Vmac VR70 Manual de usuario

System V900083

2005 - 2006 Ford E-250 - E-350

5.4L Triton V8 Gas

www.vmacair.com

VR70 UNDERHOOD

AIR COMPRESSOR

INSTALLATION MANUAL

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 1

Installation Manual for VMAC

System V900083

Ford 2005-2006 Triton 5.4L V8

E250-E350 Van

General Information..................................................................... 3

Before You Start....................................................................... 3

Part 1: Preparing for Installation............................................... 4

1.1 Preparing for Installation .................................................... 4

Part 2: Installing the Tank.......................................................... 7

2.1 Assembling the Brackets and Tank.................................... 7

2.2 Installing the Tank Assembly.............................................. 9

Part 3: Installing the Cooler, Bracket and Compressor.......... 11

3.1 Installing the Oil Cooler ...................................................... 11

3.2 Installing the Main Bracket and Compressor ..................... 12

3.3 Connecting the Hoses........................................................ 14

3.4 Completing the Installation................................................. 15

3.5 Adding Oil to the System.................................................... 16

Part 4: Installing the Control Components .............................. 17

4.1 Installing the Components.................................................. 18

4.2 Connecting the Under-hood Wiring.................................... 21

4.3 Connecting the In-cab Wiring............................................. 23

4.4 Completing and Testing the Installation ............................. 24

Part 5: Finishing the Installation................................................ 25

5.1 Before Starting the Engine Checklist ................................. 25

5.2 After Starting the Engine Checklist..................................... 25

5.3 Setup, Performance Testing and Adjustments................... 26

5.4 System Identification and Warnings................................... 27

5.5 Auxiliary Air Receiver ......................................................... 28

Accessory Products from VMAC............................................... 29

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

Document 1930078

Installation Manual for VMAC System V900083

Ford 2005-2006 Triton 5.4L V8

E250-E350 Van

Changes and Revisions

Version Revision Details Revised by/date Approved Implemented

00 Original document IB 14 Dec 2004 BC 22 Dec 2004 Jan 14 2005

A Model year confirmation IB 10 Apr 2006 SM 10 Apr 2006 Apr 14 2006

B ECN 07-145 IB 05 Nov 2007 SH 23 Nov 2007 26 Nov 2007

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

vans must follow standard shop practices.

These instructions are a general guide for installing this system on

standard production vans and do not contain information for

installation on non-standard vans. This system may not fit special

order models or those which have had other changes without

additional modifications. If you have difficulty with the installation,

contact VMAC.

The VMAC 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.

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 1-800-738-8622.

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

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 3

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 van.

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

Hose Coding

Different frame designations will affect the tank mounting position. If

you have to move the tank, the lines may be too short. Measure the

hose shortfall and order a Hose Extender Kit. The following table

shows the color code used by VMAC to identify hose diameters.

Hose Diameter Colour-Coded Label

1/2 inch

5/8 inch

3/4 inch

1 inch

Blue

Green

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

Part 1: Preparing for Installation

Preparation for installation is very important. Missing an item can

cause problems in the installation or even damage to components.

Check off each item as it is completed so that you do not miss any

preparation steps.

1.1 Preparing for Installation

□Remove the inside engine cover.

□Remove the plastic air intake connector and air filter assembly.

□Disconnect the battery.

□Remove all plastic shields from under the engine.

□Drain the coolant.

□Remove the upper radiator hose and lower radiator hose from

between the radiator and diverter (leave the diverter in place).

Keep the lower radiator hose section if you intend to return the

van to OEM condition.

□Remove the fan and the fan shroud together.

□Remove the OEM drive belt from the alternator pulley but leave

the belt in position on the engine.

□Remove the alternator and move it over to the driver’s side of the

engine.

□Replace the existing M6 bolt that secures the front right-hand

fuel rail to the intake with the supplied M6 x 20mm flat head

socket bolt (Figure 1.1).

□Remove the electrical noise suppressor from the front passenger

side cylinder head and remove the studded bolt.

Low profile bolt

Figure 1.1

□Remove the engine-to-drip rail ground strap connection from the

engine.

□Remove the bolts holding the plastic wire harness retainer to the

drip rail so that the harness can be moved out of the way during

installation.

□Remove the oil fill tube and plug the opening on the valve cover.

□Remove the bolt holding the automatic transmission dipstick tube

bracket to the intake manifold and bend the bracket up toward

the center of the engine about 90 degrees.

□Disconnect the electrical harness from the sensor on the

passenger side fuel rail and move it out of the way.

□Remove the vent hose from the passenger side valve cover and

move it out of the way.

□Remove the 3/4 inch heater hose and the small hose from the

front right spigot on the intake manifold.

□Remove the heater hose barb from the manifold intake. Keep the

fitting if you intend to return the vehicle to OEM condition.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 5

□Apply sealant to the supplied 90 degree hose barb and press it

into the heater hose coolant port (Figure 1.2). Make sure it is

pressed all the way in to the shoulder on the fitting.

90 degree hose barb

Intake Manifold

Figure 1.2

□Connect the small coolant hose to the fitting on the hose barb.

□Loosen the small bolt holding the slotted air conditioning line

mount bracket to the heater box, move it all the way to the

passenger side and tighten the bolt.

□Carefully push the vertical part of the air conditioning lines

toward the passenger side of the van to provide clearance for the

oil fill tube.

□Remove the bolts holding the sway-bar bushings on the frame

and install the supplied spacer blocks and hex head bolts.

Torque to specifications.

□Clean the inside of the OEM pulley and install the VR pulley,

making sure that the pulley is sitting flush. Apply Loctite, install

three M10 x 70mm bolts and flat washers and torque to

specifications.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

Part 2: Installing the Tank

2.1 Assembling the Brackets and Tank

The tank (Figure 2.1) will mount to the passenger side frame rail

behind the body mount (under the side doors). Note that the upper

frame clip is different for the E250 and E350.

1/4” and 3/16” tubes

3/4” hose fitting

1/2” hose fitting

C-clamp

Tank strap mount

Upper frame clip

Tank strap cable

Lower frame clip

Spacer

Oil filter

5/16” nuts and

washer

Figure 2.1

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

tank to your left and remove the oil filter.

□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 approximately 4 inches from the filter

end of the tank and the rear clamp approximately 4 inches from

the back of the tank.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 7

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

□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, apply Loctite and install the

nuts but do not tighten.

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

tank is parallel to the work bench and faces toward you.

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

clamp and thread them into the mount brackets, but do not

tighten.

□Install a 3/4 inch fitting (not supplied) in the back of the tank.

□Check tank alignment then tighten the C-clamp bolts.

□Slide the tank all the way down on the tank mount brackets

(away from you) and tighten the mounting bolts.

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