Vmac UNDERHOOD 40 Series User manual

www.vmacair.com
Installation Manual for VMAC
System
V400009
2015 – 2019 Ford Transit
3.5 L EcoBoost

VMAC - Vehicle Mounted Air Compressors
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VMAC Knowledge Base: kb.vmacair.com
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Table of Contents
Safety .........................................................................3
Warranty ......................................................................4
General Information ...........................................................6
System Identification, Warranty Registration and Warning Labels..............8
Preparing for Installation .....................................................10
Installing the Compressor..................................................... 18
Installing the Waste Heat Air Separator Package (WHASP) Tank..............24
Installing the Bulkhead Fittings ...............................................27
Hose Requirements ........................................................... 31
Connecting the Hoses .......................................................32
Adding Oil to the System .....................................................39
Installing the Control System ................................................ 40
Installing the Air Filter and Power Steering Reservoir......................... 59
Air Receiver Tank .............................................................62
Recommended Accessories ...................................................63
Completing the Installation .................................................. 64
Testing the Installation ...................................................... 65
Performance Testing and System Adjustments ............................... 68
Accessory Products from VMAC ..............................................70
Warranty Registration ........................................................76

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Document: 1930342
Changes and Revisions
Revision Revision Details Revised by
Checked by
Implemented
Eng. Tech. Qual.
Mech. Elec.
AInitial Release MSP CAM AJH GB AWG 7 Feb 2018
B ECN 19-157 Cap model year MSP N/A N/A MSP N/A 5 Nov 2019
C ECN: 20-210 Receiver tank requirement MSP MRH N/A MSP N/A 4 Nov. 2020
Additional Application Information
• Use of an air receiver tank (minimum 6 USG) is required with this application.
• 2015 – 2019 Ford Transit, 3.5 L EcoBoost.
Important Information
The information in this manual is intended for certified VMAC installers who
have been trained in installation and service procedures and/or for anyone with
mechanical trade certification who has the tools and equipment to properly and
safely perform the installation or service. Do not attempt installation or service
without the appropriate mechanical training, knowledge and experience.
Follow all safety precautions. Any fabrication for correct fit in modified vehicles
must follow industry standard “best practices”.
Notice
Copyright © 2020 VMAC Global Technology Inc. All Rights Reserved. These
materials are provided by VMAC for informational purposes only, without
representation or warranty of any kind, and VMAC shall not be liable for errors
or omissions with respect to the materials. The only warranties for VMAC
products and services are those set forth in the express warranty statements
accompanying such products and services, if any, and nothing herein shall be
construed as constituting an additional warranty. Printing or copying of any page
in this document in whole or in part is only permitted for personal use. All other
use, copying or reproduction in both print and electronic form of any part of this
document without the written consent of VMAC is prohibited. The information
contained herein may be changed without prior notice.
Printed in Canada
Registered Trademarks
All trademarks mentioned in this manual are the property of their respective
owners. VMAC’s use of manufacturers’ trademarks in this manual is for
identification of the products only and does not imply any affiliation to, or
endorsement of said companies.
Loctite®, Loctite®242 and Loctite®567 are registered trademarks of Henkel AG &
Company KGaA.
Eaton Aeroquip® is a registered trademark of EATON AEROQUIP INC.
Torx® is a registered trademark of Acument Intellectual Properties, LLC
Ford® and EcoBoost® are registered trademarks of Ford Motor Company.

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Important Safety Notice
The information contained in this manual is based on sound engineering principles,
research, extensive field experience and technical information. Information
is constantly changing with the addition of new models, assemblies, service
techniques and running OEM changes. If a discrepancy is found in this manual,
contact VMAC Technical Support prior to initiating or proceeding with installation,
service or repair. Current information may clarify the issue. Anyone with knowledge
of such discrepancies, who proceeds to perform service and repair, assumes all
risks.
Only proven service procedures are recommended. Anyone who departs from the
specific instructions provided in this manual must first ensure that their safety and
that of others is not being compromised, and that there will be no adverse effects
on the operational safety or performance of the equipment.
VMAC will not be held responsible for any liability, consequential damages, injuries,
loss or damage to individuals or to equipment as a result of the failure of anyone
to properly adhere to the procedures set out in this manual or standard safety
practices.
Safety should be the first consideration when performing any service operations.
If there are any questions concerning the procedures in this manual, or more
information is required, please contact VMAC Technical Support prior to beginning
work.
Safety Messages
This manual contains various warnings, cautions and notices that must be
observed to reduce the risk of personal injury during installation, service or repair
and the possibility that improper installation, service or repair may damage the
equipment or render it unsafe.
This symbol is used to call attention to instructions concerning
personal safety. Watch for this symbol; it points out important
safety precautions, it means, “Attention, become alert! Your
personal safety is involved”. Read the message that follows and
be aware of the possibility of personal injury or death. As it is
impossible to warn of every conceivable hazard, common sense and
industry standard safety practices must be observed.
This symbol is used to call attention to instructions on a specific
procedure that if not followed may damage or reduce the useful life
of the compressor or other equipment.
This symbol is used to call attention to additional instructions or
special emphasis on a specific procedure.
Safety

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VMAC Standard Warranty (Limited)
For complete warranty information, including both VMAC Standard
Warranty (Limited) and VMAC Lifetime Warranty (Limited)
requirements, please refer to our current published warranty located
at: www.vmacair.com/warranty
If you do not have access to a computer, please contact us and we
will be happy to send you our warranty.
VMAC’s warranty is subject to change without notice.
VMAC Lifetime Warranty (Limited)
A VMAC Lifetime Limited Warranty is offered
on the base air compressor only and only on
UNDERHOOD, Hydraulic Driven, Transmission
Mounted, Gas and Diesel Engine Driven Air
Compressors, Multifunction Power Systems, and
other products as defined by VMAC, provided that
(i) the purchaser fully completes and submits a
warranty registration form within 3 months of purchase, or 200 hours of operation,
whichever occurs first; (ii) services are completed in accordance with the Owner’s
Manual; (iii) proof of purchase of applicable service kits are made available to
VMAC upon request.
The VMAC Lifetime Warranty is applicable to new products shipped on or after
1 October, 2015.
Warranty Registration
The VMAC warranty registration form is located near the back of this manual. This
warranty registration form must be completed and sent to VMAC at the time of
installation for any subsequent warranty claim to be considered valid.
There are 4 ways the warranty can be registered with VMAC:
www.vmacair.com/warranty
[e-mail]
(877 ) 740-3202
VMAC - Vehicle Mounted Air Compressors
1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3
LIFETIME
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WARRANTY
Warranty

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VMAC warranty work must be pre-authorized by VMAC. Claims are
processed via our dealer network. If you are not a VMAC dealer,
please select one to work with via our Dealer Locator:
https://www.vmacair.com/dealer-locator/
1. Communicate with VMAC Technical Support at 1-888-241-2289 or
[e-mail] to help diagnose/troubleshoot the problem prior to repair.
VMAC technical support will require the VMAC System ID, hours on the
compressor and mileage on the vehicle.
2. VMAC will provide direction for repair or replacement of the failed components.
3. If requested, failed parts must be returned to VMAC for evaluation.
4. Dealers may login to the VMAC website to view the "VMAC Labour Time Guide"
(under “Agreements”) to see the allowable warranty labour times.
5. Warranty invoices must include the Service Ticket number, VMAC System ID#,
hours on the compressor, and a detailed description of the work performed.
6. VMAC Warranty does not cover consequential damages, overtime charges,
mileage, travel time, towing/recovery, cleaning or shop supplies.
7. Dealers submit warranty claims on behalf of the Vehicle Owner/End User
affected by the defective part(s). The dealer ensures that all warranty credits
are refunded back to the Vehicle Owner/End User who made the initial warranty
claim.
In order to qualify for Lifetime Warranty (Limited), the completed
warranty registration form must be received by VMAC within 3
months of the buyer receiving the Product(s), or 200 hours of
operation, whichever occurs first.
If the completed warranty registration form has not been received
by VMAC within 3 months of the buyer receiving the Product(s),
or 200 hours of operation, the warranty period will be deemed to
commence 30 days from the date of shipment from VMAC.
Failure to follow the warranty claim process may result in denial of
the warranty claim.
VMAC Product Warranty Policies & Warranty Registration can be found on the
VMAC website (see previous page for URL).
VMAC Warranty Claim Process

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General Information
Optional Equipment Compatibility
While VMAC strives to design systems compatible with optional OEM equipment
(such as running boards), it is impractical to develop systems that accommodate
every OEM and aftermarket option or add-on. Whenever possible, VMAC
endeavors to advise of compatibility issues in the “Additional Application
Information” section of the manual. Even when specific optional equipment is
determined by VMAC to be incompatible, it does not preclude the vehicle upfitter
or end user from modifying the optional equipment to make it compatible with
the installed VMAC system. VMAC does not warranty or accept responsibility or
liability for the fitment, function or safety of any products modified in any way not
expressly outlined in the installation manual.
Before Starting
Note and label all parts that are removed from the vehicle as many
of the OEM parts will be reused during the installation of the VMAC
system.
Read this manual prior to beginning the installation to ensure familiarity with the
components and how they will fit on the vehicle. Identify any variations from the
application list such as vehicle model, engines, or optional equipment (e.g., dual
alternator, active steering assist, etc.).
Open the package, unpack the components and identify them using the Illustrated
Parts List (IPL) included in the Fastener Pack.
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 VMAC 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.
Ordering Parts
To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial
number, part number, description and quantity. Locate the nearest dealer online at
www.vmacair.com/dealer-locator or call 1-877-912-6605.

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Table 1 — Torque Table
Standard Grade 8 National Coarse Thread
Size (in) 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4
Foot pounds (ft•lb) 918 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 (in) 3/8 7/16 1/2 5/8 3/4
Foot pounds (ft•lb) 40 60 90 180 320
Newton meter (N•m) 54 81 122 244 434
Metric Class 10.9
Size (mm) M6 M8 M10 M12 M14 M16
Foot pounds (ft•lb) 4.5 19 41 69 104 174
Newton meter (N•m) 625 55 93 141 236
Special Tools Required
• 15 mm serpentine belt wrench.
Torque Specifications
All fasteners must be torqued to specifications. Use manufacturers’ torque values
for OEM fasteners.
The torque values supplied in Table 1 are intended for VMAC supplied components,
or for use as a guide in the absence of a torque value provided by an OEM.
Torque values are with Loctite applied unless otherwise specified.
Apply Loctite 242 (blue) to all fasteners (except nylon lock nuts)
unless otherwise stated.

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Preparation for installation is very important. Missing a step
or an item can cause problems in the installation or damage to
components.
☑
Check off each item as it is completed so that no steps are
missed.
☐ Review the contents of the system using the illustrated parts list to ensure all
components are present and in the correct quantity. If any components are
missing, have the system ID ready and call VMAC Technical Support at
[phone].
The VMAC warranty form must be completed and returned to VMAC
at the time of installation for any subsequent warranty claim to be
considered valid.
☐ Complete the warranty form. The VMAC warranty form is located at the back
of this manual, as well as online at: www.vmacair.com/warranty
The System Identification Plate must be attached to the vehicle at
the time of installation. This plate provides information that allows
VMAC to assist with parts and repairs.
☐ Mark and drill 2 × 7/64 in holes in the top of the cross member in front of the
hood support. Secure the plate with the supplied self-tapping screws (Figure 1).
Figure 1 — System Identification Plate
☐ Install the VMAC belt routing diagram in a suitable location under the hood.
System Identification, Warranty
Registration and Warning Labels

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☐ 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 2).
Figure 2 — Operating Instruction label
☐ 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 (Figure 3).
Figure 3 — Advisory label

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☐ Move the driver seat completely to the rear and remove the 2 front Torx
fasteners (Figure 4).
☐ Move the driver seat completely forward and remove the 2 rear Torx fasteners
(Figure 5).
Ensure the VMAC Warranty Registration has been filled out and
the System Identification Plate and Operating Instruction Label are
installed prior to proceeding (Please see page 8 for details).
Figure 4 — Driver seat (front)
Remove
fasteners
Figure 5 — Driver seat (rear)
Remove
fasteners
Preparing for Installation

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☐ Remove the seat electrical connector (Figure 6).
☐ The seat electrical harness is hooked to a stud on the bottom of the seat.
Ensure the harness is unhooked and the wire can hang loose under the seat.
☐ Leave the seatbelt connected to the seat and lift the seat off of its mount and
move the seat out of the way of the battery box.
The driver seat is heavy, use care when lifting it to prevent injury.
☐ Remove the 2 bolts underneath the piece of carpet at the rear of the battery
cover retaining plate. Remove the metal bracket, then lift the plastic tabs on
the rear of the battery cover to remove the battery cover (Figure 7).
Figure 6 — Seat electrical connector
Remove electrical
connector
Figure 7 — Battery cover
Remove
cover

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☐ Disconnect the negative battery cable from the battery terminal stud
(Figure 8).
☐ Disconnect the vacuum tube from the intake elbow (Figure 9).
Figure 8 — Battery cables
Remove negative
battery cable
☐ Disconnect the 2 vacuum tubes that run down the passenger side of the engine
and secure them out of the way with cable ties (Figure 9).
☐ Loosen the 2 hose clamps on the intake tube (Figure 9).
☐ Remove the intake tube.
Figure 9 — Remove intake tube
Intake tube
Disconnect
vacuum tubes

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☐ Cover the engine intake, air filter, and vacuum tube openings to prevent
contaminants from entering the engine’s air intake system. (Figure 10).
☐ Remove the 2 Torx screws holding the power steering reservoir to the radiator
support and secure the reservoir to the windshield washer fill tube using a
cable tie (Figure 10).
☐ Remove the engine lifting eye and retain the fasteners (Figure 11).
Figure 10 — Cover all intake tubes
Secure
reservoir
Cover intake and
vacuum tubes
☐ Remove the hose clamp on the passenger side turbocharger outlet tube (Figure 11).
Figure 11 — Remove engine lifting eye and turbo outlet
Remove
lifting eye
Leave vacuum
tube connected
Remove
turbo outlet

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☐ Remove the 2 bolts securing the lower intake tube to the front frame
crossmember and the 2 bolts securing the lower intake tube to the upper intake
tube (Figure 12).
☐ Disconnect the quick connect cuff on the bypass hose and unplug the electrical
connector from the bypass module (Figure 13).
☐ Remove the 3 hose clamps securing the lower intake tube and remove the tube
from the engine bay (Figure 12).
☐ Remove the 2 hose clamps securing the upper intake tube. Disconnect the tube
and remove it from the engine bay.
☐ Use cardboard to protect the Charge Air Cooler (CAC) from any accidental
impacts.
☐ Remove the turbocharger outlet tube and place it out of the way on top of the
engine. The small vacuum line attached to the turbocharger tube can be left
connected (Figure 11).
Figure 13 — Intake by-pass connections
Figure 12 — Remove lower intake tube
Remove
Disconnect
hose clamp
Quick connect
Connector

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☐ Using a 14 mm wrench to release the tension, remove the OEM 4 rib belt and
discard (Figure 15).
☐ From underneath the vehicle, use a 15 mm serpentine belt wrench to release the
tension and remove the OEM 6 rib belt from the crank pulley. Tuck the belt out
the way (Figure 14).
Figure 14 — Remove 6 rib belt from crank pulley
Tensioner
bolt
Figure 15 — Remove 4 rib belt
Tensioner
bolt

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☐ Remove the 3 bolts securing the power steering pump to the OEM bracket.
Retain all of the bolts for use later.
☐ Using pliers, remove and discard the 2 aluminum locating sleeves from the
power steering pump (Figure 16).
☐ Secure the power steering pump out of the way with cable ties.
☐ Remove the bolt and Christmas tree fastener from the driver side cable tray
and set them aside for later (Figure 17).
Do not disconnect the power steering hoses from the pump.
Figure 16 — Remove locating sleeves
Remove locating
sleeves
Figure 17 — Disconnect cable tray
Driver side Passenger side
Mounting
stud
Christmas tree
fastener
☐ Remove the nut securing the passenger side of the cable tray. Pull the tab off
the mounting stud and push the wiring harness out of the way (Figure 17).
☐ Remove the OEM power steering pump bracket from the engine. Retain all of
the fasteners for use later.

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☐ Apply Loctite 242 (blue) to the 2 supplied M8 × 1.25 × 30 mm fasteners and
install them in the location shown. Torque the fasteners to specification
(Figure 18).
☐ Remove the cam cover bolt and discard it (Figure 19).
☐ Remove the OEM tensioner from the power steering bracket and set it aside
for use later. The OEM power steering bracket and fasteners can be retained in
case the vehicle will be returned to stock.
☐ From underneath the vehicle, gently deflect the metal A/C lines toward the
passenger side of the engine bay and away from the engine. Final adjustments
will be performed later in the install.
Use caution when deflecting or bending the A/C lines as excessive
or repeated bending of these lines can cause them to weaken or
rupture. Exposure to refrigerant can cause serious injury or death.
Figure 19 — Remove cam cover bolt
Remove
bolt
Figure 18 — Replace bracket fasteners
Install supplied
fasteners

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Apply Loctite 242 (blue) to all engine mounted fasteners.
The OEM 4 rib tensioner must be installed on the VMAC bracket
before installing the idler.
☐ Install the OEM 4 rib belt tensioner on the VMAC main bracket using the
original OEM bolts (Figure 20).
☐ Install the supplied idler onto the main bracket (Figure 20)
☐ Mount the compressor assembly onto the main bracket using the supplied
fasteners (Figure 20).
Figure 20 — Install main bracket components
Install OEM
tensioner first
Installing the Compressor