intake tube on ford 6.7l vr150 existing kits · intake tube on ford 6.7l vr150 existing kits...

VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201

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A700226 Retrofit Instructions Intake Tube on Ford 6.7L VR150

Existing Kits Instructions for VMAC Accessory A700226 V910010 Intake Tube Retrofit V8 6.7L Diesel Document: 1901035

Changes and Revisions Version Revision Details Revised by /date Checked by /date Reviewed by /date Implemented

A Initial Release MSP 8 Jan. 2016 DSB 13 Jan. 2016 CJH 13 Jan. 2016 13 Jan. 2016

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 mechanical work. Any grinding, bending or restructuring operations for correct fit in modified trucks must follow standard shop practices.

Notice

Manuals are subject to change without notice.

Registered Trademarks

All trademarks mentioned in this manual are the property of their

respective owners. Their use by VMAC is for identification of the

manufacturers’ products only and does not imply any affiliation or

endorsement by said companies.

Loctite, Klean N’ Prime, 242 and PST are registered trademarks of

Henkel AG & Company KGaA.

Nylok is a registered trademark of Nylok Fastener Corporation.

Copyright 2016 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 engine models and different situations that are listed in the manual. Open the package, unpack the components and identify them.

Torque Specifications 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 3/4

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 3/4

Foot-pounds (ft-lb) 40 60 90 180 320

Newton meter (N•m) 54 81 122 244 434

METRIC CLASS 10.9

Size M6 M8 M10 M12 M14 M16

Foot-pounds (ft-lb) 4.5 19 41 69 104 174

Newton meter (N•m) 6 25 55 93 141 236

Ordering Parts

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 or online at www.vmacair.com

http://www.vmacair.com/


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Important Safety Notice

The information contained in this manual is based on sound engineering principles, research, extensive field experience and technical information. Information is constantly changing with the addition of new models, assemblies and service techniques. If a discrepancy is noted in this manual, contact VMAC prior to initiating or proceeding with service. Current information may clarify the issue. Any person with knowledge of such discrepancies who performs service and repair assumes all risks.

Only proven service procedures are recommended. Anyone who departs from the specific instructions provided in this manual must first assure that their safety and that of others is not being compromised and that there will be no adverse effects on performance or the operational safety of the equipment.

VMAC will not be held responsible for any liability, injuries, loss or damage to individuals or to equipment as a result of the failure of any person to properly adhere to the procedures set out in this manual or standard safety practices. Safety should be your first consideration in performing service operations. If you have any questions concerning the procedures in this manual or require any more information on details that are not included in this manual, please contact VMAC before beginning repairs.

Safety Messages

This manual contains various warnings, cautions and notices that must be observed to reduce the risk of personal injury during service or repair and the possibility that improper service or repair may damage the equipment or render it unsafe.

This symbol is used to call your attention to instructions concerning your personal safety. Watch for this symbol; it points out important safety precautions, it means, “Attention, become alert! Your personal safety is involved”. Read the message that follows and be alert to the possibility of personal injury or death. Be alert; your safety is involved. While it is impossible to warn about every conceivable hazard, let good common sense be your guide. This symbol is used to call your attention to instructions on a specific procedure that if not followed may damage or reduce the useful life of the compressor.

This symbol is used to call your attention to additional instructions or special emphasis on a specific procedure.


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Preparing for Installation

Preparation for installation is very important. Missing a step or an item can cause problems in the installation or damage to components.

Check off each item as it is completed so that you do not miss any preparation steps.

□ Disconnect both batteries, (second one under driver’s door, mounted to frame or other location), clean off any dirt, dust or debris from air intake tube and air filter box areas.

□ Loosen hose clamps and remove both rubber elbows and intake tube between air filter box lid and the rubber bellows leading to the engine.

Figure 1.1 – Filter Box and Intake Tube *Existing parts may differ slightly from that shown above.

Ensure no dirt or debris enters rubber bellows or air filter box openings.


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Air Box Lid Removal

□ Disconnect MAF Sensor.

□ Remove Air Filter box lid, and filter element.

□ Remove the MAF sensor and the filter minder from the lid, and set aside for re-use.

Lower Air Box Removal

□ Remove fastener at left front of air filter box where the 1/2" compressor hose is held to the air filter box with a ‘p-clip’.

□ Remove nut, in bottom of air filter box and lift out filter box.

□ Remove rubber intake sleeve from front of air box. Keep the sleeve, as it will be used with the modified air box. Do not reuse if it has been modified. (Figure 1.2)

Rubber Sleeve

Figure 1.2 – Rubber Intake Sleeve

□ Remove foam piece from rear bottom of air box and save for reuse later.

□ Remove fastener holding rear air filter box support bracket (1200604) to inner fender and discard, if not previously removed.

Air Dam


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□ Remove OEM steel support bracket which had been locating the air filter box, if not previously removed. (Figure 1.3)

Figure 1.3 – Air Filter Box Support Bracket

□ Remove OEM air dam. (Figure 1.4)

Figure 1.4 – OEM Air Dam

Remove OEM air ductfor modification

Air Dam


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Wiring Harness Protection and Routing

□ Locate the wiring harness guide. (Figure 1.5 / 1.6)

Figure 1.5 – Wiring Harness Guide

Figure 1.6 – Wiring Harness Guide Location

Plastic wiring harness guide

Second Threaded OEM Hole

Forward Threaded OEM Hole

OEM Air Duct to be removed


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□ Unclip plastic wiring harness guide from sub frame by pressing on clip and discard. (Figure 1.7)

Figure 1.7 – Wiring Harness Guide Clip

Remove wiring harness wrap so middle branch out of wiring can be relocated towards the firewall. (Figure 1.8)

Figure 1.8 – Wiring Harness “Middle Branch”

Clip location on plastic guide

Wrap to be removed

Middle branch out of wiring


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□ Now that wiring harness wrap is removed take middle branch out of wires and shift back along main wiring harness. (Figure 1.9)

Figure 1.9 – Relocate Middle Branch

□ Use electrical tape and wrap harness to secure middle branch out of wires to main harness. (Figure 1.10)

Figure 1.10 – Tape Wrap

Middle branch out of wires relocated back

Electrical tape wrap


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Glow Plug Module Bracket

□ Undo battery terminals on glow plug module bracket and remove fuse block from bracket.

□ Remove fasteners holding glow plug module bracket to inner fender, firewall and in wheel-well.

□ Undo fasteners holding the glow plug module on the bracket and discard the glow plug bracket.

□ Attach the glow plug module to the new bracket using the supplied fasteners.

Figure 1.11 – Glow Plug Module Bracket

□ Modify both OEM battery cable ends (positive and negative) by removing the threaded stud from the battery cable ends and then enlarging the stud holes to allow them to fit over each of the studs on the glow plug module. The clamping portion of the battery cable ends can also be cut off. (Figure 1.12)

Use caution when modifying the battery cable ends. Use a vice or other means to hold and support the cable end when drilling. A ‘step drill’ is recommended.

M8 Flat head Bolt (Supplied)

Positive Terminal Lock Nut

Negative Post

To Stud on Firewall

Install Glow Plug Module using M6 bolts (Supplied)


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Figure 1.12 – Modifying Battery Cables

□ If the battery cable clamping portions are not cut off it will look like the image below. Be sure to wrap any exposed ‘positive’ clamp with black electrical tape to prevent short circuiting. (Figure 1.13)

Figure 1.13 – Wrap Any Exposed “Positive” Clamp


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Updating the Hood Struts

□ Using a hammer, flatten the sheet metal, raised edge around the lower hood strut area. (Figure 1.14)

Figure 1.14 – Preparing for UHMW Pad

□ Ensure there are no sharp edges remaining.

□ Remove countersunk fastener holding long leg of the glow plug bracket to inner fender.

□ Align UHMW pad, supplied, with these two holes in inner fender and the large portion of pad forward of holes. Reinstall glow plug bracket flathead fastener. (Figure 1.15)

□ Install lower hood strut bracket with supplied fasteners. (Figure 1.15)

Flatten Sheet metal edge


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Figure 1.15 – Lower hood Strut and Glow Plug Module

□ Remove hood strut ball stud from passenger side of hood and install into strut relocating bracket. Install relocating bracket with supplied fasteners as shown. Note the 8mm hex nut may need to be oriented to fit in the slot in hood. (Figure 1.16)

Figure 1.16 – Upper Hood Strut

□ Reinstall passenger side hood strut.

M8 x 16 Hex head Bolt Lower Hood Strut Relocating Bracket

M8 x 20 Flat head Bolt

UHMW Guard Pad

Glow Plug Module

OEM Hood Strut Ball Stud

M8 Nut

Relocation Bracket

M8 x 18mm Bolts


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Complete Harness Routing

□ Use the 1.5” ID x 16.0” long protective wrap supplied and wrap harness as shown. (Figure 1.17)

Figure 1.17 – Protective Wrap

□ Remove previously installed M6 screw and M6 nut from glow plug module bracket and discard. Take loomed wire and route along the top of main harness as shown. (Figure 1.18)

□ Use supplied 4.0” section of protective wrap and cover wiring harness. (Figure 1.18)

□ Secure wiring harness to glow plug module using supplied M6 x 25mm screw, washer, P-Clip and M6 nut. (Figure 1.18)

Ensure protective wrap covers harness fully down to bottom section


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Figure 1.18 – Short Harness Wrap

□ Once installed bend P-clip down toward glow plug module to provide clearance between P-clip and air box once installed. (Figure 1.18 / 1.19)

Figure 1.19 – Harness Routing

□ Take washer fluid tube and loomed wire and route along the top of the main wiring harness. Secure with supplied tie wraps. (Figure 1.19)

Securing middle branch out of wiring harness to bracket using supplied P-clip, M6 bolt and nut

Route loomed wiring along top of harness

Supplied 4.0” plastic wrap covering wiring harness


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Figure 1.20 – Harness and Washer Fluid Tube Routing

□ Locate the sub frame nut insert which the front of the air box mounts to, measure 6.0” down along sub frame and using 5.5mm, or (13/64) drill until break through into hollow section. (Figure 1.21)

Figure 1.21 – Drill for P-Clip

□ Using supplied larger P-clip and secure wiring harness to sub frame using self-tapping screw supplied. (Figure 1.22)

□ Once installed push down on P-clip toward fender liner to create clearance for air box.

Tie wraps

Loomed wire, washer fluid tube routed on top of main harness

Sub frame nut insert

Drill here until break through In to hollow section


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Figure 1.22 – Flatten P-Clip for Clearance

□ Install the supplied modified air dam.

□ Locate passenger side headlight wire and mass air flow sensor wire and route overtop modified air dam once installed. (Figure 1.23)

Figure 1.23 – Wire Routing Around Modified Dam

□ After removing plastic wire guide, install plastic protective shell over metallic heat tape on wiring harness routed alongside and front of engine. Secure in place using tie wraps. (Figure 1.24)

Mass airflow connector wire

Head light wire

Note P-Clip is flattened towards fender liner for clearance


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Figure 1.24 – Anti-Abrasion Shell

Modify Inlet Valve Fittings

□ If the 3/16” push-to-connect fitting in the inlet valve is a straight fitting, then remove the fitting and replace it with the supplied 3/16” 90 degree push-to-connect fitting. (Figure 1.25)

Figure 1.25 – Note Orientation of Fitting

This should be a 90 degree fitting(Note orientation)

Protective shell

Metallic heat tape

Ensure his is a 90 degree fitting and Note orientation


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Intake Tube Brace

□ Remove OEM fastener holding ground-strap to firewall. (Figure 1.26)

Figure 1.26 – Intake Tube Brace and OEM Ground Wire

□ Use the OEM fastener to tap threads into the existing OEM hole 1-3/4” above the ground-strap hole. Remove OEM fastener and retain. (6mm tap may also be used).

□ Install supplied brace and ground strap using OEM fastener into lower hole and then the supplied fastener into the new threaded hole above it. The brace should sit flush against the firewall with the ground strap on top of the brace. Ensure the brace does not make contact with the electrical connector on the firewall. (Figure1.27)

Figure 1.27 – Intake Tube Brace and OEM Ground Wire

Tap hole using OEM Fastener Remove OEM Fastener from Ground Strap

OEM Ground Strap


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Inlet Brace Replacement

□ Remove the existing brace from the inlet and the front of the EGR and discard fasteners.

□ Replace with the supplied thicker EGR brace. (Use supplied M6 bolts from Air End Fastener Pack, use Loctite© and torque to specifications). (Figure 1.28)

Figure 1.28 – EGR Brace Bolt Locations

□ Replace inlet brace and install fasteners finger tight only. (Do not use Loctite on these two (2) bolts). (Figure 1.29)

Figure 1.29 – Longest Bolts are used with Inlet Brace

Lower portion of inlet brace bolts here.Lower Portion of Inlet Brace Bolts Here


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□ Join the brace on the EGR to the one on the inlet valve using the supplied M8 bolts, washers and Nyloc© nuts and torque to 19 ft. lbs.

Ensure the brace bracket bolts are not preloaded before

tightening the inlet valve bolts.

Never use an impact wrench to install inlet bolts. The torque spec for inlet bolts is 19 ft. lbs.

□ Tighten the two (2) inlet valve bolts and torque to 19 ft. lbs.

Clutch Guard Replacement and P-clip Installation

□ Undo the two nuts retaining clutch guard at clutch pulley, remove

clutch guard. Retain nuts and flat washers for re-use.

□ Install new clutch guard with rubber pad.

□ Review the routing of the 1/2” hose on the compressor. The hose will route up over the compressor behind the clutch guard and through the new P-Clip supplied in the retrofit kit. This hose must be protected from damage from any fasteners or other sharp edges. (Figure 1.30)

Figure 1.30 – P-Clip Location

Clutch Guard

P-Clip mounted behind Clutch Guard


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□ Finish installing the p-clip and clutch guard using the two nuts and flat washers and ensure the clutch wire bracket does not twist out of position during tightening.

Install Lower Air Box

□ Install rubber intake sleeve previously removed from air box into opening in front of metal filter box. Groove in rubber fits in opening and rubber tab clips into holes in the front of the filter box. (Figure 1.31)

Figure 1.31 – Rubber Intake Sleeve

□ Insert modified foam filter section into rear of supplied filter box. Foam goes in original location of plastic section (groove fits in plastic lip). (Figure 1.32)

Figure 1.32 – Modified Foam Filter

Modified Air Filter Box

Modified Foam Filter


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□ Install supplied air filter box assembly. Rubber at front of air box should fit over the air dam at the radiator support frame, and the air filter box should be further forward from original position.

□ Apply Loctite blue and loosely install supplied bolt from inside the lower air box through a clearance hole in the plastic into the hole in the metal tab and into the forward OEM threaded hole in inner fender. (Figure 1.33)

Due to variations in the truck frame, the front air filter box mount bolts need to be loosely installed. Also, the air filter box sits on top of the fender liner, so in order to align the rear air box bracket mounting hole with OEM threaded hole in fender you will need to push down on the rear of the air filter box.

□ Apply Loctite blue and install supplied bolt through air box bracket, into second OEM threaded hole in inner fender, towards rear of air filter box. (Figure 1.33)

Figure 1.33 – Re-installing Air Box

□ Install P-Clip to hold oil line going to cooler and use supplied M8 bolt to go through P-Clip. (Figure 1.33)

Air box Bracket

M8 Nut to Mount P-Clip

Supplied Bolt & P-Clip


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□ Re-install the filter minder on the air box lid assembly, use the supplied hose clamp. (Figure 1.34)

□ Install MAF (mass air flow) sensor onto supplied air box lid assembly. (Figure 1.34)

Figure 1.34 – Air Box Lid Assembly

□ Install OEM air filter.

□ Fit the air box lid loosely in the silicon elbow included with the

intake tube.

□ With the air filter installed, fit the lid securely onto the air box,

securing it with the four air box clips.

□ Fit the free end of the intake tube loosely into the inlet bellows on

the engine.

□ Position intake tube for best clearance to brace. (Figure 1.35)

OEM Filter Minder

MAF Sensor Silicon Elbow

Supplied Hose and Clamp

Intake Tube


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Intake tube must be positioned as far from the intake tube brace and the firewall connector as possible before tightening the T-clamps.

Figure 1.35 – Intake Tube Brace

□ Before tightening the clamps, make sure the silicon elbow is positioned to provide an adequate sealing surface under each clamp. Align the clamps with the edges of the silicon elbow.

To seal properly, the clamps require a sealing surface which is, at minimum, as wide as the clamp strap. (Figure 1.36)

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Confirm Clearance between Brace and Intake Tube

Intake Tube Brace

Confirm Clearance between Brace and ECU


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Figure 1.36 – Ensure Proper Clamp Seal

Ensure intake tube is close to, and or resting on the clutch guard rubber pad. Loosen hose clamps and adjust tube position if required.

□ Check hood clearance to intake tube and adjust tube into rubber elbow if required.

□ Tighten the clamps, making sure they seal completely. Do not use an impact driver, as this may damage the air box lid.

□ Add ‘paint pen’ or other marker to indicate proper alignment once final position is set. (Figure 1.37)

!


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Figure 1.37 – Markings to indicate Final Alignment

□ Plug in the MAF sensor connector.

□ When the position of the intake system is finalized, ensure all the clamps are tight and apply the supplied heat shrink to the two T-bolt clamps.

The T-bolt clamps should never be removed when

servicing the air filter.

□ Re-connect both of the batteries.

□ Start engine and allow vehicle to warm up to normal operating temperature.

□ Run VMAC compressor to test for leaks.

□ Please contact VMAC Technical Support via phone or email with your VMAC System ID so that a Customer Service Reference can be created documenting this retrofit

Phone: 1-888-241-2289

Email: [email protected]

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Once final positioned, is determined use a “paint pen” or similar marker to indicate final alignment

mailto:[email protected]

intake tube on ford 6.7l vr150 existing kits · intake tube on ford 6.7l vr150 existing kits...

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