Vmac VR70 User manual

System V900082
2005 - 2007 Ford F-250 - F-550
Triton 5.4L 3 Valve 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 V900082
Ford 2005 - 2007
Triton 5.4 L 3-valve F250-F550
General Information..................................................................... 3
Before You Start....................................................................... 3
Part 1: Preparing for Installation............................................... 4
1.1 Preparing for Installation .................................................... 4
Part 2: Installing the Tank and Hoses....................................... 6
2.1 Installing the Tank and Mount Brackets............................. 6
Part 3: Installing the Cooler, Bracket and Compressor.......... 9
3.1 Installing the Oil Cooler...................................................... 9
3.2 Installing the Main Bracket and Compressor ..................... 11
3.3 Installing Drive Belts and Components.............................. 12
3.4 Installing the Hoses............................................................ 13
3.5 Adding Oil to the System.................................................... 15
Part 4: Installing the Control Components .............................. 16
4.1 Installing the Components.................................................. 17
4.2 Connecting the In-cab Wiring............................................. 18
4.3 Connecting the Underhood Wiring..................................... 21
4.4 Completing and Testing the Installation............................. 21
Part 5: Finishing the Installation................................................ 23
5.1 Before Starting the Engine Checklist ................................. 23
5.2 After Starting the Engine Checklist..................................... 23
5.3 Setup, Performance Testing and Adjustments................... 24
5.4 System Identification and Warnings................................... 25
5.5 Auxiliary Air Receiver......................................................... 26
Accessory Products from VMAC ............................................... 27

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Document #1930075
Installation Manual for VMAC System V900082
Ford 2005 - 2007 5.4L Triton 3-valve F250-F550
Changes and Revisions
Version
Revision Details
Revised by/date
Approved
Implemented
00
Original manual
IB 22 Oct 2004
SC 26 Nov 2004
07 Dec 2004
a
Application change
IB 14 Dec 2004
SM 21 Jan 2005
21 Jan 2005
b
Update to 2006
IB 15 Sep 2005
SC 20 Sep 2005
23 Sep 2005
c
ECN 06-170
IB 02 Aug 2006
SM 02 Aug 2006
04 Aug 2006
d
ECN 06-145
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
vehicles 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 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

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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
vehicle. 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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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.
□Disconnect the battery.
□Drain the coolant.
□Remove the air box, the air cleaner and the trunking.
□Remove the 1 inch coolant expansion-fill bottle to engine hose,
disconnect the 5/16 inch hose from the radiator and remove the
expansion-fill bottle.
□Remove the upper radiator hose.
□Disconnect the lower radiator hose from the radiator.
□Remove the fan and the fan shroud together.
□Remove the OEM ground connector attached to one of the
studs, then remove and discard the three OEM M10 bolts with
the M8 studded ends from the driver’s side of the cylinder head.
□Remove the air cleaner support bracket attached to the driver
side of the engine. Discard the bracket but keep the nut.
□Remove the radiator hold-down brackets, raise the radiator just
enough to clear the locating pins and move it sideways so that it
sits above the mount bracket (optional).
□Remove the rubber protective flaps attached to the cross-
member under the radiator.

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□Protect the inside surface of the radiator with a piece of
cardboard.
□Unplug the cam position sensor connector on the front of the
driver’s side cylinder head, disconnect the harness from the
hold-downs and move it on top of the valve cover. The cam
sensor wire harness must be adjusted to prevent the harness
from hitting the belt. Open the protective loom at the connector
and pull out an additional 4 inches of wire from the main loom.
Do not damage the foil covering. Cover it with a piece of loom
and tape the junction securely.
□Reposition the group of brake lines from in front of the master
cylinder to behind the sensor on the bottom of the master
cylinder by carefully bending them out of the way. Move the
rubber vibration isolator as required so the lines do not touch.
□Clean the front of the engine on the driver’s side.
□Clean the center of the OEM crank pulley.

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Part 2: Installing the Tank and
Hoses
2.1 Installing the Tank and Mount Brackets
The tank (Figure 2.1) will mount to the passenger side frame rail
behind the front cab mount. The recommended location is about 1
inch back from the end of the cab floor stiffener, a rib with an
attached ground wire.
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.

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□Position the front clamp approximately 11 inches from the filter
end of the tank and the rear clamp approximately 12 inches from
the front clamp.
□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 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 suitable 3/4 inch fitting (not supplied) in the back of the
tank.
□Check tank alignment then tighten the C-clamp bolts and the
mounting bolts.
□Insert the cable straps through the tube of the upper frame clips.
□Fit the cables onto the tank strap mounts behind the steel lines,
with the cables in the grooves of the mounts and the clips above
the right-angle end of the tank strap (Figure 2.1).
□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.

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3/16” tube
1/4” tube
Figure 2.2
□Pass the upper frame clip between the frame rail and the body
and clip it onto the top of the frame. Insert the threaded end of
each cable strap through the tubes on the lower frame locating
U-clips. Install the spacers (if necessary for narrow frames) and
nuts and tighten just enough to hold the tank in position.
□Position the tank between the two cab mounts to provide
clearance for installing the lines and filter. Make sure that the
tank mounting system does not interfere with any transmission
components.
□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
□Apply Loctite, insert M10 x 90 mm bolts into the top of the two
mount brackets (Figure 3.1) and thread them into the holes in the
top of the cooler mounting bracket. Hand-tighten the bolts
leaving about a 1/4 inch gap between the bracket and the cooler
so that the brackets can be repositioned easily.
□Position the brackets so that they are horizontal (parallel with the
top of the cooler) and point to the passenger side of the truck.
Lift the cooler into position on the inside of the cross-member
under the radiator (slide it toward the passenger side) fit the
brackets over the cross-member and pivot them down so that
they align with the holes in the bottom of the cooler mounting
bracket.
□Insert M10 x 90 mm bolts through the bottom holes and thread
them into the mount bracket.
□Adjust the cooler so that the passenger side bracket is against
the power steering cooler bracket and tighten the mounting bolts
(Figure 3.2).
□Connect the OEM hose to the passenger side cooler spigot and
secure it with a hose clamp.
□Loosen the clamp on the other cooler hose, connect it to the
engine, adjust for best fit and secure it with clamps.
□Connect the 1/2 inch hose from the VR tank to the passenger
side fitting on the cooler.

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M10 x 90 mm bolts
with washers
Mount brackets
Cross-member
Cooler mount bracket
Figure 3.1
Toengine
Toradiator
Cross-member
1/2” hose to compressor 1/2” hose from tank
Figure 3.2

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3.2 Installing the Main Bracket and Compressor
Tensioner assembly
Back
idlers
Ribbed
idler
Support bracket
Engine timing cover
OEM belt
M16
M8x110
M8x110 without
flat washer
M10x35 M10x30
Figure 3.3
□Remove the idlers and the tensioner assembly from the bracket
(Figure 3.3).
□Place the support bracket on the bottom of the driver’s side
cylinder head, insert the M16 bolt through the tube part of the
bracket into the OEM hole in the cylinder head and hand tighten.
□Place the main bracket in position to locate the mounting points
on the engine and install the M8 x 110mm bolts where the OEM
studs were removed, just enough to hold it in position.
The top M8 bolt does not use a flat washer as it must fit
into a hole that is counter-sunk. The lower M8 bolts
require flat washers.
□Push the bracket against the engine, check to make sure it fits
properly and install the M10 x 35mm fastener with washer in the
lower mounting point lightly snug down all the fasteners.

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□Route the wiring harness from the valve cover behind the top
edge of the bracket so that it is not pinched between the bracket
and the engine when the bracket is tightened in position. Feed
the cam sensor wire through the hole in the bracket.
□Install the two M10 x 30 mm bolts with washers through the base
plate into the support bracket and snug them.
□Check the fit of the bracket on the engine and support bracket to
make sure that everything aligns properly, then torque all
fasteners to specifications.
□Place the compressor in position on the mounting bracket.
□Thread the three M8 double-serrated nuts onto the compressor
mounting studs and torque to specifications.
3.3 Installing Drive Belts and Components
□Install the VR crankshaft pulley onto the OEM pulley using three
M10 x 70 mm bolts with washers and torque to specifications.
□Install the tensioner assembly (including the locknut on the back
of the bracket) and idlers on the bracket and torque the fasteners
to specifications.
□Install the supplied fan spacer on the water pump pulley.
□Install the VR drive belt (Figure 3.4). Make sure that it is aligned
correctly and clears all components, including the cam position
sensor wire harness.
□Place the supplied mounting tie-strap around the cam position
sensor wire and fasten it to the front of the VR bracket with a #10
socket head screw.
□Install the replacement air cleaner support bracket to the two
driver’s side bolts on the upper alternator securing bracket but do
not tighten the bolts until the other air inlet components are
installed. Attach the OEM ground connection under the alternator
bracket so that it touches bare metal.

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Compressor
Crankshaft
Ribbed idler
Back idler
Back idler
Back idler
Tensioner
Figure 3.4
3.4 Installing the Hoses
□Route the straight end of the 3/4 inch and the longest 1/2 inch
hoses over the cab mount and thread them into the matching
fittings on the tank but do not tighten.
□Insert the 1/4 and 3/16 tubes into the fittings on the back of the
tank and cover them with high temperature loom. Route them
along with the other hoses over the cab mount outside the frame
into the engine compartment and across the rear of the engine.
□Route the 1/2 hose along the passenger side frame rail to the
underside of the radiator, clear of suspension pinch points.
□Route the 3/4 inch hose from the VR tank to the compressor and
connect the 45 degree end to the matching fitting.
□Connect the shortest 1/2 inch hose between the compressor and
the driver’s side of the cooler. (90O connection on the cooler)
□Route the 3/16 and 1/4 inch tubes up over the engine (clear of
the exhaust manifold) and connect them to the matching fittings
on the compressor air inlet control valve.
□Tighten all hose connections at the tank, cooler and compressor.
Prevent the hoses from twisting during tightening.

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□Bunch all hoses together, secure them with tie-straps and protect
them where they might rub. Make sure that they are clear of hot
exhaust parts or moving parts, including the steering column.
Secure the hoses to the firewall using 2 inch insulated P-clips
onto the 6 mm OEM studs using the supplied 6 mm nuts.
□Apply a light film of compressor oil to the filter gasket and install
the filter on the tank. Tighten the filter an additional 3/4-1 turn
after the gasket contacts the base.
□Measure 11 inches (around the bend) from the engine end of the
OEM coolant fill hose (with the large arrow on the hose) and cut
the hose at this point. Discard the 90 degree coolant bottle end
of the cut hose.
□Connect the hose to the engine spigot with the large arrow facing
the coolant bottle, not the engine spigot. Install the supplied
plastic hose connector in the open end of the hose and adjust
the position of the hose so that is flush with the rear support
racket and clear of all bolts and other objects.
□Install the coolant expansion tank.
□Connect the longend of the supplied hose to the bottom of the
coolant expansion tank so that the hose is snug against the front
of the coolant tank and runs down in front of the compressor
regulator. Connect it to the other end of the plastic fitting in the
cut OEM hose from the engine spigot. Adjust the hoses to
provide clearance and tighten the clamps. Protect the hose with
plastic loom if it will rub on any objects.
□Replace the OEM hose clamp on the engine end of the upper
radiator hose with the supplied clamp to provide clearance for
the air cleaner assembly support bracket. After installing the air
cleaner assembly, tighten the upper alternator bracket bolts that
hold the support bracket.
□Install all other OEM components.
□Fill the cooling system with the manufacturer recommended
coolant.

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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 fill plug from the air inlet control valve and pour oil
into the oil fill hole on the inlet control valve using a funnel. Turn
the compressor clutch clockwise with a ratchet and a 1/2 inch
socket using the hex head bolt at the centre of the compressor
clutch during 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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Part 4: Installing the Control
Components
Control Box White
Interface
Connector
Throttle
Controller
Throttle
Controller
Green 4 pin
connector
White
Red
Red
Red
White
White
Compressor
Inlet valve
Clutch
G
G
r
r
e
e
e
e
n
n
Black
Connect to accelerator pedal
OEM Connector from
accelerator pedal
Black 3 pin connector
To ground
To ground
Connect
Blue
Blue
Blue
Blue
Connect to OEM circuit 294 white wire with light blue stripe key switched 12 volts
Connect to green wire with red stripe at the park brake switch
Connect to OEM circuit 76 light green wire with white stripe clean tach out
AUTOMATIC TRANSMISSION
Connect long blue wire to the
green wire with the red stripe
at the blunt-cut harness
Do not use short blue wire with
crimp connector
MANUALTRANSMISSION Connect the blue wires
Throttle
Controller
Blue
Blue
ENGINE COMPARTMENT

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4.1 Installing the Components
Lay out all of the control components and identify the wiring and
connections according to the wiring diagram.
□Remove the driver-side plastic door frame base panel and the
plastic molding ahead of the base panel.
□Mount the control box using the supplied sheet metal screws
(Figure 4.1). Route the wire harness under the floor covering,
along the inside of the door where it will be covered by the trim
piece and up under the dash.
Control box
Cut a notch for the wire
in the door trim
Driver’s Seat
Figure 4.1
□Cut a notch in the edge of the trim piece through the saw-tooth
section just inside the edge of the trim so that the wire is not cut
when the trim is installed. Place the floor covering back into
position and replace the kick panel and door trim.
□Remove the trim panel from under the dash.
□Tie-wrap the throttle control to the dash support bracket to the
right of the steering column, behind the diagnostic connector
(Figure 4.2) with the adjusting screws facing out.

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Diagnostic
connector
Throttle pedal
connector
Tie-wrap to this bracket
Figure 4.2
4.2 Connecting the In-cab Wiring
□Unplug the OEM cable from the accelerator pedal and plug it into
the matching connector from the throttle control box. Plug the
cable from the throttle control into the matching connector on the
accelerator pedal.
□Connect the two white interface connectors together.
□Connect the red wire from the throttle controller to the matching
red wire from the control box.
□Connect the green wires from the interface connector and the
throttle control to a good ground.
□Connect the single red wire from the interface connector to
switched 12 volts. You can use circuit 294 (white with light blue
stripe wire) under the dash near the diagnostic connector (Figure
4.3).
□Connect the white wire from the throttle controller to the “clean
tach out” circuit 76 (green with white stripe wire) at the blunt-cut
harness under the dash near the park brake (Figure 4.4).