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

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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

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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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□ Apply a light wipe of oil to the inside of the OEM crank pulley and

install the pulley back onto the crankshaft.

□ Place the VR crank pulley in position with the two roll pins on

both sides of the counter balance weight of the OEM pulley
(Figure 2.5).

□ Thread the M18 x 100 mm center bolt with OEM washer into the

crankshaft. Install an engine-locking tool and torque the center
bolt to 250 ft-lbs (340 N.m).

Position the roll pins here

Figure 2.5

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Part 3: Installing the Control

Components

White

Interface

Connector

Green 4 pin

connector

White

Red

Red

Red

White

White

White

Compressor

Inlet valve

Clutch

Green

Black

Black 3 pin

connector

ECM

Connect to park brake switch

Throttle

Controller

Connect to

accelerator pedal

OEM Connector

from accelerator

pedal

To ground

Blue

Blue

Throttle

Controller

Blue

Blue

Connect the blue wires

MANUALTRANSMISSION

AUTOMATICTRANSMISSION

Do not use short blue wire with

crimp connector

Throttle

Controller

Blue

Blue

Connect

Solder and seal to the orange wire

with the black stripe from the lower

ECM connector with O Volts in P/N

and 12 Volts in all other positions

Connect to SEO port of MBEC

Control Box

See Part for locating the correct wire

at the ECM connector

2

V900093 Wiring

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White

Interface

Connector

Green 4 pin

connector

White

Red

Red

Red

White

White

White

Compressor

Inlet valve

Clutch

Green

Black

Black 3 pin

connector

ECM

Throttle

Controller

Connect to

accelerator pedal

OEM Connector

from accelerator

pedal

To ground

Blue

Blue

Throttle

Controller

Blue

Blue

Connect the blue wires

MANUAL TRANSMISSION

AUTOMATIC TRANSMISSION

Do not use short blue wire with

crimp connector

Throttle

Controller

Blue

Blue

Connect

Solder and seal to the orange wire

with the black stripe from the lower

ECM connector with O Volts in P/N

and 12 Volts in all other positions

Control Box

See Part for locating the correct wire

at the ECM connector

To key switched 12 Volts

Fuse 10A

Connect to Park brake switch

To ground

2

V900103 Wiring

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3.1 Installing the Components

□ Install the control box where it will be accessible but will not be

subject to damage, such as under the center of the dash above

the transmission hump. Mark the position of the mounting holes,

drill two holes and mount the control box with the wire harness

coming out the bottom of the unit.

□ Mount the throttle control under the dash near the steering

column using plastic ties in a position where the harness

connectors on the throttle control will reach the OEM accelerator

connectors.

□ Route the following wires into the engine compartment through a

suitable OEM plug in the firewall. One location is the large wire

harness plug behind the park brake:

grey wire with a 3 pin black connector
grey wire with a 4 pin green connector
white wire with a plug connector
white wire with no connector
automatic transmission vehicles – blue wire with no connector

3.2 Connecting the In-cab Wiring

□ Unplug the OEM cable from the accelerator pedal and plug it into

the matching connector from the throttle control box. Plug the

cable from the throttle control into the matching connector on the

accelerator pedal.

□ Connect the two white interface connectors together.
□ Connect the red wire from the throttle controller to the red wire

from the interface cable.

□ Connect the ground wire from the throttle control to a good

ground under the dash.

□ Remove the connector from the park brake switch, connect it to

the piggyback connector on the black wire from the interface

connector and plug it back onto the park brake switch.

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3.2.1 V900093 Power Connection (prior to 2008)

□ Locate the Mid-Bussed Electrical Center (MBEC) under the

instrument panel and left of the steering column (Figure 3.1).

Mid-Bussed Electrical Center

SEO Port

Figure 3.1

□ Remove the cover and locate the SEO port. Connect the power

and ground plug from the interface cable to the SEO port (Figure

3.2) and replace the cover.

If the connector in the SEO port already has a wire in

location “C”, you can splice the red wire into that wire

or locate an alternate power source, such as the hot
side of an ignition switch controlled fuse on the fuse
panel.

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Red

Green

Black

White

To “C”

To “F”

Figure 3.2

3.2.2 V900103 Power Connection (prior to 2008)

□ At the fuse panel, locate fuse 42.
□ Install the fuse tap on the fuse and install the fuse so that the tap

is on the high (hot) side, not on the low (fused) side. With the

fuse removed, this should read 12 Volts with the ignition switch

in the ON position.

3.2.3 Power Connection 2008-2010 models

□ Locate the electrical box on the firewall between the park brake

and the steering column.

□ Test the connections in the center of the electrical box to locate a

source that provides 12 Volts with the ignition switch in the ON

position.

3.3 Connecting the Under-hood Wiring

Cover all underhood wiring with plastic loom. Secure the
harnesses with nylon ties and pull all excess wire back
into the cab.

□ Route the two grey wires and the white wire with the plug

connector to the compressor. Connect the wires to the matching

connectors at the compressor.

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□ Solder and seal the white wire from the throttle controller to the

appropriate wire for the correct model year at the top ECM
connector (located and marked during preparation). The
preferred connection method is shown in Figure 3.3.

OEM wire

VR wire

Shrink sleeve

Soldered joint

Figure 3.3

3.3.1 Automatic Transmission

□ Solder the blue wire to the orange wire with a black stripe at the

lower ECM connector (located and marked with tape in Part 2:
Preparing for Installation) and seal the connection with shrink
sleeve.

3.3.2 Manual Transmission

□ Cut the long blue wire to approximately 6 inches, strip and crimp

it to the short blue wire with the butt connector.

3.3.3 All Trucks

□ Pull all excess wiring back into the cab, bundle the wiring

together and tie it up out of the way under the dash.

□ Replace all dash panels and other covers removed during

installation.

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Part 4: Installing the Tank and

Hoses

4.1 Installing the Tank and Brackets

The tank will mount to the driver side frame rail between the two
body mounts (Figure 4.1).

The rear tank bracket must be positioned to conform to
variations in chassis configuration. This will affect the
positioning of the rear C-clamp.

1/4” and 3/16” tubes

3/4” hose fitting

1/2” hose fitting

C-clamp

Tank strap mount

Tank strap cable

Oil filter

5/16” nuts and

washer

Spacer

Tank strap flat bar

Figure 4.1

□ Remove the oil filter from the front of the tank, fill it with

compressor oil, cover it and place it out of the way.

□ Place the tank on a work bench with the front (oil filter end) of the

tank to your right.

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□ Remove the two 1/4 inch clamp bolts from the C-clamps. Expand

the clamps slightly and slide them over the front of the tank.
Position the front clamp about 5-1/2 inches from the front of the
tank to the front of the clamp and the rear clamp about 24 inches
from the front of the tank.

□ Place the two L-shaped tank strap mounts under the C-clamps

with the right-angle ends facing you and hanging over the edge
of the work bench.

□ Apply Loctite and thread 5/16 x 1/2 inch bolts with flat washers

into the bottom hole on each bracket, but do not tighten.

□ Install the 1/4 inch clamp bolts into the C-clamps so that the

heads of the bolts face toward you and install the nuts.

□ Rotate the tank so that the directional arrow on the end of the

tank is parallel to the work bench and faces toward you check
the distance of each C-clamp from the ends of the tank and
tighten the clamp bolt on the front clamp so that it grips the tank
securely. Leave the back clamp loose enough so that the
position can be adjusted.

□ Apply Loctite and insert 5/16 x 1/2 inch bolts through the C-

clamps and thread them into the mount brackets.

□ Center the bolts in the C-clamp slots and tighten them.
□ Apply Loctite pipe thread sealant and install a 90 degree fitting to

the outlet on the tank. Tighten it to about the eight O’clock

position for testing, then reposition as required for operational
connections (Figure 4.2).

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Align to approximately

the 8 o’clock position

Figure 4.2

□ Push the insulated tube clips toward the tank to provide

clearance for the mounting cables.

4.2 Installing the Tank Assembly

□ Remove the three clips holding the wire harness on the outside

of the driver’s side frame rail.

□ Remove the front park brake cable guide from the frame and

leave it attached to the cable.

□ Remove the brake line from the clips locating it to the top inside

of driver frame rail and remove the clips. Bend the brake line

slightly inward away from the frame to provide clearance for the

rear tank mount

□ Insert the threaded ends of the cable straps through the end hole

on each of the bar straps.

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□ Place the bar straps in position on the inside of the frame, one in

front of the transmission cross-member and one behind, with the
cable straps over the top of the frame. Do not pinch the brake
line with the backing strap or cable. Carefully bend the brake
lines as required to clear the backing straps and cables.

Depending on chassis configuration, the rear clamp
backing strap may have to be positioned either in front
of or behind the electronic brake module on the inside
of the frame. Select the best location once the tank is in
position.

□ Place the tank assembly under the driver side of the vehicle,

then lift the tank assembly and support it in position so the tops
of the two tank strap mounts fit over the top of the frame rail.
Make sure that that the wire harness is outside the mounts and
is not pinched between the mounts and the frame.

□ Wrap the two tank cable straps around the tank strap mounts.

Make sure that they fit in the upper and lower cut-outs of the tank
strap mounts (Figure 4.3).

Cable must fit
in the grooves

Figure 4.3

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!

□ Insert the threaded end of the cable through one of the lower

holes on the tank strap flat bars. Select the appropriate hole that

best matches the frame of the vehicle. If necessary, use the

supplied spacers over the threaded end to provide for proper

tightening.

□ Place a 5/16 inch flat washer and nut on each tank cable strap

and tighten just enough to hold the tank in place but loose

enough to allow the tank to be positioned along the frame.

□ Slide the tank rearward on the frame as necessary to provide

clearance for attaching the hoses.

□ Attach the swivel fittings to the front of the tank but do not tighten

them until the hoses are attached at both ends and are properly

routed.

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.

□ Route the straight end of the 3/4 inch hose from the engine

compartment over the body mount to the tank.

□ Route the longest 1/2 inch hose from the engine compartment

outside the body mount to the tank.

□ Connect both hoses to the matching swivel fittings on the tank,

but do not tighten them.

□ Locate the OEM hole in the lower frame section next to the

transmission cross-member and Insert an M8 x 25 mm bolt

through the hole.

□ Place the supplied flat bracket on the bolt and fasten the bracket

in place with an 8 mm serrated nut so that it points outward

toward the driver’s side.

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□ Place the OEM park brake cable bracket on top of the flat

bracket and fasten it in place with the OEM bolt.

□ Position the brackets so that it pulls the cable down enough to

clear the tank and brackets. Tighten all the fasteners.

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Part 5: Installing the Main Bracket

and Compressor

5.1 Installing the Cooler

□ Remove and discard the coolant fill hose plastic alignment clips

from the OEM bottom radiator hose.

□ Cut and discard 8-1/2 inches of straight hose from the lowest

section of the radiator hose.

□ Connect the cooler spigots to the cut ends of the lower radiator

hose so that the cooler is between the radiator and engine with

the oil connection fittings toward the engine (Figure 5.1). Tighten

the hose clamps.

1/2” hose from tank

1/2” hose

to compressor

H

o

s

e

t

o

e

n

g

i

n

e

H

o

s

e

t

o

r

a

d

i

a

t

o

r

Skid plate

Cut 8-1/2” from

the center of

the OEM hose

Figure 5.1

□ Route the 1/2 inch hose from the tank outside the body mount to

the cooler and connect it to the driver’s side fitting.

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□ Install the skid plate using the OEM bolts.
□ Align the holes in the skid plate with the threaded holes on the

cooler mounting plate and fasten the cooler in place with four
5/16 inch bolts and flat washers.

□ Connect the 90 degree end of the short 1/2 inch hose to the

passenger side fitting on the cooler. Tighten the fittings at the
cooler.

Connecting the 90 degree ends of the cooler hoses can
be done easily from above.

5.2 Installing the Main Bracket

□ Place the replacement metal coolant tube (Figure 5.2) in position

with the upper bracket facing the front of the truck so that it will
fasten to the rear passenger-side air conditioning compressor
mount with the OEM fastener.

If the truck does not have air conditioning, use the supplied
spacer and bolt to fasten the bracket to the rear passenger-side
air conditioning compressor mount on the VR main bracket.

Figure 5.2

□ Install the OEM O-ring and thermostatic switch from the top

engine coolant tube to the replacement tube and insert it into the
thermostat housing. Make sure that the O-ring is properly
seated.

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□ Remove OEM hose that connects to the thermostatic switch and

install the supplied thermostatic switch tube and hose clamps.

□ Remove the belt tensioner assembly and the idlers from the VR

main bracket (Figure 5.3).

VR compressor

Main Bracket

Idlers

Idlers

Tensioner

Figure 5.3

□ Place the VR bracket on the front of the engine over the two

OEM 10 mm studs that held the OEM cast bracket in place.

□ Place the pump in position and thread in the three front 10 mm

bolts. Hand-tighten the middle bolt but leave the two outer bolts

loose.

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□ Pull the bracket forward to reach the rear power steering pump

bolts. Align the two holes in the loose OEM locating bracket with
the two threaded holes in the VR cast bracket and thread in two
10 mm bolts but do not tighten them, as this will pull the pump
out of alignment if there is a gap between the OEM locating
bracket and the VR cast bracket.

□ Make sure that the rear bracket sits flat on the mount pad of the

VR casting. If necessary, pivot the power steering pump upwards
or downwards on the front center bolt until the rear bracket sits
flat on the VR bracket mount pad.

□ Tighten the two rear 10 mm bolts first, then the three front bolts.
□ Apply Loctite and install both OEM 10 mm nuts and one supplied

10 x 100 mm socket head bolt and one supplied 10 x 75 mm
socket head bolt to secure the VR bracket to the engine (Figure

5.4).

Check the fit of the bracket against the engine to make
sure that it sits flat and has no obstructions.

OEM nuts on OEM studs

Supplied socket-head
bolt 10 x 75 mm

Supplied socket-head
bolt 10 x 100 mm

Figure 5.4

!

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□ Tighten the nuts and bolts evenly and then torque them to

specifications.

□ Install the air conditioning compressor and connect the wiring.
□ Install the OEM belt and then the VR drive belt (Figure 5.5).

Crank Pulley

Tensioner

VR Compressor

Back Idler

Back Idler

Ribbed Idler

Ribbed Idler

Figure 5.5

□ Remove the compressor inlet valve and cover the opening to

protect the compressor.

□ Place the compressor on the mounting bracket.
□ Apply Loctite and install one M8 x 120mm bolt in the rear right

mounting hole.

□ Apply Loctite and install the three M8 x 110mm bolts in the

remaining mounting holes. Tighten down all four bolts evenly and

torque to specification.

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□ Re-install the compressor inlet valve.

If the bolts used to attach the inlet valve to the air end
are installed incorrectly major damage to the air end can
occur.

It must be noted that most systems use two different

length bolts in the inlet valves. The longer bolts go in

the two holes closest to the air filter and the two shorter

bolts go in the holes furthest away from the air filter

(figure 5.6).

Figure 5.6

Never use an impact wrench to install inlet bolts.
The torque spec for inlet bolts is 19 ft lbs.

□ Remove the two OEM driver side upper rocker arm cover bolts

(Figure 5.7).

Do not remove the OEM bushings holding the cover
down.

□ Move the electrical components and tie strap them out of the

way as required.

□ Apply Loctite to the M6 x 35mm bolts and the M8 nut and install

the strut support (Figure 5.7). Torque the two M6 bolts to 71 in­lbs.

!

!

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Supplied M8 x 110mm Socket Head Bolts (3X)

Supplied M8 x 120mm Socket Head Bolt

Components
Removed for
Clarity

Supplied M6 x 35mm Bolts
and Washers

Supplied M8

VR70

Nut

Bracket

Strut Support

Figure 5.7

□ Apply Loctite and install the VR tensioner and the idlers on the

bracket. Torque the fasteners to specifications.

5.3 Connecting the Hoses

□ Route the short 1/2 inch hose from the cooler up in front of the

steering box and connect the straight end to the fitting on the

side of the compressor. Tighten the fittings at both ends of the

hose.

□ Connect the 45 degree end of the 3/4 inch hose fitting to the

fitting on the back of the compressor but do not tighten until all

hose routing is completed. Loop it so that it forms a smooth

curve. The hose will run close to the booster, but must be routed

so that it does not rub on the booster. Tighten the fittings at both

ends of the hose.

No part of the 3/4 inch hose can be higher than the
compressor. If it is, the system will not function
correctly. Make sure that the hose does not rest on any
engine wire harness or other components behind the
compressor that could be damaged by heat.

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□ Insert the 1/4 and 3/16 inch tubes into the fittings on the back of

the tank and cover them with high temperature loom. Route them
through the frame up to the compressor and connect them to the
matching fittings on the compressor inlet valve.

□ Secure all hoses together and in place using plastic ties at

regular intervals along the frame, other harnesses or the cross­member so that they do not touch exhaust parts or any moving
parts.

□ Apply a light coat of oil to the gasket and install the filter on the

tank. Tighten the filter an additional 3/4 – 1 turn after the gasket
contacts the base. Adjust the swivel fittings and hoses on the
tank as necessary to provide clearance for the oil filter. Tighten
the swivel fittings and hose fittings.

□ Reposition the tank on the frame (if necessary) and tighten the

cable clamps. Thread a second nut on each cable and tighten it
against the first nut to act as a lock.

5.4 Completing the Installation

□ Open the harness securing clips and reposition the harness so

that when the harness clip is pushed into the hole in the L­bracket, the harness will be clear of the 3/4 inch compressor
hose.

□ Tie the wire harness back from the compressor hose using nylon

ties to ensure that it will not touch the hose.

□ Install the supplied radiator hose (with connector) to the top

coolant pipe and the modified top radiator hose with the short
end to the radiator and the long end to the connector (Figure

5.8). Tighten the hose clamps. The hose may require slight
modifications to clear the compressor, drive pulley and belt.

□ Place the supplied fan spacer in position and install and tighten

the fan.

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Figure 5.8

□ Place the upper fan shroud in position. Place the PTM module 3

inches down from the top of the fan shroud and mark the position

of the top and outer mounting holes on the shroud.

□ Remove the shroud and drill 1/8 inch holes in the marked

positions. Install the fan shroud and secure the PTM module

using the supplied self-tapping screws.

□ Install the air intake resonator chamber.
□ Install the supplied P-clamp over the intercooler tube. Install the

supplied bracket over the mounting stud behind the intercooler

tube with the bracket facing the intercooler tube. Pull the

intercooler tube toward the bracket and fasten the P-clamp to the

bracket. This provides additional clearance between the

intercooler tube and the main discharge hose.

□ Fill the cooling system with the approved coolant to the correct

level.

□ Connect all wiring that was disconnected in preparation and

install any other OEM parts that were removed.

□ On all trucks except the GMT900, remove and discard the hood

liner.

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□ Route the two grey wires and the white wire with the plug

connector across the engine to the compressor. Connect the
wires to the matching connectors at the compressor.

5.5 Adding Oil to the System

You must use the VMAC supplied compressor oil in this
system. Failure to use this special oil will result in
damage to the compressor and will void your warranty.

□ Remove the fill plug from the air inlet control valve and pour oil

into the oil fill hole on the inlet control valve using a funnel. Turn
the compressor clutch clockwise with a ratchet and a 1/2 inch
socket using the hex head bolt at the centre of the compressor
clutch during the fill process.

□ Allow 5 minutes for the oil to drain into the tank, then check the

level at the sight glass at the front of the tank. Continue adding
oil until the level is correct.

□ Install the fill plug in the inlet control valve and tighten it securely.

Do not overfill the system. Overfilling the system with
oil can flood the sight glass window and make the
system appear empty.

!

!

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Part 6: Finishing the Installation

6.1 Before Starting the Engine Checklist

Make sure that the following have been completed:

□ Check the vehicle coolant.
□ Check the compressor oil level.
□ Do a final inspection to make sure that everything has been

completed and tightened.

□ Perform a final belt alignment check.
□ Check all wiring for security and protection.

6.1.1 Safety Test

□ Place the automatic transmission in Park or manual transmission

in neutral and apply the park brake.

□ Turn the ignition key “ON” but do not start the engine.
□ Check the control box to see if there is a number showing in the

hour-meter. If there is no display, there is no power to the control

box.

□ Push the “ON” button on the control box. The green LED should

come on and you should hear the compressor clutch engage.

□ Release the park brake. The green LED should flash, the display

should read “PARK BRAKE” and the compressor clutch should

disengage. Apply the park brake again; the green LED should

go out and the hours will be displayed.

□ For trucks with automatic transmissions, the engine must be

running to complete the final step in the safety test. This will be

done after the pre-start checks have been completed.

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□ Turn the ignition key “OFF”.

If the vehicle fails the test, check the wiring to make
sure that all the connections are correct and secure. If
you require additional assistance, contact your local
VMAC dealer. Call 1-800-738-8622 or 250-740-3200.

6.2 After Starting the Engine Checklist

Make sure that the following have been completed:

6.2.1 Completing the Safety Test

Place the truck in a safe operating position and block
the wheels. Ensure that there are no people around the
truck before beginning the test.

□ Ensure all compressor outlet valves are closed.
□ With the engine running, engage the park brake; place your foot

firmly on the brake pedal.

□ Start the compressor and let the truck ramp up to 1800 rpm and

then drop down to 1000 rpm. Shift the truck into gear. The
engine should go to idle.

□ Repeat this test in all gear selector positions to make sure that

the engine does not idle up unless the selector is in Park or
Neutral.

6.2.2 Operational Tests for All Trucks

□ Operate the system with an air tool for at least 1/2 hour (1 hour

preferred).

□ Road test the vehicle for approximately 14 miles (20 km).
□ Watch the underhood operation to make sure that belts rotate

properly and nothing is rubbing or contacting hot parts.

If you see unusual belt fluctuations during initial
operation, stop the engine and move the tensioners
back and forth, then restart the engine. Belt fluctuations
should stop within the first 30 minutes of operation.

!

!

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□ Check all components once the engine is turned off and the

system has cooled.

□ Check the vehicle coolant after the vehicle reaches operating

temperature.

□ Check the compressor oil level after the vehicle has been shut

down and the oil level has had time to stabilize.

6.3 Setup, Performance Testing and Adjustments

This system has been adjusted at the factory for general operation. If
your tests indicate that adjustment is necessary, refer to the owner’s
manual for specific instructions on how to adjust the system.

You can test the system operation using the tools that will be
operated by the system or you can test operations using an orifice in
the outlet to simulate tool use (Figure 6.1).

Figure 6.1

1. Install the test tool in the tank outlet fitting.

2. Make sure that the ball valve is closed.

3. Place the manual transmission in neutral or the automatic
transmission in park and fully apply the park brake.

4. Allow the vehicle to run until the engine is at operating
temperature.

5. Operate the air compressor system until the oil is warm.

6. Observe the pressure gauge. Pressure should be approximately
150 psi (See the owner’s manual for adjustment procedures).

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7. Open the ball valve on the test tool and observe the engine
tachometer. Engine speed should increase to about 1,800 to
2,200 RPM.

8. Close the air valve slowly to allow the system pressure to rise.

9. Once the system pressure is at maximum, slowly open the ball
valve on the test tool until the pressure on the gauge begins to
drop. Engine speed should start to ramp-up when air pressure
drops to approximately 140 psi.

6.5 Auxiliary Air Receiver

If you intend to use an auxiliary air receiver with this
system you must observe the following installation
procedure to prevent damage to the system.

The line from the VMAC tank to the auxiliary air receiver must have a
one-way check valve installed (part #3600078) to prevent blow back
from the auxiliary tank to stop moisture from entering the VMAC tank
(Figure 6.2).

The line to the auxiliary tank must not be installed in the bottom of
the tank, but must be installed as high as possible to prevent water
from entering the line.

Install the line as high as
possible, NOT on the
bottom of the auxiliary tank

VR Tank

One-way check valve

Auxiliary Tank

Figure 6.2

!

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Accessory Products from VMAC

The following accessory products for your VR compressor system
are available from VMAC. For more information or to order these
products, call toll free 1-888-241-2289 or local 250-740-3200.

Eliminator Aftercooler

Part Number A800070

Removes up to 80% of moisture from
compressed air. Quick installation, automatic
drain and compact design

Filter Regulator Lubricator

Part Number A700151

Removes lubricants, water and dirt from the air
stream. Adds atomized tool oil to lubricate tools.
Reduces pressure for longer tool life.

Hose Reel

Part Number A700007

Secure, compact, retractable hose storage in a
sturdy reel.

Air Receiver Tank

Part Number A300010

Thirty-five gallon capacity in a compact tank,
complete with fittings and a gauge.

DE-ICING

HEATER

De-icer Kit

Part Number A700031

Insulated rope heater prevents freezing of lines
and regulator.

Service Kits

VR150 200 hour Part Number A700059
VR150 400 hour Part Number A700060
VR70 200 hour Part Number A700019
VR70 400 hour Part Number A700020

Using OEM service products will extend the life
of your system. Includes oil, filters, seals and O­rings. 200 hour and 400 hour service interval kits
are available

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VMAC Product 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 of installation.

VMAC Dealer Information

Company Name: ______________________________________

City: _____________________ State/Prov:______________

Installer Information

Company Name: ______________________________________

City: _____________________ State/Prov:______________

Installation Date: _____/_____/_____
Day Month Year

Owner Information

Company Name: ______________________________________

Address: ____________________________________________

City: _____________________ State/Prov:______________

Zip/Postal: ________________ Phone #: (____)____-_____

Vehicle Information

Year: ____________________ Make: _________________

Vehicle Identification Number: ___________________________

Unit #: ___________________

Product Information

System Identification Number: V _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Compressor Serial Number: P_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Throttle Control Serial Number: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

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Manufactured by

PH 250-740-3200

FX 250-740-3201

TF 1-800-738-8622

1333 Kipp Road, Nanaimo, BC, V9X 1R3 Canada

www.vmacair.com