Vmac VR 7000 9004 User manual

Installation Manual
For The
System #9004
UNDERHOOD AIR COMPRESSOR
1996-1999 GMC CK2500 & CK3500
5.0L (305) & 5.7L (350)
TEL: [phone]
FAX: [phone]
TOLL FREE: 800-738-8622
1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3
DOCUMENT 19144

Installation Manual
VR7000 Underhood Air Compressor
System Number 9004
Application: 1996-1999 GMC CK2500 & CK3500 5.0L (305) & 5.7L (350)
Revision Date: March 2000
Publication Number: 19144
Origination Documents: #19144a - introduction
#19145 - compressor and oil cooler installation
#19146 - air tank and line installation
#19147 - throttle controller installation
#19148 - control unit installation
#19149 - illustrated parts list
#19130 - warranty registration
Registered Trademarks:
VR7000, VMAC and Throttle Commander are registered trademarks of VMAC.
GMC, CK2500 and CK3500 are registered trademarks of General Motors Corporation
Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.
Nylok is a registered trademark of Nylok Fastener Corporation.
Notice:
Manuals and products are subject to change without notice.
Copyright 1999
The contents of this manual may not be reproduced in any form without the express
written permission of VMAC

Contents
GENERAL INFORMATION................................................................................................ 3
INTRODUCTION ........................................................................................................................ 5
INSTALLATION NOTES .............................................................................................................. 6
ORDERING PARTS .................................................................................................................... 7
WARRANTY ............................................................................................................................. 7
CHANGES AND IMPROVEMENTS .................................................................................................. 7
PART 1: INSTALLING THE COMPRESSOR, FILTER, REGULATOR
AND OIL COOLER ............................................................................................... 9
1.1 PREPARING FOR INSTALLATION .......................................................................................... 11
1.2 INSTALLING THE BRACKET AND COMPRESSOR ...................................................................... 13
1.3 INSTALLING THE FILTER AND REGULATOR ASSEMBLY ............................................................ 14
1.4 INSTALLING THE OIL COOLER ............................................................................................ 15
1.5 COMPLETING THE INSTALLATION ...................................................................................... 16
PART 2: INSTALLING THE AIR TANK AND LINES ................................................... 19
2.1 INSTALLING THE TANK MOUNTS AND THE TANK .................................................................. 21
2.2 CONNECTING THE AIR AND OIL LINES ................................................................................ 24
2.3 ADDING OIL TO THE SYSTEM ............................................................................................ 27
2.4 COMPLETING THE INSTALLATION ...................................................................................... 28
PART 3: INSTALLING THE CONTROL UNIT ............................................................... 29
3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 31
3.2 CONNECTING THE WIRING HARNESS ................................................................................... 32
PART 4: INSTALLING THE THROTTLE CONTROLLER ........................................... 35
4.1 INSTALLING THE THROTTLE CONTROLLER ASSEMBLY ........................................................... 37
4.2 CONNECTING THE CABLE ................................................................................................. 39
4.3 ADJUSTING THE CABLE ..................................................................................................... 39
ILLUSTRATED PARTS LIST .............................................................................................. 41
WARRANTY REGISTRATION .......................................................................................... 47
1

2

General Information
System #9004
1996-1999 GMC CK2500 & CK3500
5.0L (305) & 5.7L (350)
UNDERHOOD AIR COMPRESSOR
3
DOCUMENT 19144A

4

General Information
Introduction
This book provides installation instructions for:
VMAC underhood air compressor installation kit
VMAC Pneumatic Throttle Control
This kit has been designed for:
1996-1999 GMC CK2500 & CK3500 with a 5.0L (305) or a 5.7L (350)
Installation steps
The installation procedure in this manual has four main steps:
Part 1: Installing the Compressor, Filter, Regulator and Oil Cooler
Part 2: Installing the Air Tank and Lines
Part 3: Installing the Control Unit
Part 4: Installing the Pneumatic Throttle Control
Terms and symbols
This manual uses the following terms and symbols:
•OEM - Original Equipment Manufacturer
•HHCS - Hex Head Cap Screw (also called a hex bolt)
•SHCS - Socket Head Cap Screw (also called an Allen head bolt)
NOTE
WARNING
!
5
This symbol indicates that there is additional information or special emphasis
on a specific procedure.
This symbol indicates that there is a possibility of personal injury or damage to
the equipment if the indicated warning is not followed.
DOCUMENT 19144A

Installation Notes
1. It is important that you complete all the installation steps before operating the system.
2. Follow all safety precautions for underhood mechanical work.
3. Use Loctite 242 or equivalent on all engine-mounted fasteners.
4. All hoses, tubes and wires which are re-routed or shifted during installation must be
secured so that they do not contact excessively hot areas or sharp edges. Where
possible, follow the routing instructions in this manual.
5. These installation instructions are intended as a general guide. In some instances, due
to variations in vehicle manufacture or if prior modifications have been made to the
vehicle, it may be necessary to carry out grinding, bending or rearranging operations
for correct fit. These operations must follow sound, standard shop practices.
6. Left and right definitions in this manual are determined when sitting in the driver’s
seat, facing forward.
7. All fasteners must be of the correct size and torqued according to the specifications
shown below. Torque specifications are in foot pounds (ft-lb).
6
T
y
pe Grade 8 plated Class 10.9 unplated
Size In Cast or
Steel
In
Aluminum
In Cast or
Steel
In
Aluminum
3/8 48 45
7/16 77 70
1/2 117 95
M8 25 20
M10 45 40
M12 80 70
M14 145 130
DOCUMENT 19144A

Ordering Parts
To order parts, contact VMAC at:
Telephone [phone]
Facsimile 250-754-6972
Office Hours 8:00 AM to 4:30 PM Pacific Time
Please quote the VMAC part number, the description and the quantity.
Warranty
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.
The enclosed System Identification Number Plate must be attached to the vehicle at the time of
installation. This plate provides information, which allows VMAC to assist in customer inquiries and
ordering of parts. It is important that this plate is affixed to the vehicle.
Instructions
Locate the plate on the front body support on the passenger side of the in front of the hood stop
(Figure 1). Drill the two hole locations using a 7/64” drill bit. Place the plate in position and fix in
place with the two #6 pan head self tapping screws provided.
Figure 1
Changes and improvements
These products and documents are subject to changes or improvements without notice.
7
DOCUMENT 19144A

8

Part 1
Installing
the Compressor,
Filter,
Regulator
and
Oil Cooler
System #9004
1996-1999 GMC CK2500 & CK3500
5.0L (305) & 5.7L (350)
UNDERHOOD AIR COMPRESSOR
9
DOCUMENT 19145

10

Part 1: Installing the Compressor, Filter, Regulator
and Oil Cooler
1.1 Preparing for installation
1. Disconnect all battery cables, then undo the battery hold down and remove the battery from
the passenger side of the vehicle.
2. Drain the coolant from the cooling system and remove the lower radiator hose.
3. Remove and discard the rock guard from under the radiator. Keep the OEM fasteners for
use with the replacement rock guard.
4. Disconnect the top radiator hose from the radiator end but not from the engine.
5. Disconnect and remove the air inlet box.
6. Remove the positive battery cable from its position on the fan shroud.
7. Remove the upper and lower sections of the fan shroud.
8. Remove the OEM belt and the fan (Figure 1.1).
Figure 1.1
11
OEM Belt Tensioner
Alternator Cable And Heater
Hose Removed From The
Bracket
OEM Belt
OEM Fan
(
Ri
g
ht-hand Thread
)
DOCUMENT 19145

The fan has right hands threads.
9. On vehicles equipped with air conditioning, remove the OEM belt idler from the cast
alternator bracket and move it to the location below the air conditioning compressor
(Figure 1.2).
10. On vehicles without air conditioning, the OEM idler on the alternator bracket is discarded
with the bracket.
11. Disconnect and remove the wiring from the alternator.
12. Remove the OEM retaining bolts from the alternator and remove the alternator.
13. Remove the heater hoses, air conditioning line and alternator cable from the plastic locating
bracket fastened to the alternator mounting castings (Figure 1.1).
14. Remove the OEM belt tensioner from the alternator mounting bracket (Figure 1.1).
15. Remove and discard the OEM cast aluminum alternator mounting bracket (Figure 1.2).
16. Remove and discard the heater hose (complete with metal S-shaped pipe) from between
the water pump and the firewall (Figure 1.2).
Figure 1.2
12
NOTE
OEM Alternator Bracket
Bracket Holding Heater Hoses,
Air Conditioning Line And
Alternator Cable
OEM Heater Hose With Metal S-shaped Pipes
On Vehicles Without A/C Discard
The Idler Which Is Attached Here
On Vehicles
With A/C Move
The Idler From
The Cast Aluminum
Bracket To This
Location
DOCUMENT 19145

13
Do not disconnect the heater return hose quick-coupler at the manifold as it may leak if
removed and refitted.
17. Remove the long stud used to locate and secure the OEM alternator mounting bracket to
the cylinder head.
18. Check the mounting surface to make sure that it is clean and free of debris. If the VR7000
bracket does not mount flush with the cylinder head, the pulleys will not line up correctly.
Also check the edge of the intake manfold for flashing which may extend past the head
surface. Place the VR7000 bracket in place and make sure it mounts flat. If flashing
interferes, grind it off flush so that the bracket will mount flat against the head.
1.2 Installing the bracket and compressor
1. Apply Loctite to the three (3) 3/8″×11/4″ and fit to cylinder head and fasten one (1) 3/8″×
1″hex head cap screw to engine block to fasten the VR7000 bracket (Figure 1.3) in place
of the OEM alternator mounting bracket.
Figure 1.3
2. Apply Loctite to the OEM tensioner 10mm nut, fit OEM washer and install the OEM belt
tensioner. Carefully bend the air conditioning line at the radiator so that the line will clear the
tensioner.
3. Remove the hex head cap screw holding the VR7000 back idler. Apply Loctite and
reinstall the back idler. Torque the cap screw to specifications.
4. Check the fastener on the VR7000 belt tensioner. Make sure that the Nylok nut is torqued
to specifications.
5. Carefully bend the dipstick tube toward the rocker cover until it is approximately 3/4″from
the cover so that it will clear the compressor.
NOTE
DOCUMENT 19145
VR7000 belt
tensioner
OEM
tensioner
VR7000 mounting
bracket
VR7000 idler
VR7000 belt tensioner

14
6. Apply Loctite to the studs on the bottom of the compressor, position the compressor in
place on the VR7000 bracket, install the 8 mm nuts and flat washers and torque to 25 ft-lb.
1.3 Installing the filter and regulator assembly
1. Remove the two (2) 1/2″×1 1/2″ hex head cap screws which hold the VR7000 pressure
regulator to the mounting bracket (Figure 1.4). Remove the three (3) 1/4″×3/4″ hex head
cap screws which hold the VR7000 remote filter assembly to the mounting bracket.
Figure 1.4
2. Mount the bracket to the battery tray support bracket (Figure 1.5) through the two existing
holes using the supplied 5/16″x 1″hex head cap screws. Fit (2) 5/16 SAE washers and 5/16
Nylok nuts. Use the slotted hole and lower hole. Tighten the fasteners.
VR7000 Remote Oil Filter
1/4 x 3/4 NC
Hex Head Cap Screws
With Serrated Lock Washers
””
1/4 x 1-1/2 NC
Hex Head Cap Screws
With Serrated Lock Washers
””
VR7000 Mounting
Bracket Part #12182
VR7000 Pressure
Regulator Assembly
Fasten Bracket To Batter
y
Support
(
top hole hidden
)
With 5/16” Hex Head Cap
Screws, Washers And Nuts
Black Po l
y
Line
Red Poly Line
5/16” Line
From
Compressor
1/4” Line to
Tank
DOCUMENT 19145
Figure 1.5

15
1.4 Installing the oil cooler
1. Remove the OEM hex head cap screws retaining the radiator to the body.
2. Raise the radiator a few inches to gain acces to the crossmember under the radiator.
3. Fit the cooler and mount assembly to the body section under the radiator. The cooler
outlets should face toward the passenger side of the vehicle (Figure 1.6). Use three (3)
1/4″×1″hex head cap screws, Nylok nuts and washers. Tighten the fasteners.
4. Place an HS28 clamp on the hose to the water pump and an HS24 clamp on the hose to
the lower radiator fitting. Adjust the position of the hoses so that they are not crimped and
do not contact any portion of the vehicle.
5. Tighten the clamps. Figure 1.7 shows the cooler after installation.
Figure 1.6
VR7000 Oil Cooler
Part #92051
HS28 Clamp
Coolant Hose
Part #17245
3/8 x 1 NC
Hex Head Cap Screws
””
FRONTOFTRUCK
VR7000 Oil
Cooler Mounting
Bracket
1/4” x 1” Hex Head Ca
p
Screws
HS24
Clamps
Coolant Hose
Part #17116
TO WATER PUMP
TO LOW ER RADIATOR
CONNECTION
DOCUMENT 19145
3. Install the remote filter housing and regulator back onto the VR7000 bracket using the
previously removed fasteners (Figure 1.5). Tighten the fasteners.

16
Figure 1.7
1.5 Completing the installation
1. Route the heater return hose along the lower edge of the compressor and under all
compressor fittings. If necessary, secure the hose in place with nylon ties.
2. Install the supplied 5/8″×36″heater hose to replace the one which you removed earlier.
Route this hose behind the compressor air filter and over the top of the engine.
3. Check all installed components for proper fastener torque and for clearance with all moving
or hot objects. Check all hose clamps to make sure that they are tight.
4. Clean the center of the crank pulley thoroughly to remove all dirt and contamination.
Remove the OEM center bolt and the three OEM fasteners from the pulley.
5. Install the VR7000 pulley over the OEM crankshaft pulley. Apply Loctite to the supplied
7/16″×3″hex head cap screw, install and tighten. Apply Loctite to the three (3) 3/8″×3″
hex head cap screws, install and tighten.
Hose To Lower Radiator Connection
Hose To Water Pump Connection
Cross-Member In Front Of The Radiator
DOCUMENT 19145

9. Install the lower fan shroud.
10. Install the fan spacer, then install the fan. Next, install upper fan shroud.
11. Connect the upper radiator hose and tighten the clamp.
6. Install the alternator on the VR7000 bracket using the OEM fasteners. Connect the wiring
to the alternator and route the harness clear of belts and pulleys. If necessary, fasten the
harness securely with a nylon tie.
7. Install the drive belt for the required application (Figure 1.8):
Standard alternator WAC 16229
Standard alternator WOAC 16228
High capacity alternator WAC 16255
High capacity alternator WOAC 16288
8. Install the VR7000 belt (Part #16278) , following the route shown in Figure 1.9.
Figure 1.8
Figure 1.9
17
Alternator Alternator
Idler
Power Steering
Power Steering
Crankshaft
Crankshaft
Wat er
Pump
Wat er
Pump Tensioner
Tensioner
Air Conditioning
WITH AIR CONDITIONING WITHOUT AIR CONDITIONING
Crankshaft
VR7000 Air Compressor
VR7000 Tensioner
VR7000 Idler
DOCUMENT 19145

When operating the engine for the first time following installation, be sure to allow
the engine to reach full operating temperature and ensure that the cooling system
level is correct. Failure to do so could result in an overheat condition and possible
engine damage.
NOTE
14. Install the battery and secure it with the battery hold-down. Attach all battery connections
securely.
15. Install the replacement rock guard under the radiator (4x4 only). Use the OEM hex head
cap screws.
16. Check all hoses, lines, wire harnesses and cables to make sure that they clear all the belts,
pulleys or other objects that could cause damage.
18
DOCUMENT 19145
12. Fill the cooling system with the OEM recommended coolant to the correct level.
13. Route the positive battery cable back across the fan shroud and secure it in place.