VMAC 9018 Underhood Air Compressor

Specifications

• Product: Underhood Air Compressor
• Model: System #9018
• Engine Compatibility: 1999 Navistar International equipped with a Cummins M11 engine
• Manufacturer: VMAC
• Publication Date: January 1, 1999

Installation Manual

This manual provides installation instructions for the VMAC underhold air compressor installation kit and VMAC Throttle Commander. It is designed specifically for the 1999 Navistar International vehicles equipped with a Cummins M11 engine.

Installation Steps

The installation procedure outlined in this manual consists of four main steps:

1. Compressor Installation
2. Tank and Line Installation
3. Throttle Commander Installation
4. Control Unit Installation

Terms and Symbols

This manual uses the following terms and symbols:

• NOTE: This symbol indicates that there is
  additional information or special emphasis on a specific procedure.

• ! This symbol indicates that there is a possibility of personal injury or damage to the equipment if the indicated warning is not followed.

• WARNING: Indicates important safety precautions that must be followed.

Installation Notes

1. It is important to complete all installation steps before operating the system. Refer to the Owner’s Manual for further guidance.
2. Follow all safety precautions for under-hood mechanical work.
3. Use Loctite 242 or an equivalent product on all engine-mounted fasteners.
4. Secure all re-routed or shifted hoses, tubes, and wires to prevent contact with excessively hot areas or sharp edges. Whenever possible, follow the routing instructions provided in this manual.
5. In some cases, grinding, bending, or rearranging operations may be necessary for correct fit due to variations in vehicle manufacture or prior modifications. These operations must adhere to sound, standard shop practices.
6. Left and right directions in this manual are determined when sitting in the driver’s seat, facing forward.
7. All fasteners must be of the correct size and torqued according to the specifications provided below:

Installation Manual

VR7000 Underhold Air Compressor
System Number 9018
Application: 1999 Navistar International equipped with the Cummins’s
M11 Engine
Publication Date: January 1, 1999
Origination Documents: #19250a – introduction

• 19252 – compressor installation

• 19253 – tank and line installation

• 19254 – throttle commander installation #19255 – control unit installation

• 19256 – illustrated parts list

• 19130 – warranty registration

Copyright 1998
The contents of this manual may not be reproduced in any form without the express written permission of VMAC

General Information

1999 NAVISTAR INTERNATIONAL
Cummins ISB M11 Engine

Introduction

This book provides installation instructions for:

• VMAC underhood air compressor installation kit
• VMAC Throttle Commander

This kit has been designed for
1999 Navistar International equipped with a Cummins M11 engine.

Installation steps
The installation procedure in this manual has four main steps:

1. Part 1: Installing the Compressor
2. Part 2: Installing the Air Tank and Lines
3. Part 3: Installing the Control Unit
4. Part 4: Installing the Throttle Commander

Terms and symbols
This manual uses the following terms and symbols:

• OEM – Original Equipment Manufacturer
• HHCS – Hex Head Cap Screw (also called a hex bolt)
• SHCS – Socket Head Cap Screw (also called an Allenhead bolt)

This symbol indicates that there is additional information or special emphasis on a specific procedure.
This symbol indicates that there is a possibility of personal injury or damage to the equipment if the indicated warning is not followed.

Installation Notes

• It is important that you complete all the installation steps before operating the system. Refer to the Owner’s Manual before operating the system for the first time.
• Follow all safety precautions for under-hood 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. Where possible, follow the routing instructions in this manual.
• These installation instructions are intended as a general guide. In some instances, due to variations in vehicle manufacture or if prior modifications have been made to the vehicle, it may be necessary to carry out grinding, bending or rearranging operations for correct fit. These operations must follow sound, standard shop practices.
• Left and right definitions in this manual are determined when sitting in the driver’s seat, facing forward.
• All fasteners must be of the correct size and torqued according to the specifications shown below. Torque specifications are in foot pounds (ft-lb).

| Type Grade 8 plated| Class 10.9 unplated
---|---|---
Size| In Cast or Steel| In Aluminum| In Cast or Steel| In Aluminum
3/8| 48| 45| |
7/16| 77| 70| |
1/2| 117| 95| |
M8| | | 25| 20
M10| | | 45| 40
M12| | | 80| 70
M14| | | 145| 130

• The possibility exists that the primary installer may be color-blind. Always ensure that another person confirms the color codes on the wires.

Ordering Parts

To order parts, contact VMAC at:

• Telephone 250-754-6997
• Facsimile 250-754-6972

Office Hours 8:00 AM to 4:30 PM Pacific Time
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.

Changes and improvements

These products and documents are subject to changes or improvements without notice.

Installing the Compressor

System #9018

1999 NAVISTAR INTERNATIONAL Cummins ISB M11 Engine

Part 1: Installing the Compressor

Preparing for installation

1. Disconnect the batteries.

2. Drain the coolant.

3. Remove the tube which crosses over the top of the engine and connects the inter-cooler to the turbocharger inlet.

4. Remove the air conditioning compressor. Lift it upward and set it on top of the engine.
   Do not disconnect the air conditioning lines.

5. Remove and discard the air conditioning compressor mounting bracket.

6. Remove the OEM serpentine belt.

7. Remove the five (5) OEM fasteners which retain the crankshaft pulley and harmonic balancer and discard them. Remove and discard the 38 ″ thick spacer washer from behind the fasteners.

8. Remove the lower radiator hose and clamps. Keep them for later installation.

9. Remove and discard the cast aluminum lower radiator hose-to-engine block inlet and support bracket on the right side of the engine. Discard the two (2) M10 hex head cap screws, the M8 hex head cap screw and the bracket.

10. Remove the engine oil filter. Cover the filter to prevent contamination if you will be reinstalling the same filter.

11. Remove and discard the four (4) OEM hex head cap screws which secure the engine dipstick tube support plate to the right-hand side of the engine.

12. Remove the power steering reservoir from the support bracket. Keep the OEM fasteners.

13. Drain the oil from the power steering reservoir.

14. Remove and discard the ½″ oil hose from the reservoir to the steering box. Remove the ¾″ hose from the reservoir, but do not discard this hose.

15. Remove the ½″ NF cap screws holding the radiator and firewall tie-rod bracket to the frame on the left-hand side.

16. Remove the 516 ″ NC nuts from the bracket holding the radiator tie-rod to the left-hand side of the radiator.

17. Swing the tie-rod bracket away from the frame, remove and discard the power steering reservoir mounting bracket and support plate from behind the tie-bar mounting plate on the frame rail.

Installing the compressor oil cooler

1. Apply Loctite to the four (4) M10 × 30 mm hex head cap screws supplied with the installation kit.

2. Attach the VR7000 cooler to the engine block over the dipstick tube support plate using these hex head cap screws. Torque them to 45 ft-lb.

3. Push the supplied 2½″ × 6″ long coolant hose onto the 90° elbow. Place an HS4 hose clamp over this connection and tighten the clamp. Slip the second HS4 clamp over the hose, but leave it loose at this time.

4. Push the other end of the 2½″ × 6″ long coolant hose on the rear fitting of the oil cooler.

5. Attach the supplied 90° flange elbow to the engine where OEM aluminum housing for the lower radiator hose was originally mounted. The 90° elbow must point to the rear (Figure 1). Use the supplied gasket, a suitable gasket sealant and two (2) supplied M10 × 25 mm socket head cap screws. Torque the fasteners to 45 ft-lb.
   

6. Slide the second HS4 clamp into position over the cooler connection and tighten the clamp.

7. Install the OEM lower radiator hose to the cooler inlet. Tighten all hose clamps.

8. Install the oil filter. If you are using a new filter, fill it with clean, OEM recom-mended oil before installation.

9. Fill the cooling system to the correct level using OEM recommended coolant and check for leaks.

Installing the compressor

Make sure that the surfaces that the main mounting bracket will contact are clean and free of contaminants or debris. If the mounting bracket does not seat correctly against the timing cover or engine block, the compressor and crankshaft pulleys will not align correctly.

1. Install the main mounting bracket for the VR7000 to the side of the timing overusing the eight (8) threaded holes shown in Figure 2.
   

2. Thread the two (2) M10 × 35 mm hex head cap screws into the two holes on the side of the engine block (Figure 3). Use 38 ″ flat washers behind the cap screws.

3. Thread four (4) M10 × 35 mm hex head cap screws in the four (4) threaded holes originally used to mount the OEM air conditioning compressor mounting bracket
   (Figure 3). Use 38 ″ flat washers behind the cap screws.

4. Thread two (2) M10 × 35 mm hex head cap screws into the two holes on the rear of the timing cover (Figure 3). Use 38 ″ flat washers behind the cap screws.

5. Torque the cap screws which thread into the cast engine block to 45 ft-lb. Torque the cap screws which thread into the aluminum timing cover to 35 ft-lb.
   

Installing and mounting components

1. Install the VR7000 pulley over the OEM pulley and harmonic balancer. Align the mounting holes.

2. Apply Loctite and install five (5) M14 1.5 × 80 mm hex head cap screws. Torque them to 145 ft-lb.

3. Install the VR7000 pressure regulator to the mounting bracket using the supplied fasteners (Figure 4). Tighten the fasteners.

4. Fit the VR7000 belt tensioner to the front of the mounting bracket using the M12 × 80 mm hex head cap screw (Figure 4). Apply Loctite and torque it to 80 ft-lb.
   If the VR7000 belt tensioner is already fitted on the mounting bracket, remove it, apply Loctite to the M12 × 80 mm hex head cap screw and torque it to 80 ft-lb.

5. Remove the ½″ × 1¼″ UNC flange lock bolt securing the back idler to the bottom of the mounting bracket. Apply Loctite and torque to 117 ft-lb. Be careful not to lose the aluminum spacer that fits over the lock bolt and into the center of the idler.
   

6. Install the OEM 8-rib drive belt as shown in Figure 5 and tension it to manufacturer’s specifications.
   

7. Install the OEM air conditioning compressor to the top of the VR7000 bracket using the OEM fasteners. Thread two fasteners into the front slots in the bracket on the engine side of the air conditioning compressor and two fasteners into the slots on the outside of the bracket.
   Do not tighten these fasteners at this time.

8. Install the supplied V-belt on the air conditioning and engine drive pulleys.

9. Install the OEM ½″ NC adjuster bolt and locking nut to the under-side of the air conditioning compressor base-plate and adjust the drive belt to OEM specifications.

10. Torque all air conditioning fasteners to OEM specifications.
    These fasteners are threaded into aluminum. Over-tightening will damage the aluminum threads.

11. Fit the VR7000 compressor to the mounting bracket. Apply Loctite to three (3) M8 × 25 mm hex head cap screws, install them and torque them to 25 ft-lb.
    Install the supplied 6-rib VR7000 drive belt over the crankshaft pulley, VR7000 compressor pulley and the VR7000 tensioner (Figure 6). Check alignment of the pulleys and belt using a straight edge.

12. If the pulleys and belt do not line up correctly, check the installation of the mounting bracket. If the fasteners have not been tightened properly or if the bracket has not been installed flat against the timing cover, the pulleys will not align correctly.

Installing the power steering bracket

1. Swing the tie-rod bracket away from the frame rail and insert the supplied power steering bracket underneath the tie-rod bracket.
2. Swing the tie-rod bracket back into place, align the holes and install the ½″ NF cap screws back into the frame, through both brackets.
3. Align the radiator tie-rod bracket with the holes in the radiator frame and install the 5 ″ NC nuts.
4. Torque all fasteners to OEM specifications.

Installing the power steering reservoir

1. Attach the power steering reservoir to the VR7000 bracket so that the OEM clamp-style mounting bracket sandwiches the VR7000 bracket.
2. Secure the reservoir with the OEM fasteners and torque them to specifications.
3. Install the supplied ½″ hose and clamps between the reservoir and the steering box. Tighten the clamps.
4. Remove 3/4″ power steering hose from the steering box and reservoir.
5. Install the 3/4″ replacement hose with elbow.
6. 6. Tighten all hose clamps.
7. Refill the reservoir with the OEM recommended fluid.
8. Install the tube which connects the intercooler to the turbocharger inlet.
9. Make sure that the tube clears the air conditioning compressor and all other items before tightening the clamps.

Figure 7 shows the general assembly. Figure 8 shows a close-up view of the new power steering bracket installation behind the tie-rod bracket on the frame.

Part 2

Installing the Air Tank and Lines

System #9018

Part 2: Installing the Air Tank and Lines

Installing the air tank

1. Install the tank brackets to the frame rail using the rear exhaust hanger support bolts (Figure 9). The front bracket is part #12173 and the rear bracket is part #12174.
   

2. Attach the tank assembly to the brackets with the oil level window facing forward and  with the drain plug at the bottom. Make sure that the tank is installed in the correct position by checking the “THIS WAY UP” arrow at the oil level window. Tighten the straps.

Connecting preliminary air and oil lines

The lines from the tank to the other components have been designed with extra length to accommodate different situations and applications. Excess line can be stored under the cab, along the top of the transmission.

1. Install the oil and air lines between the components shown in Figure 10 according to the following steps. Route all air and oil lines along chassis rail so that they are clear of all moving parts, heat sources and sharp objects. Retain the lines using the supplied stainless steel tie wraps and chassis clips.
   For information about the location of the lines on the components, refer to the diagrams within this section.
   

2. Connect the end of the ¾″ × 136″ main air line (part #17229) with the ¾″ JIC 45° swaged fitting to the matching top fitting on the air tank at location 1 (see Figure 16). Route the line along the frame, under the cab and connect the other end to the match-ing fitting on the back of the compressor (Figure 11).
   

3. Connect the ½″ SAE 90° swaged fitting on the ½″ × 43″ cooler-compressor line (part #17222) to the matching fitting on the bottom of the compressor at location 5 (see Figure 16). This line can be secured to the cross-member in front of the engine and then attached to the front fitting on the oil cooler (Figure 12).
   

4. Connect one end of the ½″ × 151″ oil return line (part #17227) to the matching lower fitting on the air tank at location 4 (see Figure 16). This line can be routed under the engine, behind the sump and then attached to the rear fitting on the oil cooler (Figure 13).
   

5. Connect one end of the ¼″ × 151″ air pressure control line (Part #17228) to the upper outside fitting on the tank at location 2 (see Figure 16). Route the line along the frame, under the cab and attach the other end to the matching fitting on the regulator (Figure 14).
   

Adding oil to the system

1. Make sure that the vehicle is level.

2. Remove the four (4) M8 socket head cap screws which retain the air inlet control valve (Figure 15).
   

3. Remove the inlet control valve.

4. Pour six (6) litres (1.8 US Gal.) of the supplied compressor oil into the large air intake opening.
   WARNING
   You must use the supplied compressor oil in this system. Failure to use this special oil will result in damage to the compressor and will void your warranty.

5. Turn the compressor clockwise with a ratchet and socket using the hex head cap screw at the center of the compressor clutch.

6. Allow at least 10 minutes for the oil to drain into the tank, then check the level at the sight glass in the tank (Figure 16). It is important not to overfill the system.
   

7.  Install the inlet control valve with the four (4) M8 socket head cap screws. Torque the fasteners to 25 ft-lbs.

Connecting the remaining lines

1. Connect one end of the 516 ″ × 148.5″ oil scavenge line (part #17221) to the matching fitting on the tank at location 3 (see Figure 16). Route the line along the frame, under the cab and attach the line to the matching fitting on top outside of the compressor (Figure 17).
   

2.  Install the 516 ″ × 11″ compressor control line (part #17223) between the fitting on the regulator and the top inside fitting at the compressor (Figure 18).

Figure 19 shows the tank, mounted on the frame rail, with lines attached.

• NOTE Remember to ensure that the lines do not contact any sharp or hot objects. Prevent movement and abrasion by using chassis clips and tie-downs as necessary.
• NOTE There are two 516 ″ fittings on the air compressor. Make sure that you connect the correct 516 ″ line to the right fitting at the compressor.
• NOTE Make sure that the tank is mounted with the “THIS WAY UP” arrow pointing in the right direction.

Part 3 Installing the Control Unit

System #9018
1999 NAVISTAR INTERNATIONAL Cummins ISB M11 Engine

Part 3: Installing the Control Unit

Control unit installation

1. Remove the screws holding the plastic protector panel in place on the floor inside the driver’s door. Remove the panel.

2. Remove the rear outer seat rail cap screw.

3. Mount the throttle control unit to the floor on the rail using the OEM cap screw (Figure 20). Torque this fastener to OEM specifications.
   

4. Cut or drill a ¾″ hole in the plastic firewall connector where the air lines pass through the firewall (Figure 21). Be careful not to damage any lines or wires.

5. Apply the spring brakes using the spring brake control on the dash of the truck. This will vent all air out of the spring brake chambers and lines.

6. Drain all air out of the air brake system.
   WARNING
   Failure to remove air pressure from the air brake system could result in personal injury when attempting to perform the following steps.

7. Cut the yellow air line approximately 4″ down from the connector which routes through the firewall (Figure 21).

8. Remove the nuts and ferrules from the T-fitting attached to the supplied air pressure switch.

9. Slide a nut and ferrule over each end of the yellow air line.

10. . Insert the ends of the lines in the T-fitting, slide the ferrules into position against the
    T- fitting and tighten the nuts.

11. Start the engine and allow the air pressure in the air brake system to build up to cut-out pressure.

12. Release the spring brakes using the control knob on the dash. This will pressurize the brake chambers and the yellow control line.

13. Turn the engine off and check the T-fitting and switch for air leaks. If there are air leaks, correct the problem and test until the connections are air-tight.

14. Secure the air line using a small nylon tie to prevent unnecessary movement of the line (Figure 21).

Routing the wiring

1. Feed the wire harness from the tank along the frame, under the cab and through the ¾″ hole in the firewall connector. Secure the harness as necessary to prevent damage.
2. Pull the carpet back and feed the tank harness under the carpet until the wires can be connected to the control box.
3. Match the wire colors and connect the tank harness to the control box harness.
4. Feed the wires in the flat, blue harness from the control box under the carpet and bring them up past the top of the carpet under the dash on the left-hand side.
5. Feed the black and green wires from the flat, blue harness through the ¾″ hole in the firewall connector. Keep the red wire, connected to the orange wire with the inline fuse holder inside the cab.
6. Feed the white wire from the control box under the carpet and through the hole in the firewall connector.
7. Feed the red wire from the control box under the carpet and bring it up past the top of the carpet under the dash along with the blue harness.
8. Place the carpet back into position. Install the plastic protector using the OEM screws.

Part 4 Installing the Throttle Commander

System #9018
1999 NAVISTAR INTERNATIONAL Cummins ISB M11 Engine

Part 4: Installing the Throttle Commander

NOTE Use the wiring diagram in Figure 22 to determine wire connections. Secure all wires so that they will not be damaged or interfere with vehicle operation.

Mounting and connecting the Throttle Commander

1. Mount the Throttle Commander on an available hole in an OEM bracket immediately behind the steering column, under the dash, using the supplied fastener (Figure 23). Tighten the fastener.
2. Feed the gray and green wires through the ¾″ hole in the firewall connector.
3. Disconnect the multi-pin connector from the OEM throttle pedal position sensor, mounted on the floorboards and attached to the foot pedal.
4. Connect the multi-pin connector from the OEM throttle pedal position sensor to the matching connector at the Throttle Commander.
5. Connect the multi-pin connector from the Throttle Commander to the throttle position sensor.
6. Connect the single red wire from the control unit to the matching wire on the Throttle Commander.

Connecting the wiring

1. Remove the fuse panel cover. Connect the orange wire with the in-line fuse to the empty fuse numbered “F15” in the fuse panel (lower row, 2nd from the left). If this position is occupied, locate another empty fuse-holder (Figure 24). Replace the fuse panel cover.
   

2. Connect the following wires to the gang-ground on the firewall:

   • the green wire from the Throttle Commander
   • the green wire in the flat, blue harness from the control unit
   • the short black wire from the air pressure switch (installed in the yellow air line)

3. In the engine compartment, feed the white wire from the control unit into the same loom as the gray wire from the Throttle Commander.

4. Route this loom over the bottom of the outboard air cleaner mount where it attaches to the firewall. This will keep the wiring out of the way.

5. Attach the gray wire from the Throttle Commander to the connector on the pressure regulator.

6. Attach the white wire to the matching connector on the VR7000 compressor clutch.

7. Attach the black wire from the control unit to the air pressure switch installed in the yellow air line.

NOTE
Before operating this system for the first time, read the information, precautions and instructions in the VR7000 Owner’s Manual.

WARNING
Be sure that the engine oil level is at the correct level, the oil filter does not leak and that the engine coolant level is correct.

NOTE
Remember to secure all wires and lines to prevent damage.

Part 5 Illustrated Parts List

System #9018
1999 NAVISTAR INTERNATIONAL Cummins ISB M11 Engine

ILLUSTRATED PARTS LIST SYSTEM 9018 – 1999 NAVISTAR INTERNATIONAL MODELS 2574 & 2674 CUMMINS ISB M11

ILLUSTRATED PARTS LIST SYSTEM 9018 – 1999 NAVISTAR INTERNATIONAL MODELS 2574 & 2674 CUMMINS ISB M11

Warranty Registration

This form must be 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:
• Installer Name:
• City: State/Prov.
• Postal Code: Telephone:
• Installation Date: / /
• day month year

Owner Information

• Owner Name:
• Address:
• City: State/Prov.
• Postal Code: Telephone:
• Purchase Date: / /
• day month year
• Purchased From:

Application

• Vehicle Make: Year: Engine type/size:
• Vehicle Identification Number (VIN#):

Product Information

• VMAC Part Number: Description:
• Product Serial Number (if applicable):
• VMAC Part Number: Description:
• Product Serial Number (if applicable):
• VMAC Part Number: Description:
• Product Serial Number (if applicable)

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