on the left of Figure 25).
1 bulkhead fitting is supplied for locating the blowdown muffler outside of the
vehicle, (shown on the right of Figure 25).
This kit includes hoses of a fixed length to run from the compressor to the
bulkhead fittings, and from the fittings to the WHASP tank.
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 30 of this manual.
Figure 25 – Bulkhead fittings
The location of the bulkhead fittings will depend on the location of the WHASP
tank and may vary depending on the application. The following instructions are
for suggestion only. Use good judgement before installation; before drilling any
holes confirm that there are no wires, hoses or components on the other side
of the panel that may be damaged. A pilot drill hole may be required.
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□ The supplied 150 in hoses are intended for installing the WHASP tank
inside of a van body, about 12 in behind the driver side seat.
□ Locate the area shown, it is to the rear of fuel filler neck on the driver side
floor. The holes are shown for clarity and will be drilled in the following
steps (Figure 26).
Figure 26 – Vehicle Chassis bottom view
Filler
Neck
Location
Driver
side of
vehicle
Front of
vehicle
6 1/2 in
3 in
3 in
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As shown in Figure 27:
□ Using a step drill, drill bit, or hole saw, drill the following holes:
• Forward mark - 9/16 in.
• 2 middle marks - 5/8 in.
• Rear passenger side mark - 1 1/8 in.
• Driver side mark - 3/8 in. Install a 3/8 in rubber grommet (Not supplied).
Figure 27 – Bottom View
Front of
vehicle
Driver
side of
vehicle
9/16 in
5/8 in
5/8 in
1 1/8 in
3/8 in
3 in
3 in
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