Vmac VR70 User manual

System V900083
2005 - 2006 Ford E-250 - E-350
5.4L Triton V8 Gas
www.vmacair.com
VR70 UNDERHOOD
AIR COMPRESSOR
INSTALLATION MANUAL

VMAC – Vehicle Mounted Air Compressors
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Installation Manual for VMAC
System V900083
Ford 2005-2006 Triton 5.4L V8
E250-E350 Van
General Information..................................................................... 3
Before You Start....................................................................... 3
Part 1: Preparing for Installation............................................... 4
1.1 Preparing for Installation .................................................... 4
Part 2: Installing the Tank.......................................................... 7
2.1 Assembling the Brackets and Tank.................................... 7
2.2 Installing the Tank Assembly.............................................. 9
Part 3: Installing the Cooler, Bracket and Compressor.......... 11
3.1 Installing the Oil Cooler ...................................................... 11
3.2 Installing the Main Bracket and Compressor ..................... 12
3.3 Connecting the Hoses........................................................ 14
3.4 Completing the Installation................................................. 15
3.5 Adding Oil to the System.................................................... 16
Part 4: Installing the Control Components .............................. 17
4.1 Installing the Components.................................................. 18
4.2 Connecting the Under-hood Wiring.................................... 21
4.3 Connecting the In-cab Wiring............................................. 23
4.4 Completing and Testing the Installation ............................. 24
Part 5: Finishing the Installation................................................ 25
5.1 Before Starting the Engine Checklist ................................. 25
5.2 After Starting the Engine Checklist..................................... 25
5.3 Setup, Performance Testing and Adjustments................... 26
5.4 System Identification and Warnings................................... 27
5.5 Auxiliary Air Receiver ......................................................... 28
Accessory Products from VMAC............................................... 29

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2
Document 1930078
Installation Manual for VMAC System V900083
Ford 2005-2006 Triton 5.4L V8
E250-E350 Van
Changes and Revisions
Version Revision Details Revised by/date Approved Implemented
00 Original document IB 14 Dec 2004 BC 22 Dec 2004 Jan 14 2005
A Model year confirmation IB 10 Apr 2006 SM 10 Apr 2006 Apr 14 2006
B ECN 07-145 IB 05 Nov 2007 SH 23 Nov 2007 26 Nov 2007
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
vans must follow standard shop practices.
These instructions are a general guide for installing this system on
standard production vans and do not contain information for
installation on non-standard vans. 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 2007
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

VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: [phone]
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 van.
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 Coding
Different frame designations will affect the tank mounting position. If
you have to move the tank, the lines may be too short. Measure the
hose shortfall and order a Hose Extender Kit. The following table
shows the color code used by VMAC to identify hose diameters.
Hose Diameter Colour-Coded Label
1/2 inch
5/8 inch
3/4 inch
1 inch
Blue
Blue
Green
Green

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4
Part 1: 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.
1.1 Preparing for Installation
□Remove the inside engine cover.
□Remove the plastic air intake connector and air filter assembly.
□Disconnect the battery.
□Remove all plastic shields from under the engine.
□Drain the coolant.
□Remove the upper radiator hose and lower radiator hose from
between the radiator and diverter (leave the diverter in place).
Keep the lower radiator hose section if you intend to return the
van to OEM condition.
□Remove the fan and the fan shroud together.
□Remove the OEM drive belt from the alternator pulley but leave
the belt in position on the engine.
□Remove the alternator and move it over to the driver’s side of the
engine.
□Replace the existing M6 bolt that secures the front right-hand
fuel rail to the intake with the supplied M6 x 20mm flat head
socket bolt (Figure 1.1).
□Remove the electrical noise suppressor from the front passenger
side cylinder head and remove the studded bolt.

Low profile bolt
Figure 1.1
□Remove the engine-to-drip rail ground strap connection from the
engine.
□Remove the bolts holding the plastic wire harness retainer to the
drip rail so that the harness can be moved out of the way during
installation.
□Remove the oil fill tube and plug the opening on the valve cover.
□Remove the bolt holding the automatic transmission dipstick tube
bracket to the intake manifold and bend the bracket up toward
the center of the engine about 90 degrees.
□Disconnect the electrical harness from the sensor on the
passenger side fuel rail and move it out of the way.
□Remove the vent hose from the passenger side valve cover and
move it out of the way.
□Remove the 3/4 inch heater hose and the small hose from the
front right spigot on the intake manifold.
□Remove the heater hose barb from the manifold intake. Keep the
fitting if you intend to return the vehicle to OEM condition.
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□Apply sealant to the supplied 90 degree hose barb and press it
into the heater hose coolant port (Figure 1.2). Make sure it is
pressed all the way in to the shoulder on the fitting.
90 degree hose barb
Intake Manifold
Figure 1.2
□Connect the small coolant hose to the fitting on the hose barb.
□Loosen the small bolt holding the slotted air conditioning line
mount bracket to the heater box, move it all the way to the
passenger side and tighten the bolt.
□Carefully push the vertical part of the air conditioning lines
toward the passenger side of the van to provide clearance for the
oil fill tube.
□Remove the bolts holding the sway-bar bushings on the frame
and install the supplied spacer blocks and hex head bolts.
Torque to specifications.
□Clean the inside of the OEM pulley and install the VR pulley,
making sure that the pulley is sitting flush. Apply Loctite, install
three M10 x 70mm bolts and flat washers and torque to
specifications.
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6

Part 2: Installing the Tank
2.1 Assembling the Brackets and Tank
The tank (Figure 2.1) will mount to the passenger side frame rail
behind the body mount (under the side doors). Note that the upper
frame clip is different for the E250 and E350.
1/4” and 3/16” tubes
3/4” hose fitting
1/2” hose fitting
C-clamp
Tank strap mount
Upper frame clip
Tank strap cable
Lower frame clip
Spacer
Oil filter
5/16” nuts and
washer
Figure 2.1
□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 approximately 4 inches from the filter
end of the tank and the rear clamp approximately 4 inches from
the back of the tank.
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8
□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.
□Apply Loctite and thread 5/16 x 1/2 inch bolts with flat washers
into the bottom hole on each bracket, 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.
□Apply Loctite and insert 5/16 x 1/2 inch bolts through the C-
clamp and thread them into the mount brackets, but do not
tighten.
□Install a 3/4 inch fitting (not supplied) in the back of the tank.
□Check tank alignment then tighten the C-clamp bolts.
□Slide the tank all the way down on the tank mount brackets
(away from you) and tighten the mounting bolts.

3/16” tube
1/4” tube
Figure 2.2
2.2 Installing the Tank Assembly
□Insert the cable straps through the tubes of the upper frame
clips. Note that the E250 and E350 use different upper clips.
□Pass the cable strap upper frame clips over the passenger side
frame from the outside. Position the front strap about 16 inches
back from the body mount and the second frame clip and cable
strap approximately where the back tank mount will locate.
□Support the tank and L-bracket assembly in place on the outside
of the frame between the cab mounts, with the short part of the
L-bracket over the top of the frame.
□Route the cable straps through the grooves on the tank mount
brackets, behind the steel lines and under the frame (Figure 2.3).
Adjust the rear strap as necessary to line up with the tank mount
bracket.
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□Install the spacers and tighten the nuts just enough to hold the
tank in position with the front of the tank about 12 inches back
from the body mount.
Cable must fit
in the grooves
Tanknotshownforclarity
E250 E350
Figure 2.3
□When the tank is correctly positioned, tighten the securing cable
retaining nuts until the cables pull tight and snug around the
frame. Do not over-tighten.
□Install a second 5/16 inch nut and tighten it securely against the
first to act as a locknut.
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Part 3: Installing the Cooler,
Bracket and Compressor
3.1 Installing the Oil Cooler
□Insert the supplied cooler mounting bolts through the holes in the
front body support brackets under the radiator.
□Place the cooler in position over the bolts, with the hoses and oil
fittings facing to the rear of the van (Figure 3.1). Install the nylon
locking nuts and tighten them securely.
□Loosen the hose clamps on the cooler end of the radiator hoses
so that they can be adjusted and positioned.
□Install the end of the driver side hose onto the OEM diverter
valve (lubricate the fitting or the hose to make installation easier).
Position the hose for best fit and tighten the clamps.
□Install the passenger side hose on the radiator fitting, position
the hose for best fit and tighten the clamps.
Cooler to diverter hose
Cooler to radiator hose Radiator
support
bracket
Radiator
support
bracket
Figure 3.1
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3.2 Installing the Main Bracket and Compressor
□Remove the idler and tensioner pulleys from the main bracket
(Figure 3.2). Do not remove the tensioner body.
Main bracket
Idler
Back idler
Tensioner
Tensioner idler
Figure 3.2
□Place the bracket in position on the passenger side of the
engine. Apply Loctite, insert two M10 x 25 mm socket head bolts
through the bracket and down into the engine block holes under
the alternator, but do not tighten.
□Apply Loctite, insert the M10 x 100 mm socket head bolt through
the main bracket and thread it into the upper front hole on the
right side cylinder head, but do not tighten.
□Apply Loctite, insert the M8 hex head bolt (with the 5/16 flat
washer) through the lower front of the bracket and thread it into
the timing cover next to the OEM belt tensioner, but do not
tighten.
□Check all OEM wiring harnesses to make sure that they are not
trapped by the bracket and are clear of the mounting points.
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□Position the bracket securely against the engine and lightly snug
down all the fasteners.
□Tighten the two M10 x 25 mm socket head bolts, then the M10 x
100 mm socket head bolt and finally the M8 hex bolt, then torque
to specifications in the same sequence.
□Install the alternator and the OEM belt. Relocate the electrical
noise suppressor and the ground strap from the body to one of
the rear alternator bracket mount bolts.
□Lift the cross-body electrical harness out of the way and place
the compressor in position on the mounting bracket. Make sure
that no wires are trapped by the compressor.
□Apply Loctite, thread the three M8 double-serrated nuts onto the
compressor mounting studs and tighten.
□Apply Loctite and install the VR pulleys.
□Install the VR drive belt (Figure 3.3).
Back Idler
Compressor
Tensioner
Ribbed Idler
Crank
Pulley
Figure 3.3
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3.3 Connecting the Hoses
□Route the end of the 3/4 inch hose with the straight connector up
from under the van into the engine compartment and connect it
to the 90 degree fitting on the back of the compressor, but do not
tighten. Route the hose along the top of the frame to the tank
and connect it to the matching fitting on the tank. Tighten both
ends.
□Connect the straight end of the longest 1/2 hose to the fitting on
the tank, but do not tighten. Route the end with the 90 degree
fitting along the top of the frame and attach it to the passenger
side fitting on the oil cooler. Tighten both ends.
□Connect the 90 degree end of the shorter 1/2 inch hose to the
driver’s side fitting on the cooler. Route the hose across the front
of the van and up to the fitting in the left side of the compressor.
Tighten both ends.
□Insert the ¼ and 3/16 inch tubes into the fittings on the back of
the tank and install high temperature loom around tubes. Route
the tubes up and over the frame, over the side of the engine
(clear of the exhaust manifold) and out the front. Connect them
to the matching fittings on the inlet control valve.
□Secure all hoses away from sharp or hot surfaces and protect
them at contact points with plastic split loom. Tie-wrap the hoses
together and securely fasten them to the chassis and body.
□Fit the supplied P-clip over the 1/4 and 3/16 inch tubes and
secure it to the threaded hole in the back of the passenger side
cylinder head with the 10 x 20 mm bolt. Bend the P-clip as
necessary to clear the engine cover.
□Install the fuel rail sensor connector and the vent tube.

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3.4 Completing the Installation
□Reposition the wiring harnesses near the compressor so they
are above the transmission dipstick tube. Fasten the two plastic
wiring connectors away from the compressor and behind the air
conditioning tubes with nylon ties. Make sure that no wires or
harnesses are touching the body of the compressor. Fasten
them out of the way as required.
□Install the bolts holding the OEM wire harness trough to the rain
gutter on the body. Install the supplied transmission dipstick tube
bracket between the body and harness trough above the dipstick
tube and tighten all the bolts. Secure the dipstick tube to the
bracket with the supplied clamp.
□Wrap heat protector around the oil fill tube and secure it with
nylon ties. Remove the valve cover plug, fit the fill tube back onto
the valve cover, release the clamp and bolt the hanger back into
the original position. Tie the tube to the air conditioning lines to
provide clearance from the compressor body.
□Fit the VR oil fill tube under the wire harness, over the engine oil
fill and transmission dipstick tubes and attach it to the top of the
compressor. Position it as required and tighten the fitting.
□Install the 3 inch piece of heater hose to the hose barb on the
intake manifold and to one end of the supplied 90 degree plastic
fitting, with the long end of the plastic fitting pointing upward.
Route the 3/4 heater hose over the compressor and connect it to
the 90 degree fitting. Position the hose and fittings to provide
clearance and tighten the clamps.
□Install the fan and shroud together. Clip the lower hoses back
onto the driver side of the shroud. Install the upper radiator hose
and fill the cooling system with the recommended coolant.
□Replace the shrouds under the engine, install the air cleaner
assembly and replace any other OEM parts removed in
preparation for installation.

Manifold fitting
3” hose with clamps
OEM hose
Plastic barb
Figure 3.4
3.5 Adding Oil to the System
You must use the VMAC supplied and approved
compressor oil in this system. Failure to use this
special oil will result in damage to the compressor and
will void your warranty.
!
□Remove the plug from the fill tube and slowly pour oil into the
inlet control valve using a funnel. Turn the center of the
compressor clutch clockwise to speed the fill process.
□Allow 5 minutes for the oil to drain into the tank, then check the
level at the sight glass at the front of the tank. Continue adding
oil until the level is correct.
□Install the fill plug in the inlet control valve and tighten it
securely.
Do not overfill the system. Overfilling the system with
oil can flood the sight glass window and make the
system appear empty.
!
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16

Part 4: Installing the Control
Components
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White
Interface
Connector
Throttle
Controller
Green 4 pin
connector
White
White
Red
Red
Red
Red
Red
White
White
Compressor
Inlet valve
Clutch
Green
Black
Black
Connect to accelerator pedal
OEM Connector from
accelerator pedal
Black 3 pin connector
To ground
To ground
Connect
Connect to
OEM orange wire
switched 12 volts
Connect to
OEM white with pink stripe
CTO circuit 0648
Connect to
green/red stripe
wire at the park
brake switch
DDC
FIREWALL
FIREWALL
Control Box

4.1 Installing the Components
□Remove the driver-side step liner, the kick panel behind the park
brake pedal and the dash trim panel from under the steering
wheel.
□Remove the screws holding the data-link connector to the dash.
□Remove the six screws holding the under-dash cross-brace in
place and remove the cross-brace.
□Mount the control box in a convenient location in the cab,
positioned so that the wire harness will reach the air compressor.
□Route the wire harness along the trough in the bottom of the step
well, behind the park brake and up under the dash. Use tape to
hold the wires in position. Replace the step liner and the kick
panel.
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rts.
Keep wires away from the park brake mechanism.
Route wires clear of the steering column and pedals so
they do not contact moving pa
□Tie-wrap the throttle control box to a suitable location under the
dash, away from moving parts and heat duct openings.
□Apply the park brake and shift the transmission into the lowest
forward gear.
□Apply Loctite to the set-screw and mount the magnetic actuator
to the transmission arm under the dash (Figure 4.1).
Do not pinch or damage the orange shift indicator wire
during installation.
!