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UNDERHOOD AIR COMPRESSORS














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FORD (1999- 2001) SUPER DUTY F250-F5507.3 L POWER STROKE DIESEL

System # V900045

Installation Manual

Installation Manual Document 1930030

VR70 Underhood Air Compressor System Number V900045

Application: 1999-2001 Ford Super Duty F250-F550 7.3 L Power Stroke Diesel

Publication Date: Revised by S. Large, February 12, 2003

Origination Documents:#1900709a - General information#1900709b - Compressor installation#1900709c -Air tank and line installation#1900709d- Control components installation#1900709e -Illustrated parts list#1900130 - Warranty registration

Notice:

Manuals and products are subject to change without notice.

Copyright 2003The contents of this manual may not be reproduced in any form without the express written

permission of VMAC

Registered Trademarks:

VR70, VMAC and Throttle Commander are registered trademarks of VMAC.

Ford, Super Duty, F250-F550, Power Stroke Diesel are registered trademarks of Ford Motor

Company

Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.

Nylok is a registered trademark of Nylok Fastener Corporation.

Contents

PART 1: GENERAL INFORMATION ........................................................................3

1.1 INTRODUCTION ........................................................................................................5

1.2 INSTALLATION STEPS ................................................................................................5

1.3 TERMS AND SYMBOLS ..............................................................................................5

1.4 ISTALLATION NOTES .................................................................................................5

1.5 SYSTEM IDENTIFICATION NUMBER PLATE ...........................................................................6

1.6 WARRANTY ..........................................................................................................7

1.7 ORDERING PARTS ...................................................................................................7

1.8 CHANGES AND IMPROVEMENTS ....................................................................................7

PART 2: INSTALLING THE COMPRESSOR AND OIL COOLER ...........................9

2.1 PREPARING FOR INSTALLATION ................................................................................... 11

2.2 INSTALLING THE OIL COOLER ......................................................................................14

2.3 INSTALLING AND MOUNTING COMPONENTS .......................................................................15

2.4 INSTALLING THE COMPRESSOR ....................................................................................17

PART 3: INSTALLING THE AIR TANK AND LINES ..............................................19

3.1 INSTALLING THE TANK BRACKETS AND TANK ....................................................................21

3.2 CONNECTING THE AIR AND OIL LINES ............................................................................26

3.3 ADDING OIL TO THE SYSTEM ......................................................................................29

PART 4: INSTALLING THE CONTROL UNIT........................................................31

4.1 INSTALLING THE THROTTLE CONTROL UNIT ......................................................................33

4.2 CONNECTING THE WIRING HARNESS .............................................................................34

PART 5: INSTALLING THE THROTTLE COMMANDER ......................................35

5.1 INSTALLING THE THROTTLE COMMANDER ........................................................................37

5.2 ATTACHING THE WHITE WIRE .....................................................................................38

5.3 CONNECTING THE WIRING .........................................................................................40

5.4 COMPLETING THE INSTALLATION..................................................................................43

PART 6: ILLUSTRATED PARTS LIST ...................................................................45

WARRANTY REGISTRATION.................................................................................51

1

Part 1

General Information

System #V900045

1999- 2001 FORD SUPER DUTY F250-F550

7.3 L POWER STROKE DIESEL

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT #1930030

General Information

1.1 Introduction

This book provides installation instructions for:

VMAC underhood air compressor installation kitVMAC Throttle Commander

1.2 Installation steps

The installation procedure in this manual has three main steps:

Part 1: General InformationPart 2: Installing the Compressor and Oil CoolerPart 3: Installing the Air Tank and LinesPart 4: Installing the Control System Components

1.3 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

1.4 Installation Notes

1. It is important that you complete all the installation steps before operating the system.

Refer to the Owner’s Manual before operating the system for the first time.

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 securedso that they do not contact excessively hot areas or sharp edges. Where possible, followthe routing instructions in this manual.

This symbol indicates that there is additional information or special emphasison a specific procedure.

This symbol indicates that there is a possibility of personal injury or damage tothe equipment if the indicated warning is not followed.

5

WARNING

!

5. These installation instructions are intended as a general guide. In some instances, due tovariations in vehicle manufacture (or if prior modifications have been made to the vehicle) itmay 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’sseat, facing forward.

7. All fasteners must be of the correct size and torqued according to the specificationsshown below. Torque specifications are in foot pounds (ft-lb). Always use manufacturerstorque values for OEM fasteners.

Table 1 - Torque values

The above fastener torque values are applicable when Loctite is used. If the threads are dry, add20% to the torque values.

Table 2 - Hose color codes.

Table 2 above illustrates the color code used by VMAC to define the different hose diameters.

Ordering Parts

To order parts, contact your nearest VMAC dealer.

Please quote the VMAC part number, the description and the quantity.

6

STANDARD GRADE 8 NATIONAL COARSE THREAD

Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4

Foot-pounds 9 18 35 55 80 110 170 280

STANDARD GRADE 8 NATIONAL FINE THREAD

Size 3/8 7/16 1/2 5/8 3/4

Foot-pounds 40 60 90 180 320

METRIC CLASS 10.9

Size M8 M10 M12 M14 M16

Foot-pounds 19 41 69 104 174

Hose diameter Color coded label Part number prefix 1/4” Yellow 173 5/16” Orange 174

1/2” & 5/8” Blue 175 & 176 3/4” & 1” Green 177 & 178

Trucks fitted with a dual alternator will require accessory pack #A700041. This kitprovides a special bracket and bolt to be mounted on the back of the cooler wherethe cooler mounts to the engine block.

Warranty

The VMAC warranty form is located at the back of this manual. This warranty form must becompleted and mailed or faxed to VMAC at the time of installation for any subsequent warrantyclaim to be considered valid.

The enclosed System Identification Number Plate (S/N) must be attached to the vehicle at the timeof installation.

Locate the S/N plate on the drivers side frame member in front of the battery. Drill the two holelocations using a 7/64” drill bit. Place the S/N plate in position and fix in place with the two #6 panhead self tapping screws provided (Figure 1).

IMPORTANT

This S/N plate provides information, which allows VMAC to assist in customer inquiries and/orordering of parts. It is important that this S/N plate is affixed to the vehicle.

Changes and improvements

These products and documents are subject to changes or improvements without notice.

7

NOTE

Figure 1

Part 2

Installing

the Compressor and Oil

Cooler

System #V900045




9

DOCUMENT #1930030

Part 2: Installing the Compressor and Oil Cooler

2.1 Preparing for installation

1. Disconnect the batteries and remove the battery from the driver’s side box.

2. Drain the coolant from the radiator.

3. Remove the OEM fasteners from the coolant expansion bottle and move it out of the way.Do not disconnect the hoses from the bottle.

4. Loosen the clamps holding the left intercooler tube at the air intake on the engine and at theintercooler beside the radiator and remove the intercooler tube.

11

Removing OEM components

5. Remove and discard the plastic cover and attaching nuts from the center top area of theengine.

6. Remove the OEM belt

7. Remove the cooling fan and the fan shroud.

NOTE

Removing the cooling fan will provide additional clearance for removing and installing

components.

Remove This Cover

Remove Coolant Expansion Tank

12

8. Disconnect the air inlet horn from the front of the air cleaner and battery box. Leave thispart in place. This is optional for ease of removal and installation. Remove the air cleanerbox and the battery box from the driver’s side of the vehicle.

Removing OEM components

9. Remove the alternator from its mount and lay it back on top of the engine. Keep the OEMfasteners for alternator installation.

10. Remove the power steering pump pulley (noting the position of the pulley on the shaft), thenremove the power steering pump from the bracket. Keep the OEM fasteners for the powersteering pump installation. You will require the correct puller to remove the power steeringpump pulley.

11. Remove the power steering return hose from the power steering pump and discard it.

12. Fasten the pump out of the way or lay it on the frame. Do not allow it to hang from thepressure hose.

13. Remove and discard the OEM alternator and power steering pump mounting bracket.Retain the OEM fasteners for later use on the installation of the VR70 cast bracket.

14. Remove and discard the upper and lower radiator hoses.

Remove The Air Cleaner And Battery Boxes

13

Removing the OEM bracket

15. Exchange the forward right bolt and rear left stud on the aluminum cover at the top front of

the engine.

Exchanging fasteners

Exchange these two fasteners

Front

OEM Alternator And Power Steering PumpMounting BracketOEM

Fasteners

Cylinder HeadMounting Area

Engine Block Mount

FRONT

LEFT SIDEOF ENGINE

14

16. Remove and discard the 12 mm stud and nut (lower right side of the engine) and the 12 mmcap screw (lower left side of the engine) which retain the ground straps.

17. Remove and discard the positive battery cable locating bracket from the same area.

Removing ground straps

18. Clean the front of the engine block thoroughly to ensure that there is no contamination in theareas where the oil cooler and mounting bracket will fit. If the mounting area is dirty, thebracket will not mount flush, resulting in fouling of the pulley or belt.

2.2 Installing the oil cooler

1. Install the oil cooler on the engine. Insert the two (2) supplied M12 x 30 mm hex head capscrews and 12 mm serrated washers through the ground strap fittings and fasten the oilcooler in place. Torque the fasteners to specifications.

Installing the oil cooler

12 mm stud holding ground strap and transmission cooling lines

12 mm hex head cap screwholding ground strap

M12 x 30 HHCS

M12 x 30 HHCS

To engine block

To radiator

15

2. Place hose clamps on both hoses. Connect the right side cooler hose to the bottom radiatoroutlet . Tighten all the hose clamps securely.

3. Fit two (2) 4 inch lengths of 1/2 inch rubber hose around the transmission line for protectionwhere they pass the cooler bracket. Use ties to hold the rubber in position on the lines

Connecting the hoses

2.3 Installing and mounting components

1. Clean all dirt and debris from the face of the OEM pulley before installing the VR70 pulley.

2. Install the crankshaft pulley using three (3) supplied M10 x 20 mm socket head cap screws.Torque them to specifications.

3. Install the supplied VR70 mounting bracket using the four (4) OEM flange lock bolts.Apply loctite and torque them to specifications.

4. Install the power steering pump to the compressor mounting brackets using the OEMfasteners.

5. Install the power steering pump pulley. The outer edge of the power steering pump pulleymust be flush with the end of the pump shaft.

Lower radiator hose

Hose to engineblock1/2” oil line fittings

16

Installing the VR70 components

6. Install the alternator onto the compressor mounting bracket using the OEM fasteners.

NOTE

7. Install the supplied 3/8 x 36 inch power steering return hose.

8. Install one of the OEM hose clamps on the end which will attach to the power steeringpump fitting. Install the hose on the pump.

9. Re-align the power steering hoses to clear the steering column.

The alternator must be mounted 180 degrees (upside-down) from the original

mounting position. Rotate the alternator 180 degrees in a counterclockwise

direction.

OEM bolt locations

VR70 Tensioner

Ribbed Idler

VR70 Cast bracket

17

2.4 Installing the compressor

1. Install the compressor to the mounting bracket using the three supplied 8 mm doubleserrated lock nuts. Torque them to specifications.

2. Remove the M12 x 80 mm hex head cap screw which retains the compressor belttensioner. Apply Loctite, install the fastener and torque it to specifications.

3. Remove the 1/2 x 1-1/4 inc NC hex head cap screw which retains the idler. Apply Loctite,install the fastener and torque it to specifications.

4. Install the OEM belt. Be sure to use the correct routing.

OEM belt routing

5. Install the VR70 belt. Be sure to use the correct routing.

VR70 belt routing

VR70 CrankshaftPulley

VR70Tensioner

VR70 AirCompressor

VR70Idler

VR70 Drive Belt

Crankshaft pulley

Power steeringWater pump

Alternator

Idler

Idler

Tensioner

Air conditioning

6. Install the fan and the fan shroud.

7. Install clamps on the supplied upper radiator hose and fit it on the engine and radiator

fittings.

8. Rotate the hose on the thermostat housing and radiator fitting until the hose clears both the

compressor belt and the fan shroud. Tighten the clamps.

Installing components

18

9. Install the intercooler tube and tighten the clamps. Be sure that the tube clears the back ofthe compressor and power steering pump and the bead inside the rubber OEM bellows sitsin the groove properly before tightening the clamps.

If the locating rib on the inside of the flexible tube does not seat correctly in the groove on

the intercooler tube, it is possible that the connection will come undone, allowing unfiltered

air into the engine. This can result in engine damage.NOTE

Part 3

Installing the

Air Tank and Lines

System #V900045




19

DOCUMENT #1930030

Part 3: Installing the Air Tank and Lines

3.1 Installing the tank brackets and tank

1. The tank is mounted on the frame on the driver’s side of the vehicle, positioned so that it will

clear the body mounts.

21

Cab Mount

Tank

CrossmemberSkidplate

Positioning of the tank

When positioning the tank brackets on the frame, make sure that they will not pinch or

damage any wiring harnesses, lines or hoses.NOTE

Mounting bracket components

2. Clean the area on the frame between the two body mounts so that the brackets will mountcorrectly.

3. Remove the pinch bolts from the C-clamps and expand the clamps just enough so that youcan slide them over the front of the tank.

4. Rotate the C-clamps so that the flat mounting surfaces are on the left side of the tank, asviewed from the front of the tank.

L-bracket

Frame mount U-clip

Spacer (F250-F350 only)

5/16” nuts

Wire Cable

C-clamp mounting screws

Tube Clamp

22

5. Insert the pinch bolt from the top, then install the washer and nut, but do not tighten.

6. Thread the fittings on the 1/4 and 5/16 inch steel tubes into the matching fittings on the rearof the tank (1/4 inch in the top fitting). Tighten the fittings slightly by hand, but leave themloose enough so that the lines can move in the fittings.

7. Place the two small insulated double-tube clips over the lines with the flat side facing awayfrom the tank and the end with the hole hanging down. Position the 1/4 inch steel tubeabove the 5/16 inch tube.

8. Place an L-shaped tank brackets against the one of the C-clamp on the tank with the shortarm of the “L” at the top of the tank, facing away from the tank. Install a 5/16 x 1/2 inchhex head cap screw with flat washer into the bottom hole on the bracket. Do not tighten.

9. Fit the second hex head cap screw through one of the small insulated double-tube clips andinstall it through the top hole in the C-clamp and into the top hole on the L-bracket. Do nottighten. Repeat this procedure with the second L-bracket, C-clamp and double-tube clip.

10. Make sure that the tubes are parallel to the tank and fit properly in the clips. The flexiblelines attached to the tubes will be routed into the engine compartment when the tank isinstalled on the truck.

Installing the L-brackets Attaching the L-brackets to the C-clamps

Insulated double tube clip Tubes in place

23

11. Locate the correct application in the Frame Application Diagram (on the next page)which corresponds to the model of truck on which you are installing this system. Check themeasurements to make sure that the location of the clamps and brackets on your tank matchthose in the diagram. Adjust the C-clamps to match your application. Make sure that whenthe tank is mounted, the drain plug is at the lowest location and that the tank orientation hasthe direction arrow pointing upward

12. Insert the wire rope securing cables through the tube of the upper frame locating clips thenpass the cable between the cab body and the frame from the inside, behind the transmissioncross member, with the cable on the outside of the frame.

13. Support the tank and L-bracket assembly in place on the outside of the frame, with theshort part of the L-bracket positioned over the top of the frame and pass each wire ropesecuring cable around the L-bracket, between the bracket and the tank. Make sure that thecable rests between the guide and the C-clamp.

14. Insert the threaded end of the securing cable through the tube on the lower frame locating “U” clips. These lower “U” clips have the tube welded parallel to the “U” shape section.

Slide the “U” section over the frame rail and fit a 5/16 inch nut supplied. Tighten the nutsenough to hold the tank then install the appropriate spacers and position the tank asapplicable.

Cable straps over the frame U -clip mounting on the inside of the frame

On F250 & F350 trucks (all models) install the 1/8 inch thick 5/16 x 3/4 inchwashers, the 1/2 x 2 inch spacer and the 5/16 inch nuts.

On F450 & F550 trucks (all models) install the 1/8 inch thick 5/16 x 3/4 inchwashers and the 5/16 inch nuts. Discard the 1/2 x 2 inch spacer.

15. Refer to the Frame Application Diagram to ensure that the positioning dimensions arecorrect for your model.

NOTE

U-shaped frame clip

Threaded cable end

5/16 inch nut

24

On the F450 & F550 standard cab models (2x4 and 4x4) position the rear tankbracket so that the front edge of the backing strap is approximately 1-1/4 inchesback from the forward edge of the cut-out for the transfer case. Make sure thatthe threaded end of the securing cable is not positioned next to the transfer casehousing, as torque movement will cause the transfer case housing to strike thethreaded end of the securing cable.

16. When the tank is correctly positioned, tighten the securing cable retaining nuts until the cablespull tight and snug around the frame. Do not overtighten the nuts.

17. Install a second 5/16 inch nut and tighten it securely against the first to act as a locknut.

NOTE

Illustration of the wider lower frame locating U-clip being used on a double frame section.

Front tank mount Tank mount clip positions

25

F250 & F350 standard cab 2x4 and 4x4

F450 & F550 standard cab 2x4 and 4x4

F250 & F350 super cab 2x4 and 4x4

F450 & F550 super cab and crew cab 2x4 and 4x4

Front cab mount

Front cab mount

Front cab mount

Front cab mount

19.25

16.25

17.25

16.25

17.25

1.25

11.75

Transfer case

Frame Application Diagram

26

18. Check the alignment of the tank to make sure that the “UP” arrow on the end of the tankpoints directly upward and that the tank is aligned correctly, then tighten the C-clamp pinchbolts securely, but not so much as to distort the mounting surfaces. Tighten the 1/4 and 5/16inch steel tube fittings at the back of the tank.

19. Remove each of the hex head cap screws holding the C-clamp to the L-bracket and applyLoctite.

20. Replace the cap screws and tighten to specifications. Make sure that the tank is level.

This alignment is extremely important. Improper installation can result in an extremelyhazardous situation which could cause severe personal injury or could damage theequipment.WARNING

!

3.2 Connecting the air and oil lines

If lines are grouped together, make sure that you insulate the lines from each other andfrom other components to prevent abrasion wear. Use the supplied plastic sleeve cut tosuitable length (approximately 4 inches) and secure them in place with plastic tie wraps.Use stainless steel hose wraps to secure the hoses as necessary.

The lines must be installed in the correct locations or the system will not functionproperly. In addition, a hazardous situation may develop from oil spray, potential fire orexplosion.

WARNING

!

NOTE

1. Connect the end of the 3/4 inch main discharge line with the straight connector to the topfront tank fitting.

2. Route this line around the outside of the front body mount and install protective plastic

sleeves. Fasten it to the cab floor with stainless ties using OEM holes. Route the line up to

the back of the compressor.

3. Connect the 45 degree swivel fitting to the fitting on the back of the compressor. Tighten

the fitting at the compressor while angling the fitting to allow the line to route outside of the

steering column. Secure the line away from the steering column with ties.

4. Route the 5/16 inch line from the tank up along the frame to the compressor.

5. Connect the 5/16 inch line fitting to matching 5/16 inch 90 degree elbow fitting on thefirewall side of the inlet control valve on the compressor.

6. Route the 1/4 inch line above the front cab body mount and around the outside of the

steering column. Install protective plastic and tie this line to the pressure control line. You

can also fasten this line to holes in the floor strengthening rib for better support.

7. Connect the end of the 1/4 inch line to the 45 degree elbow fitting on the front of the air inlet

valve on the compressor.

27

3/4 inch main discharge line (upper) and 1/2 inch oil return line (lower)

Lines installed on tank

12. Some adjustment of the tank brackets along the frame may be necessary if the hoses aretoo tight or too loose and hang down under the truck.

13. Install the rock guard on the front of the tank using three (3) 1/4 -20 hex head cap screws.

28

Line connections at the compressor

8. Connect the straight end of the longest 1/2 inch oil return line to the lower tank fitting and the90 degree end to the left (driver) side fitting on the oil cooler. Route this lineover the framerail and around the steering box. Secure it so that it clears all belts and moving parts.

9. Connect the 90 degree end of the shortest 1/2 inch oil return line to the right (passenger)side fitting on the cooler and the straight end to the 90 degree fitting on the bottom of thecompressor. Route this line across the cooler, behind the coolant hose to the engine, acrossthe engine block to the compressor secure it, making sure that the hose is clear of thecooling fan, pulleys and belts.

10. Make sure that you tighten all fittings. Check your routing to make sure that the lines do notcontact hot areas or other moving components. Make sure that the lines do not interferewith other components.

11. Protect the lines from abrasion and damage by making sure that they are secured asrequired using stainless frame clamps or ties and protective plastic sleeve on contact points.

Scavenge Line

Main Discharge

Air LinePressure

Control

Line

29

Line connections at the cooler

3.3 Adding oil to the system

1. Make sure that the vehicle is level.

2. Remove the oil filler plug from the air inlet control valve.

3. Pour the supplied compressor oil into the filler hole using a funnel.

4. Turn the compressor clutch clockwise with a ratchet and socket using the hex head cap screwat the center of the compressor clutch and continue adding oil until the correct level isattained.

5. Observe the sight glass at the front of the tank to ensure that the correct oil level is attained.It is important not to overfill the system.

6. Insert the filler plug in the air inlet control valve and tighten it.

You must use the supplied compressor oil in this system. Failure to use this

special oil will result in damage to the compressor and will void your warranty.WARNING

!

30

Before operating the compressor for the first time, be sure and run the engine until itreaches operating temperature. Always check the coolant level to be sure it is correct.

7. Fill the cooling system with the OEM recommended coolant.

8. Check all fasteners, hose clamps and fittings to make sure that they are tight.

9. Remember to check the oil in the tank to be sure that it is at the correct level.

NOTE

Oil fill location

Part 4

Installing the

Control Unit

System #V900045

1999-2001 FORD SUPER DUTY F250-F550



31

DOCUMENT #1930030

33

Part 4: Installing the Control Unit

4.1 Installing the control unit

1. Remove the driver-side plastic door frame base panel and the plastic moulding ahead

of the base panel (Figure 4.1).

Figure 4.1

Remove ThisDoor-frame Base Panel

Remove ThisInside Left KickPanel

Driver’s Seat

2. Mount the control unit using the supplied sheet metal screws (Figure 4.2).

Figure 4.2

34

3. 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.

4. Place the floor covering back into position. Replace the door trim piece. Cut a notch in the

edge of the trim piece for the wire (Figure 4.3). Make sure that you cut a path for the wire

through the saw-tooth piece just in from the edge of the trim or when you install the door

trim or it will cut the wires.

Figure 4.3

4.2 Connecting the wiring harnesses

1. Make a slit or cut a small cross (about 1”) in the steering column boot and feed the small

gray harness cable with the green plug connector through the boot into the engine

compartment. Route the cable clear of the steering column and pedals so that it does not

make contact with any moving parts.

2. Route the gray wire from the temperature sensor on the compressor along the engine and

firewall and connect the green compressor sensor wire harness connector to the matching

green connector on the harness from the control unit.

Cut A Notch In The Panel For The Wire

approximately 16” from front 1/2” gap

Remove jagged teeth

Part 5

Installing the

Throttle Commander

System #V900045




35

DOCUMENT #1930030

37

5.1 Installing the Throttle Commander

1. Fasten the Throttle Commander under the dash, to the right of the steering column with the

adjusting screws pointing downward . The mounting bracket acts as a ground for the

control unit. This bracket must be securely fastened to a metal bracket under the dash, not

to a non-conductive surface.

Wire connections are shown in Figure 5.1.

2. Unplug the two (2) cables from the foot pedal assembly and connect them to the matching

connections at the Throttle Commander.

3. Connect the two (2) Throttle Commander cables to the matching connections at the foot

pedal assembly.

4. Feed the pressure sensor cable from the Throttle Commander through the steering column

boot into the engine compartment and plug it to the matching connector on the pressure

sensor, fitted to the compressor.

5. Feed the small white wire (without a connector) from the back of the Throttle Commander(complete with plastic loom) through the steering column boot. Attach the white wire to thegreen cam position (CMP) sensor wire (Figure5.1). You will have to remove one of therelays to access the harness.

6. Connect the white four-cable connector at the Throttle Commander to the matching whiteplug on the cable from the control unitfrom the control unit. Route the cable up over the

steering column clear of all moving parts and secure in place using ties.

White to CMP

Black to park brake

Yellow (auto trans only)

Red to power

Large white to compressor clutch

Foot pedal connectors

Foot pedal connector

Throttle Commanderto contol unit connection

Compressor temperature sensor connector

Compressor pressure sensor

Figur 5.1 Wiring locations

38

5.2 Attaching the white wire

1. Cut the green wire. Strip approximately 3/8” insulation from each cut end (Figure 5.3).

Figure 5.3

Green CMP Sensor Wire

Cover Shown Here For

Reference Purposes Only

Figure 5.2

39

2. Slip on the supplied meltable liner shrink tube (Figure 5.4).

3. Strip 1″ of insulation from the end of the white wire and twist it onto the free ends of the

green wire (Figure 4.5).

Figure 5.4

Figure 5.5

4. Solder the connection using the supplied 60/40 rosin core solder. Apply sufficient heat to

allow the solder to flow through the twisted bundle (Figure 5.6).

Figure 5.6

5. Slide the shrink tube over the solder joint and shrink with a heat gun until the meltable innercore extrudes slightly from each end (Figure 5.7). Do not overheat and be sure to protect

the other nearby wire bundles with sheet metal or cardboard.

40

5.3 Connecting the wiring

1. Feed the large white wire with the blue bullet connector through the steering column boot,

route it across the firewall and along the engine to the compressor. Connect it to the

matching connector at the compressor clutch.

2. Keep the black wire and the red wire inside the operator’s compartment for later internal

connections.

3. Secure all wires so that they will not be damaged or interfere with vehicle operation.

4. Locate the blue with pink stripe OEM wire under the dash. This wire may be difficult to

locate. Figures 4.9 and 4.10 may assist in locating the wire.

5. Attach the red wire from the Throttle Commander to the light pink/blue OEM wire using the

supplied quick-connector.

Figure 5.7

Figure 5.8

6. Push the green wire and the splice back into the OEM plastic loom. Slide the supplied 3/

16″ ID loom on the white wire forward and insert the end into the slit in the OEM plasticloom. Secure the connection with the supplied nylon wire (Figure 5.8).

41

Figure 5.9

Speed control

connection to

vehicle harness

Blue with pink stripe

Figure 5.10

OEM diagnostic connector

removed from under dash

for clarity

Speed control connection

to vehicle harness

(Blue with pink stripe)

42

5.3.1 Standard transmission vehicles only

1. Remove the OEM connector from the park brake switch on the park brake assembly.

2. Attach the black wire from the Throttle Commander with the female spade connector to the

black extension wire with a male connector on one end and a piggy-back connector on the

other end.

3. Route the wire to the park brake assembly and connect it to the park brake switch.

4. Attach the OEM park brake light switch wire to the piggy-back connector on the end of the

black VR70 wire at the park brake light switch.

5.3.2 Automatic transmission vehicles only

1. Install the Drive Disable Circuit under the dash using twist ties.

Figure 4.11 shows the connections at the Drive Disable Circuit.

2. Connect the black wire from the Throttle Commander with the female spade connector to

the black wire with the male spade connector from the DDC.

3. Remove the OEM connector from the park brake switch on the park brake assembly.

4. Route the black wire with the piggy-back connector from the DDC to the park brake and

connect the piggy-back connector to the switch.

5. Connect the OEM park brake wire to the piggy-back connector at the park brake switch.

6. Connect the yellow DDC wire from the control panel to the yellow wire from the DDC.

7. Route the blue wire from the DDC through the firewall to the OEM wiring connectors on

the driver’s inner fender near the firewall.

8. Locate the forward-most connector on the inner fender liner (Figure 4.12).

9. Locate wire connection #12 on the connector (blue wire with an orange tracer).

10. Install the supplied female tap quick connector onto the blue/orange wire. Use pliers to

close and latch the connection.

43

Black

Black

Yellow

Blue

Attach OEM park brake wireConnect to matching connector on the yellow wire from the VR70 Control Panel

Connect to quick connector on blue/orangeOEM park/neutral wire at location #12 of the underhood connector

Connect to black park brake wirefrom VR70 Throttle Commander

Connect to the OEMpark brake switch

Piggy-backconnector

Figure 5.11 DDC wiring connections

1 2 3 4

5 6 7 8

9 10 11 12

Front ofvehicle

Top of connector

Blue/Orangewire location

Figure 5.12 Connector and wire location

11. Connect the blue wire from the DDC to the female tap quick connector.

5.4 Completing the installation

1. Check all under-dash and engine-compartment wiring to ensure that it will not contact any

hot or moving components and will not interfere with the operation of the vehicle. Secure all

wiring with nylon ties as required.

2. Install the relay which you removed earlier to connect the CMP sensor wire.

3. Install the air cleaner and battery box.

4. Install the battery and connect the cables.

5. Install the covers and connect all hoses and tubing.

Part 5

Illustrated

Parts List

System #V900045




45

DOCUMENT # 1930030

47

ILLUSTRATED PARTS LIST SYSTEM V9000045 - 1999-2001 FORD SUPER DUTYF250 - F550 7.3 POWER STROKE DIESEL

ASSY. ITEM UNIT QTY PART# DESCRIPTION 1.0 Main bracket assembly

1.1 ea 1 1100138 VR70 main bracket 1.2 ea 1 2600075 Tensioner 1.3 ea 1 1400129 Idler spacer 1.4 ea 1 1570048 7/16” flat washer 1.5 ea 1 1520419 12mm x 80mm HHCS 1.6 ea 2 C/W item 1.2 1.7 ea 1 C/W item 1.2 1.8 ea 1 1300007 Idler, back 1.9 ea 1 1510161 ½” x 1 ¼” NC HHCS FL 1.10 ea 1 1400051 Idler bolt spacer 1.11 ea 1 1300008 Idler, 6 rib 1.12 ea 3 1540145 10mm x 20mm SHCS 1.13 ea 1 1800146 VR70 crankshaft pulley 1.14 ea 1 1650231 VR70 belt

2.0 P120045 Compressor assembly 2.1 ea 1 P120002 VR70 compressor 2.2 ea 1 9200212 Inlet control valve 2.3 ea 1 3550363 Temperature probe 2.4 ea 1 5000112 45 DEG street elbow – 1/8” NPT 2.5 ea 1 3500288 Pressure sensor 2.6 ea 1 1550221 ¼” NC nut 2.7 ea 1 1500519 ¼” NC x 2.62” threaded rod 2.8 ea 1 1570038 ¼” SAE flat washer 2.9 ea 1 1550029 ¼” NC Nylok nut 2.10 ea 1 3600042 Filter cover 2.11 ea 1 3600037 Paper filter element 2.12 ea 1 4900045 Hollow hex plug #8 SAE 2.13 ea 1 5000081 90 DEG elbow 1/8” NPT 2.14 ea 1 5000085 45 DEG elbow – 1/8” NPT x ¼” SAE 2.15 ea 2 2200097 Cable clamp, ¼” 2.16 ea 1 4900032 1” Male BSPP to ¾” male 37 DEG tube 2.17 ea 1 5830004 O-ring 3 1/8” ID x 1/8” wide, Viton 2.18 ea 1 5830002 O-ring 2 3/8” ID x 3/32” wide, Viton 2.19 ea 1 9200104 Filter blank plate 2.20 ea 1 5830045 O-ring ¾” ID x 3/32” wide, Viton 2.21 ea 1 9200103 Filter blank plate fitting 2.22 ea 1 5000074 90 DEG elbow, ½” tube – ½” NPT 2.23 ea 1 P200035 Clutch complete 6 groove

48

ILLUSTRATED PARTS LIST SYSTEM V900045 - 1999-2001 FORD SUPER DUTYF250 - F550 7.3 POWER STROKE DIESEL

ASSY. ITEM UNIT QTY PART# DESCRIPTION 3.0 9200345 Tank Assembly

3.1 ea 1 9200199 Main tank body 3.2 ea 1 5000089 Brass connector ½” NPT – ½” SAE 3.3 ea 1 3200227 Ring, window 3.4 ea 1 5830008 O-ring 1 15/16” ID x 3/32” wide, Viton 3.5 ea 1 3600077 Sight glass window 3.6 ea 1 1500385 Retaining ring 3.7 ea 1 9200039 VR70 Oil Filter 3.8 ea 1 4900033 Steel Connector ¾” NPT x ¾” JIC 37 Deg 3.9 ea 1 4900035 ¾” – 16 Threaded Nipple 3.10 ea 1 3600054 200 PSI Relief Valve 3.11 ea 1 5830066 O-ring, 4 ¾” ID x 1/8” wide, Viton 3.12 ea 1 9200217 Blowdown cap 3.13 ea 1 3600036 Coalescing filter element 3.14 in 2 1500077 10 – 32x3/8” Button Head SHCS 3.15 ea 1 4800241 Scavenge screen barb assembly 3.16 ea 1 3600064 Tank rear cap seal 3.17 ea 1 5840068 Compression spring 3.18 ea 1 5830055 O-ring, Viton, 1 5/16”ID x 3/32” 3.19 ea 1 5830104 O-ring, Viton, 1 38”ID x 1/16” 3.20 ea 1 3200321 Cover, sight glass

4.0 Hose Kit 4.1 ea 1 1752042 Hose, crimped 1/2” x 41.5” 4.2 ea 1 1752086 Hose, crimped 1/2” x 86.0” 4.3 ea 1 1730099 Hose, crimped 1/4” x 99.0” 4.4 ea 1 1740092 Hose, crimped 5/16” x 92.0” 4.5 ea 1 1771057 Hose, crimped 3/4” x 57.0”

5.0 Throttle Control Assembly 5.1 ea 1 T510038 VR70 throttle control

6.0 Tank Brackets 6.1 ea 2 2200105 Tank mounting bracket (C-clamp) 6.2 ea 2 1200236 Tank strap mount 6.3 ea 2 2200120 Tank cable strap 6.4 ea 2 2200113 Tank strap flat bar 6.5 ea 2 1400162 Cable spacer 6.6 ea 2 2200133 Tube Clamp 6.7 ea 2 1200266 Clip, tank mount

49

ILLUSTRATED PARTS LIST SYSTEM V900045 - 1999-2001 FORD SUPER DUTY

F250 - F550 7.3 POWER STROKE DIESEL

ASSY. ITEM UNIT QTY PART# DESCRIPTION

7.0 4800208 Cooler Assembly

7.1 ea 1 9200191 VR70 Cooler

7.2 ea 1 1200253 Cooler leg

7.3 ea 4 2200027 Hose clamp HS32

7.4 ea 1 1710418 Radiator hose

7.5 ea 1 1710420 Radiator hose

8.0 Electrical Assembly

8.1 ea 1 3550388 VR70 control box

8.2 ea 1 3550498 Drive disable circuit

8.3 ea 1 3550509 Standard transmission park brake jumper

9.0 Misc.

9.1 ea 1 1720246 Intercooler tube

9.2 ea 1 1710580 3/8” x 36” rubber hose

9.3 ea 2 2200001 Hose clamp MH-6

9.4 ea 2 2200026 Hose clamp HS28

9.5 ea 1 1710252 Upper radiator hose