Vmac UNDERHOOD 40 Series User manual

www.vmacair.com
Installation Manual for VMAC
System
V400044
With Advanced Digital Controls
2023+Ford Transit
3.5 L Gas PFDI Duratec

VMAC - Vehicle Mounted Air Compressors
VMAC Technical Support: 888-241-2289
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Table of Contents
Safety ..............................................................3
Warranty ...........................................................4
General Information.................................................6
Component Identification and Overview.............................8
Preparing for Installation ........................................... 11
Main Bracket and Compressor Installation ..........................18
Waste Heat Air Separator Package (WHASP) Tank Installation ......21
Bulkhead Fittings Installation...................................... 24
Hose Requirements ................................................27
Hose Installation .................................................. 28
Adding Oil to the System ......................................... 35
Electrical Schematic .............................................. 36
Harness Reference .................................................37
Electronics and Control Component Installation ................... 40
Telematics Integration (Optional) .................................. 50
Remote Start Integration (Optional) ................................51
Installing the Air Filter and Power Steering Reservoir............... 52
Completing the Installation ....................................... 53
Air Receiver Tank.................................................. 56
Recommended Accessories ....................................... 57
Testing the Installation............................................ 58
Basic Operation....................................................62
Performance Testing .............................................. 64
System Adjustment, Optimization, and Basic Parameters........... 65
Accessory Products from VMAC................................... 66
Warranty Registration..............................................72

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Document: 1930507
Changes and Revisions
Revision Revision Details Revised by
Checked by
Implemented
Eng. Tech. Qual.
Mech. Elec.
AInitial release MSP CAM ASE RB LPH 19 Dec. 2023
Additional Application Information
• Use of an air receiver tank (minimum 6 USG) is required with this application.
• 2023+ Ford Transit, 3.5 L Gas PFDI Duratec engine.
• For 3.5 L Ecoboost, refer to the V400039 system.
• Dual alternator vehicles must be converted to single alternator prior to
proceeding with the VMAC installation.
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.
Ford® and Duratec® are registered trademarks of Ford Motor Company.
Posi-TapTM is a trademark owned by Swenco® Products, Inc.
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 © 2023 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

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Safety
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 additional instructions or
special emphasis on a specific procedure.
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 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.

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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]
[phone]
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/
VMAC Warranty Claim Process
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, and hours on the
compressor.
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, loss of income, over-
time charges, mileage, travel time, towing/recovery, cleaning or shop supplies.
7) Dealers submit warranty claims on behalf of the Vehicle Owner/End User af-
fected 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.
VMAC Product Warranty Policies & Warranty Registration can be found on the
VMAC website (see previous page for URL).
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 “Standard” 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.

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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
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. Replacement hoses can be
ordered from a VMAC dealer or sourced locally. Refer to this Knowledge Base
article for compatible hoses: EXT-ALL-010-Required-VMAC-Hoses.pdf
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.
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.

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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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Electrical Modules
• Ensure the Digital Throttle Control (DTC) and Control Module (Controller) are
mounted away from the pedals, park brake mechanism, or where they could be
inadvertently knocked by occupants.
• The DTC throttle pedal harness cannot be modified, ensure the DTC is mounted
close to the throttle pedal.
• The display box is not weather proof; ensure it is mounted where it will be
protected from rain, snow, mud, direct sunlight, and or where it could be
inadvertently knocked by occupants, etc. (e.g. inside the cab, service body or
cabinet).
Control Components Overview
Figure 1 — General component overview
(Actual installation locations may vary)
Compressor
DTC
WHASP
Tank
Display
Box
Display Box
(alternate location)
Component Identification and Overview
Controller

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Control Module (Controller) (Figure 2)
The control module serves as the primary input/output interface between the
vehicle and the various VMAC components (compressor, DTC, WHASP Tank, Display
Box, etc.).
Figure 2 — Control module
Display Box (Figure 3)
The display box serves as the operator’s control panel and contains the “ENTER”
(compressor on/off), “–” (decrease), “MENU”, and “+“ (increase) buttons, power and
“ERROR” indicator LEDs, and the screen, The screen includes information such as
compressor hours, service reminders, warning messages, error codes, access to the
advanced settings, and diagnostic information.
Figure 3 — Display box
Error
indicator
LED
Light sensor
for auto dim
LED display
Power
indicator
LED
LED
Display
Power/Enter
button
Navigation
buttons

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Pressure Sensor (Figure 5)
The system pressure sensor is mounted on the side of the WHASP tank and
measures the system pressure. The clutch will disengage once system pressure is
achieved.
Figure 4 — VMAC DTC
Pressure
sensor
Figure 5 — WHASP Tank pressure sensor
Digital Throttle Control (DTC) (Figure 4)
The DTC responds to signals from the control module and commands the vehicle’s
throttle to increase or decrease engine speed in response to air demand.
Not used
Controller Vehicle
CAN bus
Accelerator
pedal
Loop back
connector

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☐ 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].
Preparing for Installation
☐ Move the driver seat completely to the rear and remove the (×2) front fasteners
(Figure 6).
Figure 6 — Driver seat (front)
Remove
fasteners
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.
Prior to proceeding, ensure “Transport Mode” has been deactivated
(contact a local Ford dealership or refer to the vehicle’s owner’s
manual for instructions).
Dual alternator vehicles must be converted to single alternator prior
to proceeding with the VMAC installation.

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☐ Move the driver seat completely forward and remove the (×2) rear fasteners
(Figure 7).
Figure 7 — Driver seat (rear)
Remove
fasteners
☐ Remove the seat electrical connector (Figure 8).
Figure 8 — Seat electrical connector
Remove electrical
connector
☐ 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;
place the seat on the floor outside of the driver side of the van.

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☐ Disconnect the negative battery cable(s) from the battery terminal stud
(Figure 10).
Figure 10 — Battery cables
Remove negative
battery cable
☐ 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 9).
Figure 9 — Battery cover
Remove
cover
The driver seat is heavy, use care when lifting it to prevent injury.
☐ Remove the center console or step guard.

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☐ Optional: Remove the passenger side headlight and set it aside (this greatly
improves access).
☐ To provide better access to the tensioner bolt, remove the (×2) coolant valve
fasteners and shift the coolant valve out of the way (Figure 11).
☐ 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 12).
Figure 11 — Access tensioner bolt
Figure 12 — Remove 6 rib belt
Move coolant
valve
Tensioner
bolt

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☐ Vehicles that have been converted to single alternator, skip this step:
Remove the stretch fit A/C compressor belt (Figure 13).
Figure 13 — Remove 4 rib belt
The stretch fit A/C compressor belt is not reused and can be cut to
save removal time.
☐ Remove the bolt and Christmas tree fastener from the driver side cable tray and
set them aside for later (Figure 14).
Remove bolt
and Christmas
tree fastener
Figure 14 — Remove cable tray
Ecoboost engine shown, the Duratec engine will be similar.

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☐ Remove and discard the stud 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 15).
Remove
stud
Figure 15 — Remove cable tray
Shift harness
out of the way
☐ Remove and discard the timing cover bolts (Figure 16).
Figure 16 — Remove timing cover bolts
Remove
bolts

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☐ Leaving the A/C lines connected, remove the A/C compressor and secure it up
and out of the way (Figure 17).
Remove A/C
compressor
Use caution when working around A/C system as excessive or
repeated bending of the A/C lines can cause them to weaken or
rupture.
Exposure to refrigerant can cause serious injury or death.
Figure 17 — Remove A/C compressor
☐ Disconnect the electrical connectors from the A/C compressor.

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Figure 18 — Install main bracket
Main Bracket and Compressor Installation
Figure 19 — Install tensioner
☐ Using the supplied fasteners, mount the main bracket onto the engine
(Figure 18).
☐ Reinstall the A/C compressor onto the engine.
☐ Using the (×2) supplied M8×1.25×50 mm bolts, install the 4 rib belt tensioner
onto the VMAC main bracket (Figure 19).
M10×1.5×45
M8×1.25×35
M8×1.25×70
M8×1.25×50