DOCUMENT 19323
Installation Manual
For The System #9010

UNDERHOOD AIR COMPRESSOR
1995.5-1997 FORD F250 HD – F350, Super Duty
7.3 Power Stroke Diesel

Installation Manual Document 19323
VR7000 Underhood Air Compressor
System Number 9010
Application: F250 HD – F350, F SUPER DUTY 1995.5-1997
7.3 L POWER STROKE DIESEL W/WO AC
Publication Date: October 13, 1999
Origination Documents: #19323a – introduction

19324 – compressor installation

19325 – air tank and line installation

19327 – control unit installation

19326 – throttle commander installation

19328 – illustrated parts list

19130 – warranty registration

Registered Trademarks:
VR7000, VMAC and Throttle Commander are registered trademarks of VMAC.
Ford, Super Duty, F250-F550, Power Stroke Diesel are registered trademarks of Ford Motor Company
Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.
Nylok is a registered trademark of Nylok Fastener Corporation.
Notice:
Manuals and products are subject to change without notice.

Copyright 1999
The contents of this manual may not be reproduced in any form without the express written permission of VMAC
General Information
System #9010
F250 HD – F350, F SUPER DUTY 1995.5-1997
7.3 L POWER STROKE DIESEL

Introduction

This book provides installation instructions for:
VMAC underhood air compressor installation kit
VMAC Throttle Commander
This kit has been designed for:
F250 HD – F350, F SUPER DUTY 1995.5-1997
7.3 L POWER STROKE DIESEL W/WO AC

Installation steps

The installation procedure in this manual has four main steps:
Part 1: Installing the Compressor
Part 2: Installing the Air Tank and Lines
Part 3: Installing the Control Unit
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 Allen head 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

1. 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.

2. Follow all safety precautions for underhood mechanical work.

3.  Use Loctite 242 or equivalent on all engine-mounted fasteners.

4. 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.

5. 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.

6.  Left and right definitions 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 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

8. 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 and Cooler

System #9010
F250 HD – F350, F SUPER DUTY 1995.5-1997
7.3 L POWER STROKE DIESEL

UNDERHOOD AIR COMPRESSOR

1.1 Preparing for installation

1. Disconnect the batteries.
2.  Drain the coolant from the radiator.
3.  Remove the fan from the water pump.
4.  Remove the fasteners from the fan shroud, then remove the fan and shroud from the vehicle.
5. Remove the OEM belt.
6.  Remove the lower radiator hose.
7.  Disconnect the top radiator hose from the radiator and tuck it back out of the way.
8. Remove the OEM fasteners holding the alternator in place and move it back out of the way.
9. Remove the OEM tensioners and idlers from the alternator bracket.
10. Remove the OEM alternator bracket.
11. Remove the plastic cover from the air inlet on top of the engine.
12.  Remove the heater hose and the fitting from the inside of the left cylinder.
13. Remove and discard the plastic battery cable holder from the radiator bulkhead.
14. Remove the radiator from the vehicle.
15.  Cut 1 inch from the hose that goes to the bottom of the pressure tank.
16. Cut 3/4 inch from the spigot on the coolant tank at the pressure tank end (Figure 1.1)
17.  Cut 6 inches from the hose that runs from the block to the heater.
18. Remove the speed clips from the radiator bulkhead flange.
19.  Remove the radiator supports.
20.  Remove the OEM fasteners from the crankshaft pulley.
21.  Peen the edge of the valve cover flat against the cylinder head in the area where the compressor mounting bracket will attach. This allows the compressor mounting bracket to sit flush with the cylinder head surface (Figure 1.2).

1.2 Installing components

1. Replace the block inlet fitting (Figure 1.2) with the brass hose barb.

2. Install the speed clips that you removed from the bulkhead flange to the radiator flange.

3. Insert the radiator between the flanges and the bulkhead and push it forward as close to the bulkhead as possible.

4. Fasten the radiator in place using the supplied 8 x 25 mm hex head cap screws. Insert the caps crews through the bulkhead flange , the 1/4 inch spacer and into the speed clips (Figure 1.3). Use the OEM bolts in the lower holes.

5. Route the heater hose under the wires at the AC cannister. Fit the hose under the cannister and under the lower point of the windshield washer bottle. Make sure that you do not kink the hose.

6. Apply Loctite to the three (3) 10 x 20 mm socket head cap screws, install the VR7000 pulley over the OEM crankshaft pulley and insert the cap screws. Torque them to 45 ft-lbs.

7. Install the VR7000 compressor mounting bracket to the engine using four (4) 10 x 35 mm hex head cap screws and flat washers. Use Loctite and torque them to 45 ft-lbs.

8. Feed the battery cables and wiring harness into the space between the compressor plates and secure them in place with nylon ties or clamps. Make sure that the positive battery cable passes in front of the coolant bottle hose. You may have to loosen the securing clamps on the cable and pull sufficient cable throught them to prevent the cable from rubbing on the compressor bracket.

9. Make sure that the fitting on the bottom of the compressor will point away from the engine when it is mounted.

10. Install the straight end of the 1/2” x 40” oil retrun hose to the 90 degree fitting on the bottom of the compressor. Tighten the connection.

11. Apply Loctite to one end of each of the three (3) 8 mm studs and thread them into the bottom of the compressor, then apply Loctite to the other end of the studs.

12. Install the compressor on the mounting bracket and fasten it in place using the three (3) 8 mm nuts and washers.

13. Install the OEM and VR7000 tensioners and idlers as shown in Figure 1.4. Use Loctite on all fasteners and tighten them securely.

14. Install the OEM and VR7000 belts as shown in Figure 1.4.

1.3 Installing the cooler

1. Remove and discard the two (2) battery 12 mm studs and nuts which retain the ground straps on the lower left and right sides of the engine. Remove and discard the positive battery cable locating bracket.

2. Clean the front of the engine block to ensure that the brackets will fit correctly. Install the oil cooler, complete with attached hoses, to the front of the engine. Slide the short hose on the cooler over the water pump fitting during installation or remove it and install it later..

3. Fasten the cooler in place (Figure 1.5) using the supplied 12 x 30 mm hex head cap screws and serrated washers. Use Loctite and torque the fasteners to specifications.

4. Connect the lower cooler hose to the bottom radiator outlet. Tighten all hose clamps securely.

5. On automatic transmission vehicles, fit 4 inch lengths of rubber hose around the transmission lines where they pass the cooler bracket and fasten them in place with nylon ties.

6. Apply Loctite to the threads on the fan spacer and install it on the fan, then apply Loctite to the water pump and install the fan assembly along with the fan shroud. Secure the battery cable in front of the radiator using nylon ties.

7. Install the top radiator hose, the hose between the cooler and the expansion tank and all other components removed in preparation for assembly.

8. Refill the radiator with the OEM recommended coolant to the correct level.

9. Check all clamps, fasteners and fittings to make sure that they are tight. Check all lines and hoses to make sure that they do not interfere with any hot or moving parts. Check the alignment of the belts to make sure it is correct.

Installing the Air Tank and Lines

System #9010
F250 HD – F350, F SUPER DUTY 1995.5-1997
7.3 L POWER STROKE DIESEL

2.1 Installing the tank

1. Install the tank brackets on the passenger side frame under the cab as shown in Figure 2.1. Use the supplied hex head cap screws, nuts and washers. Install the brackets through existing holes in the frame.

2. Install the air tank into the brackets and install the supplied hex head cap screws, washers and nuts in the tank clamp straps.

3. Rotate the tank until it is aligned as shown in Figure 2.2.
   This alignment is extremely important. Improper installation can result in personal injury, death or damage to the equipment.

4. Use the dimensions shown in Figure 2.1 to properly locate the tank. Tighten the fasteners.

2.2 Connecting the lines

The lines must be installed in the correct locations or the system will not function properly. In addition, a hazardous situation may develop from oil spray, potential fire or explosion.

1.  Connect the 2/4” JIC swivel end of the main air line between the tank at location 1 (Figure 2.2). Route the hose along the chassis, through the engine compartment and connect the other swivel end to the fitting on the back of the compressor. Tighten the connections.
2. Connect the ‘/s” hose to the tank at location 2 (Figure 2.2). Route the hose along the same path and connect it to the side fitting on the regulator block which is attached to the compressor. Tighten the connections.
3.  Connect the straight end of the /16” hose to the tank at location 3 (Figure 2.2). Route the hose along the same path and connect the 90 degree end to the 90 degree /10” elbow on the side of the inlet control valve. Tighten the connections.
4.  Connect one end of the ‘/2” x 72’/2” line to the tank at location 4 (Figure 2.2) Route the hose along the same path and connect the other end to the the passenger side fitting on the cooler. Tighten the connections.
5. Connect the end of the ‘/2” hose from the bottom of the compressor to the driver’s side fitting on the cooler. Tighten the connection.

2.3 Adding oil to the system

1. Make sure that the vehicle is level.

2. Remove the filler plug on the air inlet control valve.

3. Pour six (6) litres (1.6 US Gal.) of the supplied compressor oil into the large air intake opening.
   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.

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

5. Observe the sight glass at the front of the tank to ensure that the correct oil level is attained.
   It is important not to overfill the system.

6. Install the inlet control valve filler plug and tighten it securely.

Installing the Throttle Commander

System #9010
F250 HD – F350, F SUPER DUTY 1995.5-1997
7.3 L POWER STROKE DIESEL

3.1 Installing the Throttle Commander

1. Fasten the Throttle Commander under the dash, to the right of the steering column (Figure 3.1).

2. Unplug the two (2) cables from the foot pedal assembly and connect them to the Throttle Commander (Figure 3.2).

3. Connect the two (2) Throttle Commander cables to the foot pedal assembly (Figure 3.3).

4. Feed the gray, three-core cable with plug through the steering column boot into the engine compartment (Figure 3.4). Make sure that the cable is clear of all moving parts.

5. Plug the pressure sensor cable from the Throttle Commander into the connector on the pressure regulator (Figure 3.4).

6. Connect the black wire from the back of the Throttle Commander to the parking brake sensor switch.

7. Connect the red wire from the back of the Throttle Commander to the red wire with the mating bullet plug at the compressor control panel.

3.2 Attaching the white wire

1. Locate the white wire with the pink stripe at the connector block on the engine side of the firewall. Connect the white wire to this wire using the provided connector. The white/pink wire is located at the bottom of the firewall connector near the center (Figure 3.5). This connection cannot be made inside the cab.

Installing the Control Unit

System #9010
F250 HD – F350, F SUPER DUTY 1995.5-1997
7.3 L POWER STROKE DIESEL

4.1 Installation

1. Locate a suitable position for the control unit under the dash, above the hump, towards the driver’s sideposition. Locate it directly ahead of the 4WD shifter, if applicable.
2. Feed the white 14 gauge wire through the firewall and connect it to the bullet terminal on the compressor clutch.
3. Route the blue three-core cable with the red, black and green wires, up over the steering column and clear of any moving parts under the dash. Secure the wire as required.
4. Connect the red wire with the fuse to a fuse connector at the fuse box that has power only when the ignition switch is in the ON position.
5. Connect the green wire with the piggy-back terminal to the parking brake switch.
6. Connect the black wire to a good ground.
7. Route the wiring from the tank up the inner fender and along the firewall. Feed the wires through the grommet in the firewall on the driver’s side.
8. Connect the harness to the matching connector at the control unit. Make sure that you match the colors of the wires correctly.
9. Use the wiring diagram in Figure 4.1 to identify the wire connections. Secure all wires so that they will not be damaged or interfere with vehicle operation.

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):

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Download this manual  >>