Vmac VR70, V900093, V900103 Installation Manual
System V900093
2007 – 2006 GM 2500HD – 3500HD
Duramax Diesel
System V900103
2010 – 2007 GM 2500HD – 3500HD
GMT900 Duramax Diesel
www.vmacair.com
VR70 UNDERHOOD
AIR COMPRESSOR
INSTALLATION MANUAL
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
1
Installation Manual for VMAC
System V900093
2007 – 2006 GM 2500HD – 3500HD
Duramax Diesel
System V900103
2010 – 2007 GM 2500HD – 3500HD
GMT900 Duramax Diesel
General Information..................................................................... 3
Before You Start ....................................................................... 3
Special Installation Notes ......................................................... 3
Part 1: Warranty and System ID ................................................. 5
Part 2: Preparing for Installation ............................................... 8
2.1 Preparing for Installation .................................................... 8
Part 3: Installing the Control Components .............................. 15
3.1 Installing the Components .................................................. 17
3.2 Connecting the In-cab Wiring ............................................. 17
3.3 Connecting the Under-hood Wiring .................................... 19
Part 4: Installing the Tank and Hoses....................................... 21
4.1 Installing the Tank and Brackets ........................................ 21
4.2 Installing the Tank Assembly .............................................. 23
Part 5: Installing the Main Bracket and Compressor .............. 27
5.1 Installing the Cooler ............................................................ 27
5.2 Installing the Main Bracket ................................................. 28
5.3 Connecting the Hoses ........................................................ 33
5.4 Completing the Installation ................................................. 34
5.5 Adding Oil to the System .................................................... 36
Part 6: Finishing the Installation ................................................ 37
6.1 Before Starting the Engine Checklist.................................. 37
6.2 After Starting the Engine Checklist .................................... 38
6.3 Setup, Performance Testing and Adjustments ................... 39
6.5 Auxiliary Air Receiver ......................................................... 40
Accessory Products from VMAC ............................................... 41
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Installation Manual - Document #1930105
System V900093
2007 – 2006 GM 2500HD – 3500HD Duramax Diesel
System V900103
2010 – 2007 GM 2500HD – 3500HD GMT900 Duramax Diesel
Changes and Revisions
Version
Revision Details
Revised by/date
Approved
Implemented
M
ECN 09-081
SL 1 Oct 2009
PD 1 Oct 2009
1 Oct 2009
N
ECN 09-109
SL 27 Oct 2009
TG 27 Oct 2009
28 Oct 2009
P
ECN 10-041
SH 1 Sept 2010
SM 1 Oct 2010
6 Oct 2010
Q
ECN 12-156
SAR 14 Nov 2012
MH 16 Nov 2012
28 Nov 2012
R
ECN 13-013
SH 18 Jul 2013
SC 13 Oct 2013
22 Oct 2013
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 underhood mechanical work. Any
grinding, bending or restructuring operations for correct fit in modified
vehicles must follow standard shop practices.
All hoses, tubes, and wires that are rerouted or shifted
during installation must be secure so that they do not
contact excessively hot areas or sharp edges. Where
possible use rubber coated P-clips. Follow the routing
suggestions in this manual and cover all hoses with the
supplied plastic loom.
These instructions are a general guide for installing this system on
standard production trucks and do not contain information for
installation on non-standard trucks. This system may not fit special
order models or those that have had other changes without
additional modifications to the truck. If you have difficulty with the
installation, contact VMAC.
Copyright 2009
All trademarks used in this manual are the property of the respective copyright holder.
The contents of this manual may not be reproduced in any form without the express written permission of VMAC,
1333 Kipp Road, Nanaimo, BC V9X 1R3.
Printed in Canada
VMAC – Vehicle Mounted Air Compressors
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Fax: 1-250-740-3201
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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 model years and different
situations that are listed in the manual. Open the package, unpack
the components and identify them.
All fasteners must be torqued to specifications. Use manufacturers
torque values for OEM fasteners. Apply Loctite 242 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
¾
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 ¾ Foot-pounds (ft-lb)
40
60
90
180
320
Newton meter (N•m)
54
81
122
244
434
METRIC CLASS 10.9
Size
M8
M10
M12
M14
M16
Foot-pounds (ft-lb)
19
41
69
104
174
Newton meter (N•m)
25
55
93
141
236
Special Tools
36 mm 12 point 1/2 inch drive socket for removing the OEM
crankshaft bolt
crankshaft locking tool (GM #J-44643) or VMAC equivalent
(Part #5900010)
VMAC crankshaft pin extraction tool (Part #5900076)
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!
The following additional materials are recommended:
assorted sizes of fireproof protective plastic loom
assorted lengths of nylon tie-straps
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 our 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.
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Part 1: Warranty and System ID
□ Complete the warranty form. 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.
System Identification and Operating Instructions
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 customer inquiries and the ordering of
parts.
□ Mark and drill two 7/64-inch holes in the top of the cross member
in front of the OEM air filter box. Secure the plate with supplied
self- tapping screws
□ Clean cross member beside the number plate and stick the
VMAC belt routing diagram to the cross member.
□ Apply battery warning label to driver side of primary cooling
reservoir.
□ 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 1.1).
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Figure 1.1
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□ 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 1.2)
Figure 1.2
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 1-888-241-2289.
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Part 2: Preparing for Installation
2.1 Preparing for Installation
Preparation for installation is very important. Missing an item can
cause problems in the installation or even damage components.
Check off each item as it is completed.
2.1.1 V900093 Automatic Transmission Trucks
□ Locate the ECM in the engine compartment (Figure 2.1) and find
all wires that are orange with a black stripe in the bottom
connector. Use a digital voltmeter (DO NOT USE A TEST
LIGHT) to determine which wire has 0 Volts in Park/Neutral and
12 Volts in all other gear selector positions with the ignition on.
Mark the wire with a piece of tape and turn the ignition off.
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FWD
Do not connect
to the ATCM which
is mounted on the
radiator shroud on
all trucks with an
automatic transmission
Radiator
Power steering fill
ECM - under the radiator
hose between the power
steering fill and the driver
side battery. Has a black
cover
Battery
Location of tach wire
Bottom connector
orange wire with a
black stripe
FWD
Figure 2.1
2.1.2 V900103 Automatic Transmission Trucks
□ Locate the engine control module and connector ECMX2.
□ Locate the three orange wires with a black stripe. Switch the
ignition on and measure the voltage at the three wires. The
correct wire will read 0 Volts in Park/Neutral and 12 Volts in all
other gears
2.1.3 V900103 Tach Wire (CKP signal)
□ Locate the white wire with a black stripe in the top ECMX1
connector at the engine control module.
□ Start the engine and test for a constant 3 Volts at 600 RPM. If
you have a multi-meter that can measure frequency, the reading
will equal engine RPM.
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2.1.4 V900093 Tach Wire (CKP signal)
□ For 2007 Classic: Find the white wire with the black stripe in the
top ECM connector (Figure 2.1). You can verify that you have
the correct wire by checking for a constant 3 Volts with the
engine idling at about 600 RPM. If your multi-meter can measure
frequency, the reading will equal engine rpm.
□ For 2006 Models: If there is a white wire with a black stripe in
the top ECM connector (Figure 2.1), ensure that it is the correct
wire by using the same verification process as for the 2007
Classic. Mark it with a piece of tape and turn the engine off.
If there is no white wire with a black stripe, find the three wires
that are dark blue with a white stripe in the top connector. Use
the same verification process as for the 2007 Classic to locate
the correct wire. Mark it with a piece of tape and turn the engine
off.
2.1.5 Preparing the Truck
□ Disconnect the batteries.
□ Drain the coolant.
□ Remove the top radiator hose. Measure 10 inches from the
engine end (around the curve) and mark the hose. Measure 13/4 inches from the radiator end and mark the hose. Cut the
hose to length at the marks.
□ Remove the air filter assembly.
□ Remove the ATCM module from the top of the fan shroud and
remove the upper fan shroud.
□ Remove the three bolts from the fan stator, pull the fan stator
forward and unscrew the fan nut. Remove the fan and stator
together and discard the stator.
□ Remove the air intake resonator chamber from the engine.
□ Remove the OEM serpentine belt.
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□ Disconnect the wiring from the air conditioning compressor,
remove the four retaining bolts and move the compressor out of
the way.
Do not disconnect or damage the air conditioning lines
□ Remove the top engine coolant tube from the thermostat housing
and the top of the engine and remove the O-ring and
thermostatic switch.
□ Remove the wiring harness from the retaining clip on the driver’s
side of the engine and move it out of the way (Figure 2.2).
Figure 2.2
□ If equipped, remove the battery splitter box and ground tab
bracket from the back of the power steering pump and remove
all the power steering pump bolts. Move the pump to one side
but do not disconnect the hoses.
!
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□ If equipped, remove the ground jumper cable and the bracket
from the splitter box and secure the box and connecting harness
to the vehicle main electrical harness so that it is out of the way.
□ Remove the two 10 mm bolts and two 10 mm nuts, then remove
the OEM cast bracket that holds the air conditioning compressor
and power steering pump. Keep the bolts.
□ Remove the bolts holding the fan blades to the hub. Place the
supplied 4-1/2 inch fan spacer on the hub and install the fan
blades using the four supplied M8 bolts.
□ Remove the skid plate from under the vehicle.
2.1.3 Installing the Crankpin and Pulley
□ Install a crankshaft locking tool, remove the crank pulley bolt and
remove the crank pulley. If you are using the VMAC tool:
put the socket on the nut
put the single-pin end of the tool on the front of the pulley with
the locking tool hanging straight down
put a short extension and long flex-bar on the socket
turn the engine until the pin on the tool makes contact and the
tool jams against the protruding center-piece of the cross-
member under the front of the engine
□ Remove the crankshaft pin using the VMAC extraction tool
(Figure 2.3):
fit the split end of the tool (on the end of the shaft) over the
crankshaft pin and tap downward with the slide-hammer to
make sure that it is seated correctly
tighten the pinch bolt securely
use the hammer action of the slider in an upward motion to
remove the pin from the crankshaft
□ Install the replacement crankshaft/harmonic balancer locating pin
and tap it home using a brass drift and a small hammer. Ensure
that the head of the pin is aligned with the crankshaft by twisting
it into position with a crescent wrench (Figure 2.4).
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Slide
Pinch Bolt
OEM Crank Pin
Figure 2.3
High-strength
crank pin
Figure 2.4
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