Vmac VR70 User manual

System V900094
2009-2007 Dodge 2500-3500
5.9L 24 Valve Cummins Diesel
www.vmacair.com
VR70 UNDERHOOD
AIR COMPRESSOR
INSTALLATION MANUAL

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Installation Manual for VMAC
System V900094
2009-2007 Dodge 2500-3500
5.9L 24 Valve Cummins Diesel
General Information..................................................................... 3
Before You Start....................................................................... 3
Part 1: Warranty and System ID................................................. 4
Part 2: Preparing for Installation............................................... 7
2.1 Preparing for Installation .................................................... 7
Part 3: Installing the Tank.......................................................... 9
3.1 Assembling and Installing the Brackets ............................. 9
3.2 Installing the Tank Assembly.............................................. 11
Part 4: Installing the Cooler and Compressor......................... 12
4.1 Installing the Oil Cooler ...................................................... 12
4.2 Installing the Main Bracket and Compressor ..................... 14
4.3 Connecting the Hoses........................................................ 15
4.4 Completing the Installation................................................. 16
4.5 Adding Oil to the System.................................................... 20
Part 5: Installing the Control Components .............................. 22
5.1 Installing the Control Box and Throttle Control .................. 23
5.2 Connecting the Wiring........................................................ 23
5.3 Completing and Testing the Installation............................. 27
Part 6: Finishing the Installation................................................ 28
6.1 Before Starting the Engine Checklist.................................. 28
6.2 After Starting the Engine Checklist .................................... 28
6.3 Setup, Performance Testing and Adjustments................... 29
6.4 Auxiliary Air Receiver ......................................................... 30
Accessory Products from VMAC ............................................... 31

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Document 1930132
Installation Manual for VMAC System V900094
2009-2007 Dodge 2500-3500 5.9L 24 Valve Cummins Diesel
Changes and Revisions
Version
Revision Details
Revised by/date
Checked by/date
Reviewed by/date
Implemented
A
ECN 07-145
IB 10 Nov 2007
SH 23 Nov 2007
N/A
26 Nov 2007
B
ECN 09-038
SL 31 March 2009
RD 29 Mar 2009
N/A
3 April 2009
C
ECN 12-156
SAR 14 Nov 2012
MH 16 Nov 2012
N/A
30 Nov 2012
D
ECN 13-013,
ECN 13-104
SH 18 Jul 2013,
MC 05 Nov 2013
MP/RD 17 Dec 2013
N/A
20 Dec 2013
E
ECN 13-120
JR 22 Apr 2014
MH 22 Apr 2014
DB 24 Apr 2014
01 May 2014
Important Information
The information in this manual is intended for certified VMAC
installers who have been trained in installation procedures and for
people with mechanical trade certification who have the tools and
equipment to properly and safely perform the installation. Do not
attempt this installation if you do not have the appropriate
mechanical training, knowledge and experience.
Follow all safety precautions for underhood mechanical work. Any
grinding, bending or restructuring operations for correct fit in modified
trucks must follow standard shop practices.
These instructions are a general guide for installing this system on
standard production trucks and do not contain information for
installation on non-standard trucks. This system may not fit special
order models or those which have had other changes without
additional modifications. If you have difficulty with the installation,
contact VMAC.
The VMAC 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.
To order parts, contact your VMAC dealer. Your dealer will ask for
the VMAC serial number, part number, description and quantity. To
locate your nearest dealer, call 1-800-738-8622.
Copyright 2009
All trademarks used in this manual are the property of the respective copyright holder.
The contents of this manual may not be reproduced in any form without the express
written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3.
Printed in Canada

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!
General Information
Before You Start
Read this manual before attempting installation so that you can
familiarize yourself with the components and how they fit on the
truck. Identify variations for different model years and different
situations that are listed in the manual. Open the package, unpack
the components and identify them.
All fasteners must be torqued to specifications. Use manufacturers
torque values for OEM fasteners. Apply Loctite 242 or equivalent on
all engine-mounted fasteners. Torque values are with Loctite applied
unless otherwise specified.
STANDARD GRADE 8 NATIONAL COARSE THREAD
Size
1/4
5/16
3/8
7/16
1/2
9/16
5/8
¾
Foot-pounds (ft-lb)
9
18
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
3/8
7/16
1/2
5/8
¾
Foot-pounds (ft-lb)
40
60
90
180
320
Newton meter (N•m)
54
81
122
244
434
METRIC CLASS 10.9
Size
M8
M10
M12
M14
M16
Foot-pounds (ft-lb)
19
41
69
104
174
Newton meter (N•m)
25
55
93
141
236
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 our 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.

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Part 1: Warranty and System ID
□Complete the warranty form. 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.
System Identification and Operating Instructions
The System Identification Number Plate must be attached to the
vehicle at the time of installation. This plate provides information that
allows VMAC to assist in customer inquiries and the ordering of
parts.
□Mark and drill two 7/64-inch holes in the top of the cross member
in front of the OEM air filter box. Secure the plate with supplied
self- tapping screws
□Clean cross member beside the number plate and stick the
VMAC belt routing diagram to the cross member.
□Apply battery warning label to driver side of primary cooling
reservoir.
□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 1.1).

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Figure 1.1

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□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. Thoroughly clean the
selected area before affixing the label (figure 1.2)
Figure 1.2
To order parts, contact your VMAC dealer. Your dealer will ask for
the VMAC serial number, part number, description and quantity. To
locate your nearest dealer, call 1-888-241-2289.

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Part 2: Preparing for Installation
Preparation for installation is very important. Missing an item can
cause problems in the installation or even damage to components.
Check off each item as it is completed so that you do not miss any
preparation steps.
2.1 Preparing for Installation
□Disconnect the battery terminals.
□Disconnect the mass air flow sensor, remove the air cleaner
assembly and the passenger side intercooler tube.
□Drain the coolant and remove the upper and lower radiator
hoses.
□Disconnect the fan clutch wire and remove it from the mounting
clips
□Remove the fan shroud from the engine locating brackets.
□Remove the fan and the OEM belt. Use cardboard to protect the
radiator.
□Remove the passenger side upper fan shroud mounting bracket
from the front of the engine.
□Remove the wire harness from the clips on the top front of the
cylinder head.
□Remove the upper alternator mount and lifting lug, remove the
lower alternator mount bolt and set the alternator aside.
□Remove the OEM crank pulley and scrape off the clear coat from
the front face.

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□Place the OEM crank pulley on the front of the crankshaft and
rotate it to align it with the locating pin. Place the VR pulley in
front of the OEM crank pulley and align it with the locating pin.
□Apply Loctite to the four OEM bolts and install them through the
two pulleys into the crankshaft. Torque the bolts to
specifications.
□Remove the plug from the passenger side of the cylinder head
(Figure 2.1). Save this plug as it will be re-used later. Use thread
sealant on NPT fittings. Install the supplied pipe nipple, and tee
fitting in the cylinder head port. Face the tee fitting towards the
passenger side of the truck, and install the hose barb in the tee.
Remove this plug
Figure 2.1

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Part 3: Installing the Tank
The tank will mount on the passenger side of the vehicle between
the two cab mounts.
1/4” and 3/16” tubes
Mount bracket
Strap mounts
5/16” bolts and nuts
C-clamps
5/16” nuts and flat washer
3/4” fitting
1/2” fitting
Mounting cable
FRAM
E
Figure 3.1
3.1 Assembling and Installing the Brackets
□Place the tank on a work bench with the front (oil filter end) of the
tank to your left and remove the oil filter.
□Remove the two 1/4 inch clamp bolts from the C-clamps. Expand
the clamps slightly and slide them over the front of the tank.
□Position the front clamp right behind the weld on the filter end of
the tank and the rear clamp approximately 18 inches from the
weld.
□Place the two L-shaped tank strap mounts under the C-clamps
with the right-angle ends facing you and hanging over the edge
of the work bench.

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□Apply Loctite and insert 5/16 inch bolts with flat washers into the
bottom hole on each bracket, install the nuts but do not tighten.
□Install the 1/4 inch clamp bolts into the C-clamps so that the
heads of the bolts face toward you, apply Loctite and install the
nuts but do not tighten.
□Rotate the tank so that the directional arrow on the end of the
tank is parallel to the work bench and faces toward you.
□Install a 3/4 inch fitting (not supplied) in the back of the tank.
□Apply Loctite and insert 5/16 inch bolts through the C-clamps
and the mount brackets, install the nuts but do not tighten.
□Check tank alignment then tighten the C-clamp bolts.
□Slide the tank all the way up on the tank mount brackets (away
from you) and tighten the mounting bolts.
Figure 3.2

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3.2 Installing the Tank Assembly
□Insert the threaded ends of the mounting cable through a hole on
each tank strap flat bar. Route the cables over the top of the
frame so that the flat bars are on the inside of the frame.
□Support the tank body in position against the frame rail with the
tank strap mounts on the outside of the frame rail and the short
arms over the top of the frame.
□Route the cable through the cable guide slot at the top of the
tank strap mount, through the guide slot at the bottom of the tank
strap mount and through the bottom hole in the flat bar (Figure
3.1).
□Install a 3/8 inch nut and washer on each cable, adjust the tank
for best fit between the cab mounts and tighten the nuts. Install
and tighten a second 3/8 inch nut on each cable as a lock.

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Part 4: Installing the Cooler and
Compressor
4.1 Installing the Oil Cooler
□Remove OEM hose clamps from OEM lower radiator hose. Cut 2
sections out of hose as seen in Figure 3.1.
Figure 4.1
□Install cooler in engine bay on the passenger side beside engine.
Tab on cooler will be bolted to the top of the body lift tab above
passenger side frame. The cooler tab faces forward with oil ports
facing up (Figure 4.2).

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Figure 4.2
□Attach short elbow from OEM hose to the radiator and front
spigot of cooler. Attach long section from OEM hose to engine
and rear spigot of cooler (Figure 4.2).
□Install supplied bolt through cooler with washer and nut on
bottom side of the body lift tab. Secure hoses with supplied hose
clamps and tighten bolt to specifications.
□Connect the supplied 3/4 inch heater hose to the fitting on the oil
cooler, route it up the passenger side of the engine and connect
it to the 3/4 inch hose barb in the cylinder head. Make sure that
it does not contact any sharp surfaces or interfere with any belts
or moving components by securing with nylon ties and supplied
hose clamps.
□Disconnect the small rubber hose on the upper passenger side
of the primary radiator. Fill the coolant system at the reservoir
tank, using the disconnected hose as an air bleed. Once coolant
is seen coming out of the hose and/or port on the radiator, re-
connect the hose and finish filling the reservoir to the marked
level.
TO TANK
TO COMPRESSOR

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□Once the air is purged from the system, install the OEM plug
(from the cylinder head) in the top of the tee fitting installed
during section 2.1 (using thread sealant).
4.2 Installing the Main Bracket and Compressor
□Remove the belt tensioner assembly and the two idlers from the
VR main bracket.
□Position the main bracket on the passenger side front of the
engine cylinder head with the idler stubs facing forward and align
holes on passenger side of the bracket with the holes from the
engine lifting lug and the upper alternator mount. Make sure that
the wire harness is clear of the bracket.
□Apply Loctite and install (Figure 4.3):
one M8 x 30 mm hex head bolt with flat washer into the top
right passenger side hole in the main bracket
three M10 x 35 mm hex head bolts with washers in the top
back hole and the two bottom holes on the passenger side of
the bracket
one M8 x 25 mm socket head bolt into the lower hole on the
front of the bracket
□Snug all fasteners down equally then torque to specification.
□Place the compressor on the bracket and fit the two studs into
the engine side holes on the main bracket. Install nuts with
captive serrated lock washers to each stud and hand tighten.
□Apply Loctite and install the M8 x 30 mm hex head bolt with flat
washer through the bracket and into the front passenger side
hole on the compressor. Torque the fasteners to specifications.

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M10 x 35 mm
M10 x 35 mm
M8 x 30 mm
M8 x 25 mm
M8 x 30 mm
Main bracket
Figure 4.3
4.3 Connecting the Hoses
□Connect the 45 degree end of the 3/4 inch hose to the top front
tank fitting, route it along the frame rail and up the passenger
side of the engine and connect it to the matching fitting on the
back of the compressor.
□Connect the straight end of the longest 1/2 inch hose to the
matching fitting on the tank. Route the hose along the passenger
side frame rail and attach the 90 degree fitting to the passenger
side fitting on the top of the cooler.
□Connect the straight end of the remaining 1/2 inch oil hose to the
90 degree fitting on the driver side of the compressor, route it
behind the compressor and down the passenger side of the
engine. Attach the 45 degree fitting to the driver side oil fitting on
the top of the cooler.
□Insert the 1/4 and 3/16 inch tubes into the fittings on the back of
the tank and cover them with high temperature loom. Route the
tubes through the frame up to the compressor and connect them
to the matching fittings on the compressor inlet valve.

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4.4 Completing the Installation
□Install the alternator to the VR main bracket using the OEM
fasteners and torque to specifications.
□Install the OEM belt (Figure 4.4).
Figure 4.4
□Apply Loctite and install the VR tensioner, smooth idler and the
ribbed idler. Ensure the ribbed idler is installed with the narrow
shoulder towards the bracket. Torque all fasteners to
specifications.
□Install the VR belt (Figure 4.5).
Figure 4.5
□Install the fan spacer.

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□Remove the OEM screws holding the fan to the hub and replace
it with the supplied replacement fan, fastening it in place with the
5/16 x 5/8 inch button-head screws.
□Install the replacement passenger side upper fan shroud
mounting bracket to the compressor mounting bracket. Attach it
by fitting the M8 x 30 mm socket head bolt through the shroud
mounting bracket, the top front hole of the compressor mounting
bracket and into the engine (Figure 4.3) and with the M8 x 16
mm socket head bolt threaded into the compressor mounting
bracket.
□Place the supplied template on the fan shroud and align it with
the front edge. Mark and cut the area on the passenger side for
fan clearance.
□Cut a 2 x 1 inch rectangular hole under the original location on
the driver’s side of the shroud for the fan wire harness.
□Pry open the steel locking tab in the bottom part of the steel
sheath, pull out some of the harness and reroute it to the other
side of the sheath, above the locator tab.
□Lay the supplied replacement fan in the centre of the shroud and
pass the fan wire harness and steel sheath through the new hole
in the shroud (Figure 4.5 - viewed from the front).

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Figure 4.6
□Lower the replacement fan and shroud in front of the engine.
Thread the fan onto the spacer and tighten; then position the
shroud.
□Install the replacement fan harness attachment bracket on the
back of the lower driver side OEM fan shroud bracket. The
spacer on the attachment bracket should face forward and sit
below the locator (Figure 4.7). Use the OEM fastener.