Vmac VR70 User manual

System V900095
1999 - 2002 GMC/Chevrolet CK2500, CK3500HD
Seirra and Silverado 6.0L Gas
www.vmacair.com
VR70 UNDERHOOD
AIR COMPRESSOR
INSTALLATION MANUAL

VMAC – Truck Mounted Air Compressors
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Installation Manual for VMAC
System V900095
GMC/Chevrolet 1999 – 2002 6.0L
Sierra and Silverado CK2500 and CK3500HD
General Information..................................................................... 3
Before You Start ....................................................................... 3
Additional Requirements .......................................................... 4
Part 1: Preparing for Installation................................................ 5
1.1 Preparing for Installation .................................................... 5
Part 2: Installing the Control Components ............................... 9
2.1 Installing the Control Box ................................................... 9
2.2 Connecting the Wiring ........................................................ 11
Part 3: Installing the Tank and Hoses........................................ 13
3.1 Installing the Tank and Brackets ........................................ 13
3.2 Installing the Tank Assembly.............................................. 16
Part 4: Installing the Cooler, Bracket and Compressor........... 18
4.1 Installing the Crank Pulley.................................................. 18
4.2 Installing the Oil Cooler ...................................................... 18
4.3 Installing the Main Bracket and Compressor ..................... 20
4.4 Connecting the Hoses ........................................................ 23
4.5 Completing the Installation ................................................. 24
4.6 Adding Oil to the System.................................................... 26
4.7 Installing the Pneumatic Throttle ........................................ 26
Part 5: Finishing the Installation................................................ 31
5.1 Safety Test ......................................................................... 32
5.2 Before Starting the Engine Checklist ................................. 32
5.3 After Starting the Engine Checklist..................................... 33
5.4 Setup, Performance Testing and Adjustments................... 33
5.5 System Identification and Warnings................................... 34
5.6 Auxiliary Air Receiver ......................................................... 36
Accessory Products from VMAC............................................... 37

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Installation Manual - Document #1930125
Installation Manual for VMAC System V900095
GMC/Chevrolet 1999 - 2002, 6.0L SIERRA and SILVERADO
CK2500 and CK3500HD
Changes and Revisions
Version Revision Details Revised by/date Approved by/date Implemented
00 Original manual IB 14 July 2006 SC 14 July 2006 17 July 2006
a ECN 06-184 Sequence chg IB 22 Aug 2006 TG 24 Aug 2006 28 Auug 2006
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 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.
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 2006
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 Coding
Different frame designations will affect the tank mounting position.
You may have to move the tank rearward from the standard position
on your application. If you must move the tank, the lines may be too
short. If this is the case, measure the hose shortfall and order a
Hose Extender Kit. The following table shows the color code used
by VMAC to define the different hose diameters.
Hose Diameter Colour-Coded Label
1/4 inch
5/16 inch
1/2 inch
5/8 inch
3/4 inch
1 inch
Yellow
Orange
Blue
Blue
Green
Green

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Additional Requirements
Accessory Packs
Trucks with a 5.3L engine will require accessory pack # A700042.
This accessory pack contains the correct radiator hose and
instructions for the lower radiator-to-cooler connection.
Special Tools
OEM flywheel locking tool part number J42386.

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Part 1: Preparing for Installation
1.1 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.
□Remove the plastic cover from the top center of the engine.
□If the truck has an automatic transmission, locate the wiring
harness that runs up from the transmission and over the center
of the engine intake manifold, through the trough on the driver’s
side of the intake (Figure 1.1). Remove the harness from the
protective loom, cut the tape open and locate the light green
wires in the bundle.
Locate light green wire
in this harness
Figure 1.1
There are two light green wires in the bundle. Only one
of the wires can be used for system control.

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□Turn on the ignition switch and probe the green wires.
□The correct wire will show 12 Volts in PARK and 0 Volts in all
other gear selector positions.
□Turn the ignition switch off. Mark the wire for electrical
connections later in the installation process.
□Disconnect the battery terminals and remove the battery.
□Remove the battery mounting plate.
□Remove the air intake tube and resonator box.
□Drain the coolant.
□Remove the radiator end of the top OEM radiator hose, unclip it
from the fan shroud and move it out of the way.
□Remove the upper radiator fan shroud.
□Remove the fan assembly and the lower radiator fan shroud.
□Remove the engine end of the lower radiator hose.
□Remove the OEM belt
□Mark the position of the power steering pump pulley in relation to
the pump shaft and remove the pulley with a recommended
puller.
□Remove the power steering pump. Remove the support bracket
from the back of the power steering pump and bend the tab that
attaches to the side of the engine block upwards about 5
degrees to align with the compressor bracket. Install the modified
bracket onto the power steering pump.
□Remove the bracket holding the large, red battery cable splitter
box from the alternator and power steering pump bracket. Keep
the two M6 OEM cap screws.

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□Unclip the large wiring harness from the driver side valve cover
and the small wiring harness attached to the red battery cable
splitter box bracket.
□Disconnect the wiring and remove the alternator.
□Remove the OEM aluminum alternator and power steering pump
mounting bracket.
□Remove the OEM back idler from the bracket.
□Clean the inside of the OEM crankshaft pulley and remove the
OEM crankshaft pulley center bolt.
□Clean the driver side of the engine. Check all threaded holes to
make sure that they are clean and free from damage.
□Remove the driver side fender liner.
□Remove the Power Train Control Module (PCM) from the driver
side fender (do not disconnect the wiring) and place the module
out of the way.
□Bend the PCM locating tab on the fender down so that it is flush
with the surface (Figure 1.2).
Figure 1.2

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□Remove both OEM fasteners from the fender support bracket on
the passenger side of the truck (Figure 1.3). On four-wheel drive
trucks, remove the hex head bolt on the bottom of the frame that
holds the tow hook in place. Some trucks may have a hole in the
frame where the tow hook would be attached.
□Replace the inner fastener with the supplied low profile M10 x 30
mm hex head bolt without a flat washer, as the high profile head
on the OEM bolt will interfere with the cooler bracket.
Remove these bolts
Front of truck
Passengersidefender
Figure 1.3
□Clean the frame on the passenger side of the truck between the
two body mounts. If equipped, remove the fuel line from the
plastic clips so that it can be moved out of the way when
mounting the tank.
□If equipped, remove the OEM wire harness securing bracket
from the top of the frame so that it can be moved out of the way
when mounting the tank.

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Part 2: Installing the Control
Components
2.1 Installing the Control Box
□Locate a suitable location for the control box where it will be
accessible but will not be subject to damage. Recommended
locations include the side panel just behind the door opening or
under the dash (Figure 2.1).
Driver seat
Sidepane
l
Underthedash
Figure 2.1
□Tighten the two side brackets on the control box and position it in
the selected mounting location. Mark the position of the
mounting holes and drill two 7/64 inch holes for the brackets.
□Mount the control box with the wire harness coming out the
bottom or the back of the unit. If the control box is mounted to
the body panel, remove the plastic door trim and route the wiring
along the body panel under the trim and up under the dash.
□Remove the center panel from under the steering wheel and
mount the switching box under the dash using plastic ties. Make
sure that it does not interfere with other parts.

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Green 7 pin connector
Control Box
Switching
Box
White
Interface
Connector
Green 4 pin
connector
White Red
Red Red
White
Compressor
Clutch
Green
Black
OEM FUSE PANEL
To ground
Solder to light green
wire in vehicle harness
from transmission
Blue
Throttle Control
Black
Black
Black
DDC
AUTO TRANS
Park brake
switch
AUTO TRANS
MAN. TRANS
OR

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2.2 Connecting the Wiring
□Connect the green 7 pin connector between the control box and
the switching box.
□Connect the interface cable to the matching connector from the
switching box.
□Route the wire with the green 4 pin connector, the red wire
without the fuse holder and the white wire with the bullet
connector through a suitable opening in the firewall. If
necessary, cut a small slit in an OEM rubber boot.
□Connect the green wire with the ring connector to a good ground
under the dash.
2.2.1 Manual Transmission Trucks
□Unplug the connector from the park brake switch. You may have
to remove the cover from the large OEM electrical connector
located on the firewall of the truck next to the park brake to gain
access to the connection.
□Connect the female spade connector with the piggyback
connector from the interface cable to the connector on the park
brake switch.
□Connect the OEM park brake connector to the piggyback
connector.
2.2.2 Automatic Transmission Trucks
□Install the Drive Disable Circuit (DDC) under the dash using
nylon ties.
□Connect the black wire from the DDC to the black wire from the
interface connector.
□Unplug the connector from the park brake switch. You may have
to remove the cover from the OEM electrical connector to gain
access to the connection.

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□Connect the female spade connector with the piggyback
connector from the interface cable to the connector on the park
brake switch.
□Connect the OEM park brake connector to the piggyback
connector.
□Route the blue wire into the engine compartment through the
same opening that you used for the other wires.
2.2.3 Completing the Automatic Transmission Wiring Connections
□Cut the light green wire (marked during preparation) and remove
about 1/2 inch of insulation from each end. Slide a shrink sleeve
over one end of the wire.
□Remove about 1 inch of insulation from the DDC blue wire.
□Join the wire and solder the joint using the supplied solder. Slide
the shrink sleeve over the joint and heat to seal the connection.
The preferred method is shown in Figure 2.2.
OEM wire
DDC wire
Shrink sleeve
Soldered joint
Figure 2.2
□Replace the tape on the bundle. Fit the loom back over the
harness and tape it in place.

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Part 3: Installing the Tank and
Hoses
3.1 Installing the Tank and Brackets
The tank will mount to the passenger side frame rail
between the two body mounts (Figure 3.1).
1/4” line
5/16” line
3/4” hose fitting
1/2” hose fitting
C-clamp
Tank strap mount
Tank strap cable
Tube clamp
Oil filter
5/16” nuts and
washer
Tank strap flat bar
Figure 3.1
□Place the tank on a work bench with the front (oil filter end) of the
tank to your left. Remove the oil filter from the front of the tank.
□Remove the two 1/4 inch pinch bolts from the C-clamps. Expand
the clamps slightly and slide them over the front of the tank.
□Position the C-clamps about 6 inches from each end of the tank.

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□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.
□Align the holes, 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 pinch bolts into the C-clamps so that the
heads of the bolts face toward you and install the nuts.
□Rotate the tank so that the directional arrow on the end of the
tank is parallel to the work bench and faces toward you (Figure
3.2).
□Check the distance of each C-clamp from the ends of the tank
and tighten the pinch bolts so that the clamps grip the tank
securely.
Figure 3.2
□Thread the 1/4 and 5/16 inch fittings on the steel lines to the
matching fittings on the back end of the tank, but do not tighten
the fittings. Route the lines along the top of the tank across the
two C-clamps.
□Place the two insulated tube clips over the steel lines with the
mounting holes upward and align them with the top C-clamp
mounting holes (Figure 3.3).

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□Apply Loctite and insert 5/16 x 1/2 inch bolts through the clips
and the C-clamp and thread them into the mount brackets.
□Center the bolts in the C-clamp slots and tighten them.
Tank strap mount
5/16" tub
e
1/4" tube
Insulated double tube clamp
5/16" x 1/2" bolt
Figure 3.3
□Apply Loctite pipe thread sealant and install a fitting to the outlet
on the tank. A 90 degree fitting is recommended. Tighten it to
about the four o’clock position for testing, then reposition as
required for final connections (Figure 3.4).
Figure 3.4

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3.2 Installing the Tank Assembly
□Insert the threaded end of the cable straps through the single
hole end of the bar straps.
□Place the bar straps in position on the inside of the frame, one in
front of the transmission cross-member and one behind, with the
cable straps over the top of the frame (Figure 3.5).
Cable must fit
in the grooves
Figure 3.5
□Lift the tank assembly and support it in position so the tops of the
two tank strap mounts fit over the top of the frame rail.
Make sure that the OEM wire harness is outside the
mounts and is not pinched between the mounts and the
frame.
□Wrap the two tank cable straps around the tank strap mounts.
Make sure that they fit in the upper and lower cut-outs of the tank
strap mounts (Figure 3.4).
Make sure that the cable straps are behind the two steel
lines and the OEM wire harness and that there are no
lines or wires pinched between the cable and the mount.
!
!

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□Insert the threaded end of the cable through the one of the lower
holes on the tank strap flat bars. Select the appropriate holes
that best match the frame of the truck.
□Place a thick 5/16 flat washer and nut on each tank cable strap
and tighten just enough to hold the tank in place but loose
enough to allow the tank to be positioned along the frame.
□Slide the tank rearward on the frame to provide clearance for
attaching the hoses.
□Route the 45 degree end of the 1 inch hose and the straight end
of the shortest 1/2 inch hose from the engine compartment over
the body mount to the tank.
□Connect the 1 inch hose to the matching fitting on the tank.
Angle the fitting upwards to allow the hose to easily pass over
the body mount and to allow the level sight-glass cover sufficient
room to lift; then tighten the fitting.
□Connect the 1/2 inch hose to the front of the tank. Adjust the
position of the hose so that it clears the filter and allows access
to the sight glass cover; then tighten the connections.
□Slide the tank forward, providing sufficient space for connections
to the fitting on the rear of the tank and enough room to easily
change the oil filter.
□Tighten the nuts on the cable straps until the tank and the bar
straps are tight against the frame and the tank is secure.
□Thread a second nut on each cable clamp and lock the two nuts
together using two wrenches.

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Part 4: Installing the Cooler,
Bracket and Compressor
4.1 Installing the Crank Pulley
□Place the VR crankshaft pulley in position over the OEM pulley.
Make sure that it fits flat against the OEM pulley and install the
M16 x 170mm replacement crankshaft bolt with the large spacer.
□Rotate the VR crankshaft pulley counterclockwise until the lugs
on the back of the pulley are tight against the OEM pulley lugs
and tighten the crankshaft pulley bolt sufficiently to hold the
pulley in position
Do not use an impact tool to tighten the pulley bolt.
□Remove the starter motor and install the OEM flywheel locking
tool.
□Pre-torque the crankshaft bolt to 37 ft-lbs (50 N.m) then final-
torque the bolt 140 degrees using the reference marks that are
machined into the front of the VR crankshaft pulley.
□Remove the OEM flywheel locking tool and install the starter
motor.
4.2 Installing the Oil Cooler
The oil cooler (Figure 4.1) is installed on the passenger
side of the truck, just below the corner of the radiator,
with the oil fittings facing to the passenger side.
□If you did not remove a bolt from the bottom of the frame, insert
the supplied M12 x 30 mm hex head bolt through the hole in the
frame from the inside of the frame so that the threads point
downward through the hole.
!