Vmac V400015 User manual

www.vmacair.com
Installation Manual for VMAC
System
V400015
2017 – 2020 GM Savana
2017 – 2020 Chevrolet Express
6.0 L Vortec

VMAC - Vehicle Mounted Air Compressors
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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 Main Bracket and Compressor .................................. 17
Installing the Waste Heat Air Separator Package (WHASP) Tank..............22
Installing the Bulkhead Fittings ...............................................25
Hose Requirements ...........................................................29
Connecting the Hoses ....................................................... 30
Adding Oil to the System .................................................... 35
Installing the Control System .................................................36
Air Receiver Tank ............................................................ 45
Recommended Accessories .................................................. 46
Completing the Installation ...................................................47
Testing the Installation ...................................................... 48
Performance Testing and System Adjustments ................................ 51
Accessory Products from VMAC ............................................. 53
Warranty Registration ....................................................... 60

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Document: 1930350
Changes and Revisions
Revision Revision Details Revised by
Checked by
Implemented
Eng. Tech. Qual.
Mech. Elec.
AInitial Release MSP KRM AJH GB AWG 14 Feb 2018
B ECN: 20-210 Receiver tank requirement MSP MRH N/A MSP N/A 5 Nov. 2020
C ECN: 22-009 Cap model year MSP N/A N/A MSP N/A 31 May 2022
Additional Application Information
• Use of an air receiver tank (minimum 6 USG) is required with this application.
• 2017 – 2020 GM Savana, 6.0 L Vortec.
• 2017 – 2020 Chevrolet Express, 6.0 L Vortec.
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.
Lisle® is a registered trademark of the Lisle Corporation.
Loctite®, Loctite®242 and Loctite®567 are registered trademarks of Henkel AG &
Company KGaA.
Eaton Aeroquip® is a registered trademark of EATON AEROQUIP INC.
Chevrolete®, GM®, and GMC® are registered trademarks of General Motors
Company LLC.
Vortec™ is a trademark owned by General Motors Company LLC.

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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
• Pneumatic fan wrench (Lisle®43300 or equivalent) or a manual fan pulley
holder (such as KD3900).
• Pulley removal tool kit (such as a Lilse 39000, Jet H3565 or Performance Tool
389708 or equivalent.
• 6 mm Hex Ball End Extended Socket
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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☐ Locate the Engine Control Module (ECM) on the driver side fender near the
brake fluid reservoir (Figure 4).
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).
Do not use a test light to probe for power on vehicle circuits, the
increased current draw of the test light may damage components.
☐ Remove the electrical tape and peel back the plastic loom for the X1 connector
(at the bottom of the ECM) and the X2 connector (in the middle of the ECM).
Figure 4 — ECM location
ECM
connectors
Preparing for Installation

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There are 2 orange wires with black stripe in the ECM X1 bundle.
Follow the test below to determine the correct wire.
☐ Locate the orange wire with black stripe going to pin 34 in the ECM X1
connector (Figure 5).
☐ Turn the ignition to “RUN” but do not start the vehicle. Use a multimeter to
verify the correct wire. The correct wire will show 0 V in “PARK” or “NEUTRAL”
and 12 V in all other gear selector positions.
☐ Turn the ignition switch to “OFF”. Mark the correct wire for electrical
connections later in the installation process.
☐ Locate the white wire with black stripe going to pin 56 in the ECM X2 connector
(Figure 6).
Figure 5 — ECM connector X1 (connector “face” view)
Pin 34
Figure 6 — ECM connector X2 (connector “face” view)
Pin 56

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☐ Start the vehicle and use a multimeter to verify the correct wire. The correct
wire will show a stable voltage reading of 2.3 V - 2.8 V while the engine is
idling.
☐ Turn the ignition switch to “OFF” and mark the correct wire for electrical
connections later in the installation process.
☐ Disconnect and cover the battery terminals.
Optional: Raise the front of the vehicle and support on axle stands (if the vehicle
is raised, ensure it is adequately supported on axle stands).
☐ Disconnect the Mass Airflow (MAF) sensor (Figure 7).
☐ Remove the 2 front bolts on the airbox and pull the airbox upward to remove it
(Figure 7).
☐ Disconnect the Positive Crankcase Ventilation (PCV) hose from the passenger
side of the intake tube.
☐ Remove intake tube from between the airbox and the throttle body.
Figure 7 — MAF sensor
MAF
connector
Airbox
fasteners

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☐ Cover the throttle body to prevent contaminants from entering the engine.
☐ Remove the bolt securing the front of the coolant reservoir, orient the overflow
drain hose upwards, and pull the coolant reservoir forward, out of the rear
securing tabs. The hose does not need to be disconnected nor the coolant
drained. Position the reservoir on the passenger side of the engine so that it
will not spill.
☐ Disconnect the support clips on the upper radiator hose and the wiring loom
running over the top of the fan shroud.
☐ Remove the upper fan shroud. There are 2 bolts on the top and 3 bolts on each
side of the shroud.
Optional: Remove the radiator fan (the installation can be performed with the fan
in place but is much easier with the fan removed).
☐ Remove the Front End Accessory Drive (FEAD) belt and retain it in the vehicle.
In the unlikely event of a compressor failure, the VMAC belt can be removed
and the OEM belt can be reinstalled to operate the vehicle.
☐ Disconnect the power wire from the alternator.
☐ Disconnect the 3 wire electrical connector from the alternator.
☐ Remove the 2 alternator bolts and remove the alternator. Set them aside for
reinstallation later (Figure 8).
Figure 8 — Remove alternator

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☐ Remove the OEM idler from the top of the bracket and set it aside for
reinstallation later (Figure 9).
Leave the power steering hoses connected to the power steering
pump and secure the pump out of the way.
☐ Remove the 3 power steering pump bolts (the bolts can be accessed through
the holes in the pulley). Retain the bolts for reinstallation later (Figure 10).
Figure 9 — Remove idler
Remove idler
Figure 10 — Remove power steering pump
Remove power
steering pump bolts

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☐ Remove the 4 OEM alternator / power steering bracket bolts and remove the
bracket. Retain the bolts for reinstallation later (Figure 11).
☐ Remove the bushings from the OEM bracket (Figure 12).
Figure 11 — Accessory bracket removal
Remove power
steering bracket
Figure 12 — Bracket bushing removal
Remove OEM
bushings

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☐ Remove the idler installed on the VMAC bracket.
☐ Install the 2 OEM bushings, and the 2 supplied dowels into the VMAC main
bracket (Figure 13).
Figure 13 — VMAC bracket bushing and dowel installation
VMAC supplied
dowels
OEM
bushings

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Apply Loctite 242 (blue) to all engine mounted fasteners.
☐ Install the VMAC main bracket in the location shown and torque the fasteners
to specification (Figure 14).
☐ Install the OEM idler in the original position on the VMAC bracket (Figure 15).
☐ Install the VMAC idler onto the VMAC bracket (Figure 15).
☐ Install the OEM alternator using the OEM bolts. Connect the power wire, and
the 3 wire electrical connector.
Figure 14 — Main bracket installation
Figure 15 — Installing FEAD components
OEM idler
VMAC idler
Installing the Main Bracket and
Compressor

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There are 2 dowels on the side of the VMAC bracket, these are used
to locate the compressor in the correct position for bolt installation
and belt alignment.
☐ Position the compressor on the 2 dowels on the VMAC bracket.
☐ Install the 3 compressor bolts (Figure 16).
Figure 16 — Compressor installation
☐ Connect the straight end of the supplied longer 3/8 in hose to the matching
fitting on the side of the VMAC compressor and tighten the fitting. The
remainder of the hose installation will be covered later in the installation.
☐ Install the air filter bracket onto the compressor (Figure 17).
Figure 17 — Air filter bracket