Vortech Alpha H3 Hummer - 2008 User Manual

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GM ALPHA

H3 HUMMER

Supercharger System

Installation Instructions

50 State Smog Legal per CARB EO #D-213-27

2008 Model Years

ENGINEERING, LLC

1650 Pacific Avenue, Channel Islands CA 93033-9901 • Phone: 805 247-0226

Fax: 805 247-0669 • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST)

DP/N: 4GN020-015 - v2.0 10/20/08

FOREWORD

his manual provides information on the installation, maintenance and service of the Vortech supercharger kit expressly designed for this vehicle. All information, illustra-

tions and specifications contained herein are based on the latest product information available at the time of this publication. Changes to the manual may be made at any time without notice. Contact Vortech Engineering for any additional information regarding this kit and any of these modifications at (805) 247-0228 8:00am-4:30pm PST.

Take note of the following before proceeding:

1. Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the installation to determine if you should refer the job to a professional installer/technician. Please contact your dealer or Vortech Engineering for possible installers in your area.

2. This product was designed for use on stock (un-modified, OEM) vehicles. The PCM (computer), engine, transmission, drive axle ratios and tire O.D. must be stock. If the vehicle or engine has been modified in any way, check with Vortech prior to installation and use of this product.

3. Use only premium grade fuel with a minimum of 91 octane (R+M/2).

4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard use (no boost) until the problem is resolved.

5. Vortech is not responsible for any clutch, transmission, drive-line or engine damage.

Exclusions from Vortech warranty coverage considerations include, but not limited to:

1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation.

2. Continued operation with an impaired vehicle or sub-system.

3. The combined use of Vortech components with other modifications such as, but not limited to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM programming or other such changes.

into another language in any form, by any means without written permission of Vortech Engineering, LLC.

TABLE OF CONTENTS

FOREWORD ..............................................................ii

TABLE OF CONTENTS..................................................... iii

IMPORTANT NOTES.......................................................iv

TOOL & SUPPLY REQUIREMENTS............................................v

PARTS LIST (2008 H3 HUMMER) ............................................vi

1. PREPARATION/REMOVAL............................................ 1

2. OIL DRAIN INSTALLATION (OIL FED MODELS ONLY) ..................... 3

3. OIL FEED INSTALLATION (OIL FED MODELS ONLY) ...................... 4

4. FUEL INJECTOR REPLACEMENT ..................................... 5

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION ............. 6

6. RADIATOR HOSE MODIFICATION .....................................12

7. CHARGE COOLER INSTALLATION ....................................13

8. AIR INLET INSTALLATION............................................17

8. AIR INLET INSTALLATION "TEMPLATE" ................................19

9. PCV VALVE INSTALLATION ..........................................21

10. FINAL CHECKOUT..................................................22

iii

20OCT08 v2.0 08HummrH3(4GNv1.0)

P/N: 4GN020-015

HUMMER H3

IMPORTANT NOTES

2008 Models

This kit requires the installation of a Vortech ECU Reflash. The ECU must be sent directly to Vortech by the installing customer (the charge for this service with reflash installation has been included in the purchase price).

• Included in this kit is a prepaid next-day air shipping box and a credit tag for one (1) Vortech ECU Reflash.

• An ECU reflash is created specifically for each individual vehicle with respect to the factory ECU calibration.

• Simply contact the Vortech Service Department at (805) 247-0226 to request a Return Authorization Number (See ECM Module Credit Tag for more details).

- Mail to Vortech the enclosed "ECU Reflash" (send original tag - no photocopies will be accepted) and ECU in the supplied box.

- Turnaround time will be 1-2 days (each application varies). Vortech will give an estimate at the time of your order.

Your Vortech ECU Reflash comes with a twelve (12) month limited warranty from the original date of purchase of your supercharger system (see Owner's Manual for details).

Note: Vortech Engineering is not responsible for engine or ECU damage due to an improperly installed/mishandled ECU.

This product is protected by state common law, copyright and/or patent. All legal rights therein are reserved. The design, layout, dimensions, geometry, and engineering features shown in this product are the exclusive property of Vortech Engineering, LLC. This product may not be copied or duplicated in whole or part, abstractly or fundamentally, intentionally or fortuitously, nor shall any design, dimension, or other information be incorporated into any product or apparatus without prior written consent of Vortech Engineering, LLC.

GM 2008 H3 Hummer

ENGINEERING, LLC

Installation Instructions

50-State Smog Legal, as per CARB EO # D-213-27

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH® Supercharger!

Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Automotive Limited Warranties Program and the Warranty Registration form.

Vortech supercharger systems are performance improving devices. In most cases, increases in torque of 30-35% and horsepower of 35-45% can be expected with the boost levels specified by Vortech Engineering. This product is intended for use on healthy, well maintained engines. Installation on a worn-out or damaged engine is not recommended and may result in failure of the engine as well as the supercharger. Vortech Engineering is not responsible for engine damage.

Installation on new vehicles will not harm or adversely affect the break-in period so long as factory break-in procedures are followed.

For best performance and continued durability, please take note of the following key points:

1. Use only premium grade fuel 91 octane or higher (R+M/2).

2. The engine must have stock compression ratio.

3. If the engine has been modified in any way, check with Vortech prior to using this product.

4. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until problem is

resolved.

5. Perform an oil and filter change upon completion of this installation and prior to test driving your vehicle. Thereafter, always use a manufacture-rated, high grade engine oil or a high quality synthetic, and change the oil and filter every 3,000 miles or less. Never attempt to extend the oil change interval beyond 3,000 miles, regardless of oil manufacturer's claims as potential damage to the supercharger may result.

6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs every at least 15,000 miles and spark plug wires at least every 50,000 miles.

TOOL & SUPPLY REQUIREMENTS

• Factory Repair Manual

• 3/8" Socket and Drive Set: SAE & Metric

• 1/2" Socket and Drive Set: SAE & Metric

• 3/8" NPT Tap, 1/4 -20 Tap and Handle

• Adjustable Wrench

• Open End Wrenches: 3/8", 7/16", 1/2", 9/16", 7/8”, 10mm

• Center Punch and a 5/8" Tapered Punch

• 3/8” Springlock Fuel Fitting Disconnect Tool

• 5 Quarts manufacturer specified Engine Oil

• Oil Filter and Wrench

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Heavy Grease

• Silicone Sealer

• Drill Motor

• 1/8", 3/16", 27/64" Drill Bits

• 5/16" Allen Wrench

• Wire Strippers and Crimpers

• Utility Knife

• Power Steering Pulley/Puller & Installer

If your vehicle has in excess of 15,000 miles since its last spark plug change, then you will also need:

• Spark Plug Socket

• NEW Spark Plugs

20OCT08 v2.0 08HummrH3(4GNv1.0)

P/N: 4GN020-015

GM 2008 H3 Alpha Hummer

Part No. 4GN218-040L

ENGINEERING, LLC

PARTS LIST

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages

or damaged parts immediately.

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY.

2F328-030 V3 SC-TRIM,CW,CRVD,STN,H3-A 1

2A036-333 S/C PULLEY 3.33" 6 GROOVE 1

4GN111-051 ASSY, MNTG BRKT H3 ALPHA 1

4GN011-051 BRKT, S/C MNT H3 ALPHA 1 4GN011-061 BRKT, SPRT H3 ALPHA 1 4GN017-011 SPACER, S/C MNT TOP H3 ALPHA 1 4GN017-021 SPACER, S/C MNT LWR H3 ALPHA 1 2A017-102-299 SPACER, 1"OD X .406"ID X 2.992" 1 2A017-875-198 SPACER, .875"OD X .406"ID X 1.98 2 2A017-625-025 SPACER, .625"OD X .375"ID X .025" 1 7C010-025 M10-1.5 X 25MM HXCSP 1 7C010-111 M10 X 1.5 X 110 HXHD, ZINC 1 7C010-120 M10 X 1.5 X 120 HXHD, ZINC 1 7C010-130 M10 X 1.50 X 130 HEX HEAD 1 7A375-124 3/8-16 X 1-1/4 HHCS, G5, PLATED 4 7A375-352 3/8-16 X 3.5" HX HD GR8 1 7A375-075 3/8-16 X 3/4 GR5 HXHD ZINC 1 7A375-400 3/8-16 X 4" BOLT HXHD GR8 3 7A375-426 3/8-16 X 4.25" HX HD GR8 1 7K375-040 3/8 AN960 FLAT WASHR PLATED 13 4FR016-150 STEEL IDLR PLY, 3" 6 RIB SMOOTH 1 4FH016-150 IDLER PULY, 6RIB 3" FLANGD 1 2A017-177 SPACER, Ø.875 X 1.772 W/PLT 1 2A017-016 PILOT, 6203/5 BRG, 3/8 SCREW 1 2A046-114 BELT, K061145-GATES 4.6 2V 1 7J750-394 SPACER, .375/M10 IMPELLER NUT 1 7J625-030 SHIM, Ø.692" ID X .030" THK X 1

8N201-340 CHARGE COOLR ASY, 08, H3 ALPHA

8N101-340 WELDED CORE ASSY, H3 ALPHA 1 8N055-050 PLASTIC CAP, SURGE TANK 1 7R002-044 #44 SAE TYPE F SS HOSE CLAMP 2 7S275-500 SLEEVE, 2.75" X 5.00"L, BLUE 1 7S300-300 SLEEVE, 3" X 3", BLUE 1 4GN012-020 DUCT, DISC. H3 ALPHA 1 4GL012-030 ELBOW,3.88"-3.0" X 90 GM TRK 1 7R002-048 #48 SAE TYPE F SS HOSE CLAMP 3 7R002-060 #60 SAE TYPE F SS HOSE CLAMPS 1 8F001-402 PUMP, WATER, PIERBURG 1 7R003-027 ADEL CLAMP,1-11/16" 2 7E010-075 #12 X 3/4" SHT METL SCRW HEX 2 7U030-046 5/32" VACUUM LINE 1.5 8D001-001 STD COMPRESS BYPASS VALVE 1 7U034-016 1" GS HEATER HOSE 0.83 7R002-016 #16 SAE TYPE F SS HOSE CLAMP 4 8N010-230 BRKT, UPR SPRT SETRAB H3 1 8N010-240 BRKT, SETRAB MNT H3 1 8N006-010 WATER COOLR, SETRAB SINGLE PASS 1 7P500-026 1/2NPT X 3/4 BARB 90 BRASS 1 7P500-078 1/2NPT X 3/4 HOSE FIT STRT 3 7P375-075 3/4" HOSE BARB UNION, BRASS 1 7U038-012 HOSE,3/4"DIA 90 ,4X12 LEGS 2 7U038-150 HOSE, 3/4"X150 MOLDED HOSE 1 4GV014-010 WATER PIPE, L BEND 1 7U038-000 3/4" HEATER HOSE 4.33 7R007-001 NYLON RATCHET CLAMP 1-1/8" 10 5W001-015 FUSE, BLADE TYPE 20 AMP 1 5W001-071 FUSE HOLDER,16GA WIRE 1 5W018-020 18GA STRD WIRE BLK, UL1015 5 5W001-024 MINI ATC FUSE TAP 1 5W001-025 FEM SLIDE,INSUL,MINI,22-16AWG 1 5W001-012 18-22 GA BUTT CONN RED INSUL 1 7C080-016 M8 X 1.25 X 16 HXHD 1 5W001-046 16-14 GA RING TERM .33" HOLE 1

4GN112-030 AIR INLET ASSY, H3 ALPHA

4GN013-010 AIR CLEANER COVER, H3 1 4GN013-020 BRACKET, AIR FILTER CVR SPRT 1 7S350-200 SLEEVE, 3-1/2 X 2, BLUE 2 8H040-235 AIR FILTER, 4.0FLG X 7.0L 1 7F006-093 6MM NYLOCK NUT 1 7A250-063 1/4-20 X .63 HHCS SS 2

7S350-350 ELBOW,Ø3.5" 90 DEG W/BUNG 1 4FA012-012 INTAKE ELBOW,90 DEG W/O BOSSES 1 7R002-056 #56 SAE TYPE F SS HOSE CLAMP 4 8A002-041 MAF, 2008 H3 ALPHA Ø3.44" ID 1 7C040-008 M4-.7X8MM SCHD SS 2 7A250-074 1/4-20 X .75 HHCS PLTD 2 7A250-101 1/4-20 X 1 HHCS ZINC PLTD 1 7J250-001 1/4 WASHER, SAE, PLTD 6 7U035-001 3-1/2" FLEX HOSE 0.83 7R002-052 #52 SAE TYPE F SS HOSE CLAMP 2 7U032-016 3/8" EFI FUEL HSE HI-PSR 1 7P375-050 3/8" HOSE UNION, BRASS 1 7P375-037 3/8 NPT MALE X 3/8 HSE BARB 90º 1 4GN013-030 SHIELD, SPUND SPR 1 4GN125-100 SOUND ABS. MAT 1

4GN139-098 PCV MOD ASSY, H3 ALPHA 1

7P375-106 PCV VALVE, FORD, 3/8" HOSE 1 7P625-377 REDUCER, 5/8 BARB TO 3/8 BARB 1 7R001-008 #8 STNLS HOSE CLAMP 1 7R004-002 STEPLESS CLAMP, 17.0-70 2 7U033-020 HOSE, 5/8"ID CLASS 1 EMISSIONS FUEL 0.125

4GN114-020 COOLANT PIPE ASSY. H3 ALPHA 1

7R002-020 #20 SAE TYPE F SS HOSE CLAMP 2 4GN014-020 RAD. PIPE Ø1.375, H3 ALPHA 1 4GN014-010 TUBE ASSY.,Ø.75 X 2.5 X 4.5 X 75° 1 7U133-024 5/8"MOLDED ELBOW HSE, 24" 1 7U038-012 HOSE,3/4"DIA 90 ,4X12 LEGS 1 7P375-075 3/4" HOSE BARB UNION, BRASS 1 7P625-016 5/8" HOSE UNION, BARBED ENDS 1 7R003-016 ADEL CLAMP, 1.0" 1 7R001-008 #8 STNLS HOSE CLAMP 4

8F060-047 FUEL INJ 47LB, DELPHI MULTEC 3.5 SHORT 8 4GN020-015 INSTR MAN, H3 ALPHA HUMMER 1 008110 SMALL SILVER DIE CUT DECAL 2 008130 LICENSE PLATE FRAME, VORTECH 1 008447 S/C STRT INFO PKG ASSY VORT 1 009035 LUBE ASSY 1

1. PREPARATION/REMOVAL

A. Disconnect the negative battery cable, and

remove the plastic engine cover.

NOTE:

1. Locate the vehicles ECU and TCM modules behind the washer fluid/coolant reservoir assembly passenger side firewall.

2. Temporarily loosen the washer fluid/coolant reservoir assembly to gain adequate access to the modules.

3. Unplug the four factory harness connections and remove the modules from the vehicle.

4. Contact the Vortech Service Department for a Return Authorization Number. Send both the ECU and TCM and supplied credit tag to Vortech using the enclosed shipping materials.

B. Disconnect the MAF electronics harness con-

nection from the meter. (See Fig. 1-a)

C. Disconnect the passenger side valve cover

vent line fom the valve cover. Remove the 90° rubber elbow and set aside to be reused in a later step.

D. Using a 5/16” nut driver, loosen the hose

clamp securing the inlet duct to the throttle body. Remove the air filter lid and inlet duct to the throttle-body. (See Fig. 1-b)

E. Disconnect the MAF harness from the lower

half of the air box. Using a 13mm socket and long extension remove the fasteners retaining the lower portion of the air filter enclosure to the inner fender. Set the air box aside, it will not be reused.

F. Remove the MAF electronics from the previ-

ously removed air filter assembly and set aside to be reused in a later step. (See Fig. 1-a)

G. Using a 15mm wrench detention the factory

belt tensioner and remove the accessory belt.

H. Remove the three 15mm headed retainers

securing the factory belt tensioner to the water pump.

I. Remove the front skid plate and set aside.

Drain the engine coolant into a clean container and set aside to be reused in a later step. Once the coolant is drained remove the retainer securing the heater hose support bracket to the front of the passenger side cylinder head. (See Fig. 1-c & 1-d)

Fig. 1-a

Fig. 1-b

Fig. 1-c

20OCT08 v2.0 08HummrH3(4GNv1.0)

P/N: 4GN020-015

1. PREPARATION/REMOVAL, CONT’D.

J. Disconnect the 1/4" coolant line from the

heater hose assembly. Disconnect the heater hoses where they attach to the water pump and fire wall on the passenger side. Remove the heater hose assembly and set aside. (See Fig. 1-d & 1-e)

K. Remove the stud that formerly retained the

front drivers side corner of the engine cover and discard. (See Fig. 1-f)

HEATER HOSE

SUPPORT BRACKET

1/4" LINE

Fig. 1-d

Fig. 1-e

Fig. 1-f

STUD

2. OIL DRAIN INSTALLATION (ENGINE OIL-FED KITS ONLY. APPLICATIONS WITH V3 SUPERCHARGERS SKIP AHEAD TO STEP 4)

NOTE: To provide an oil drain for the supercharger,

it is necessary to make a hole in the oil pan.

A. Locate and remove the fasteners that secure

the factory transmission cooler to the front cross-member. Push the cooler up and temporarily secure out of the way. (See Fig. 2-a)

B. Remove the 10mm headed fastener that

secures the plastic wire loom to the front of the oil pan. (See Fig. 2-b)

C. Mark the hole location as shown on the front

of the pan. Center punch the hole location to be drilled. (See Fig. 2-c)

D. Drill an 1/8” pilot hole at the previously

marked location. Locate the oil drain assembly (4GN130-036). Use the supplied 9/16” cutter to enlarge the pilot hole, making sure to break through easily. Do not stop the drill motor until the cutter has been extracted so that the cutout does not fall into the pan. It

may help to pack the cutting tool with grease to help prevent any stray chips from entering

the oil pan.

E. Thread the hole with a 3/8” NPT tap to

approximately 1/2" deep or until the fitting can be started. Pack the flutes of the tap with grease to minimize the amount of debris that gets into the engine. Access is restricted so inserting the tap in a socket and then using a ratchet to rotate it is helpful.

TRANSMISSION COOLER

Fig. 2-a

Fig. 2-b

NOTE: When tapping the hole be careful

not to bottom out the tap. If the tap does bottom before the thread is large enough you will need to trim the end of the tap to facilitate a deep enough thread cut.

F. Thoroughly clean the threaded area and the

interior of the engine. Apply a small amount of silicone sealer to the new threads. Apply more sealer to the 3/8” NPT MALE X .5 FEMAL INVERTED FLARE hose fitting and secure in the hole. Make sure a seal is formed all around the fitting. (See Fig. 2-d)

G. Loosely install the TUBE NUT ASSEMBLY

into the previously install fitting. The supercharger oil drain hose connection will be made in a later step. Leave the transmission cooler and wire loom loose until then. (See Fig. 2-d)

H. Drain the engine oil and change the filter.

2 5/8"

1.5"

Fig. 2-c

Fig. 2-d

20OCT08 v2.0 08HummrH3(4GNv1.0)

P/N: 4GN020-015

3. OIL FEED INSTALLATION (ENGINE OIL-FED KITS ONLY. APPLICATIONS WITH V3 SUPERCHARGERS SKIP AHEAD TO STEP 4)

A. Install the 1/8” NPT x 90° -4 fitting into the

supplied oil feed adaptor as seen in figure 3-a.

B. Locate the factory oil passage cover just

above the oil filter on the driver’s side of the engine. Using a 10mm socket remove the factory retainers and discard.

C. Using the new gaskets and 6mm hardware

provided reinstall the factory oil passage cover and oil feed adapter. The 90° fitting should be facing the front of the vehicle. (See Fig. 3-b)

D. Attach one end of the supplied –4 stainless

steel oil line to the previously installed –4 x 90° fitting and secure. (See Fig. 3-b)

E. Route the line toward the front of the engine

and up to where it will be attached to the supercharger oil feed. Using the supplied cable ties secure the line away from hot, sharp or moving parts. (See Fig. 3-c)

F. Cover the open end of the line to prevent

contamination until the connection to the supercharger is made in a later step.

Fig. 3-a

Fig. 3-b

OIL FEED LINE

Fig. 3-c

4. FUEL INJECTOR REPLACEMENT

NOTE: Caution should be used when working on

the fuel system. Fuel may be under high pressure. Fuel injector replacement should be performed in a well ventilated area free of any possible ignition source. It is recommended that you have a fire extinguisher nearby.

A. Relieve the fuel system pressure. B. Disconnect the eight fuel injector wiring clips

and retainers from the injectors.

C. Remove the four 8mm bolts securing the fuel

rails to the intake manifold. Lift up on the rails evenly, removing all eight injectors. Separate and set aside the factory injectors as they will not be re-used.

D. Using a small amount of clean motor oil,

lightly lubricate the O-rings on both ends of the supplied fuel injectors.

E. Install the new fuel injectors into the fuel rails

and secure using the factory retaining clips.

NOTE: The injector plug connections must

face outwards.

F. Carefully lower the fuel rail-injector assembly

down onto the intake manifold. Check to see that each injector has been seated properly into the manifold.

G. Secure the fuel rail assembly using the origi-

nal hardware and attach the wiring clips to the injector terminals.

20OCT08 v2.0 08HummrH3(4GNv1.0)

P/N: 4GN020-015

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION

NOTE: For the following section, refer to Fig 5-l &

Fig. 5-m on page 10 and 11, for screw and spacer location. Do not tighten until instructed to.

A. Locate the supercharger mounting bracket

assembly (4GN111-051)

B. Clearance (grind) the end of the passenger

side valve cover flush with the head surface. (See Fig. 5-a)

C. Install the support bracket to the passenger

side cylinder head using the M10 X 25mm screw and washer. Make sure the head surface is clean and no wires or hoses are between the bracket and mounting surface. Loosely install one of the factory tensioner mounting retainers in the lower cylinder head hole location as a guild. Tighten the previously installed M10 screw. Remove the tensioner retainer used as a guild. (See Fig. 5-b)

D. Using two 3/8-16 x 4” screws and the lower

bracket spacer, loosely install the supercharger mounting bracket.

E. Install one of the Ø1.0” x 2.992” spacer using

the M10 x 110mm screw, do not use a washer when installing this fastener as tensioner bracket interference will result. (See Fig. 5-c)

F. Using a one of the factory tensioner retainers,

M10 x 120mm, and 3/8-16 x 4” retainers and washers install the upper (three hole) spacer between the supercharger bracket and the previously installed support bracket. Tighten all hardware installed to this point. (See Fig. 5-c)

G. Locate the factory spring tensioner and sup-

plied mounting hardware: Place the 0.121” thick washer onto the M10 x 130mm screw and insert it through the factory spring tensioner. Insert the 3/8-16 x 4.25” screw and washer through the tensioner. Place the two Ø.875” x 1.98” spacers on the previously installed hardware. Insert the 3/8-16 x .75” screw and washer through the remaining tensioner hole and place the .025” spacer on it. Carefully install this assembly. The M10 screw will go through the support bracket and into the head. The 3/8-16 x 4.25” screw secures to the support bracket. And the 3/816 x .75” screw secure to the supercharger mounting bracket. (See Fig. 5-d, 5-l, 5-m)

Fig. 5-a

M10 x 25mm

Fig. 5-b

M10 x 110mm

Fig. 5-c

Fig. 5-d

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, CONT’D.

H. Remove the 15mm headed screw securing

the ribbed tensioner pulley to the tensioner arm. Install the supplied 3” steel smooth idler and secure using the factory hardware and Ø.692" I.D x .030" thick spacer.

I. Locate the coolant pipe assembly (4GN114-

020). Secure the Ø3/4” x 90° and Ø5/8” x 90° molded hoses to their corresponding water pump ports using the factory hose clamps from the previously removed hose assembly. (See Fig. 5-e)

J. Using the supplied adel clamp secure the

Ø5/8” hose to the coil (front passenger side) retainer. Route the hose to the heater core connection at the firewall. Locate and cut the factory heater hose assembly to obtain the factory clip connectors (leave yourself extra hose and trim as necessary) set the 3/4" connector aside. Connect the factory 5/8” clip connector to the heater core. Use the supplied Ø5/8” union and hose clamps to connect the previously installed mold hose to the factory heater hose (trim as necessary for best fit). (See Fig. 1-f, 5-f & 5-g)

Ø 5/8" HOSE

Ø 3/4" HOSE

Fig. 5-e

COIL

ADEL CLAMP

Fig. 5-f

FACTORY 5/8" HOSE

Fig. 5-g

UNION

5/8" HOSE

20OCT08 v2.0 08HummrH3(4GNv1.0)

P/N: 4GN020-015

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, CONT’D.

K. Install the Ø3/4” aluminum 105° tube into the

open end of the previously installed Ø3/4” molded 90° hose (the 1/4" barb should face slightly forward). Connect the factory 3/4" clip connector to the heater core. Insert the open end of the 105° aluminum tube into the open end of the factory 3/4" hose. Secure all hose connections with the provided hose clamps. Secure the factory 1/4" bleed hose to the 1/4" barb on the 105° aluminum tube. (See Fig. 5-h)

L. (OIL-FED MODELS ONLY) Using one of the

supplied #6 hose clamps secure the provided 1/2" oil drain hose to the 1/2" oil drain fitting on the bottom of the supercharger. (See Fig. 5-i)

M. Mount the supercharger to the supercharger

bracket using the four 3/8-16 x 1.25” screws and washers. Attach the supplied 3” flanged smooth idler to the mounting bracket using the Ø.875” x 1.772” piloted spacer, 3/8-16 x

3.5” screw, and pilot washer. (See Fig. 5-j, & 5-k, 5-l)

N. (OIL-FED MODELS ONLY) Install the

1/8”NPT x 90° x –4 fitting into the supercharger oil feed port and orient so it faces down. (See Fig. 5-j)

FACTORY

Ø 3/4"

HOSE

1/4" BLEED

HOSE

105° ALUMINUM

TUBE

Ø 3/4" MOLDED

90°HOSE

Fig. 5-h

1/8 NPT x 90° x

-4

3" FLANGED

SMOOTH IDLER

Fig. 5-i

Fig. 5-j

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, CONT’D.

S/C

3”

FLANGED

IDLER

ALT.

IDLER

TENSIONER

WATER

PUMP

POWER

STEERING

CRANK

O. (OIL-FED MODELS ONLY) Connect the 1/2"

oil drain hose from the S/C to the 1/2" tube assembly previously installed in the oil pan and secure. Using a cable tie secure the line to the A/C line away from the A/C pulley

NOTE: Ensure that the hose does not have

any dips or kinks in the routing. Supercharger failure may be the result of a restricted drain path.

P. (OIL-FED MODELS ONLY) Connect the open

end of the –4 stainless steel oil feed line to the –4 x 90° fitting on the supercharger.

Q. Install the supplied drive belt as shown. (See

Fig. 5-k)

Fig. 5-k

20OCT08 v2.0 08HummrH3(4GNv1.0)

P/N: 4GN020-015

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, CONT’D.

3/8-16X3.5” WITH PILOT WASHER

3/8-16X4”

M10-1.5X120MM

FACTORY TENSIONER RETAINER

M10-1.5X25MM

3/8-16X4.25”

M10-1.5X130MM&0.121” THICK WASHER

M10-1.5x110MM NO WASHER

3/8-16X4”

3/8-16X.75”

3/8-16X4”

4X3/8-16X1.25”

Fig. 5-l

UPPER (3 HOLE) SPACER

LOCATED BETWEEN S/C

BRACKET AND SUPPORT

BRACKET

Ø .625”X.025” SPACER

LOCATED UNDER TENSIONER

MOUNTING BOSS

LOWER (2 HOLE) SPACER

LOCATED BETWEEN S/C

BRACKET AND SUPPORT

BRACKET

Ø1.0” X 2.992” SPACER

LOCATED BETWEEN S/C

BRACKET AND SUPPORT

BRACKET

Ø0.875” X 1.98 SPACERS

LOCATED UNDER TENSIONER

MOUNT BOSSES

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, CONT’D.

Fig. 5-m

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6. RADIATOR HOSE MODIFICATION

A. Locate the upper radiator hose. B. Cut the hose after the 45° leaving as much

straighht section as possible (approximately 1"). See Fig. 6-a.

C. Make a second cut approximately 2" before

the 90° bend. See Fig. 6-a.

D. Install the provided stainless steel radiator

tube and secure using the supplied #20 hose clamps. See Fig. 6-b.

NOTE: Adjust the hose ends as necessary to pro-

vide the best possible drive belt and idler pulley clearance.

Fig. 6-a

Fig. 6-b

7. CHARGE COOLER INSTALLATION

Refer to Fig.7-h for assistance throughout this manual. A. Remove the four screws and two nuts that

secure the grill to the core support.

B. Pull forward on the ends of the grill to release

the push clips holding the grill in place.

C. Locate the Charge Air Cooler assembly

(8N201-340).

D. Install one 1/2"NPT x 3/4" barb 90° brass

elbow and one 1/2"NPT x 3/4" barb straight fitting into the supplied heat exchanger and orient as shown*. (See Fig. 7-h.)

E. Remove the two 13mm headed screws and

two 10mm headed screws securing the hood latch support assembly to the core support. Unclip the wire harness that runs behind the support. Set the support aside to be reinstalled later. (See Fig. 7-a.)

F. Secure the heat exchanger bracket (8N010-

240) to the heat exchanger using the 1/4-20 x .75" screws, washers and Nyloc nuts provided. Loosely install the heat exchanger assembly into position. (See Fig. 7-a, 7-h.)

G. Reinstall the hood latch support (the heat

exchanger bracket is between the core support and the hood latch support) secure using the factory hardware. Feed the sensor leads through their respective sides and reconnect to the sensors.

150° MOLDED

HOSE

90° HOSE

Latch

Support

Fig. 7-a

NOTE: Careful not to pinch wires between the

brackets.

H. Place the supplied piece of 1/8" x 4" tape foam

on the heat exchanger. It may be necessary to trim the tape to fit. Install the upper heat exchanger bracket and secure using a 1/4-20 x .75" screw, washer and Nyloc nut provided. (See Fig. 7-b.)

I. Using the supplied Adel clamps, self-tapping

screws and washers, secure the provided water pump, to the cooling fan shroud. (See Fig. 7-c.)

NOTE: Orient the pump discharge so that it points

to the front passenger side of the vehicle.

J. Secure the supplied Ø2.75" X 5" sleeve to the

supercharger discharge using a #44 hose clamp. (See Fig. 7-d.)

K. Using the supplied Ø3.88” to Ø3.0” reducer

elbow and Ø3.0” x 3” sleeve, install the discharge duct between the CAC and the throttle body, secure using the #48 & #60 hose clamps provided. See Fig 7-d)

HOSE FROM CAC

WATER PUMP

Fig. 7-b

150° HOSE

Fig. 7-c

* Use pipe sealant on tapered pipe threads.

20OCT08 v2.0 08HummrH3(4GNv1.0)

P/N: 4GN020-015

7. CHARGE COOLER INSTALLATION, CONT’D.

L. Install the two 1/2" NPT x 3/4" barb fittings

into the charge air cooler (CAC*).

M. Cut a piece of the supplied Ø3/4" rubber

hose (7U038-000) approximately 24" long. Connect the cut hose between the CAC discharge (bottom driver’s side fitting) and the water pump inlet as shown. (See Figs. 7-c, 7-d 7-h.)

N. Connect the supplied 150° x Ø3/4" molded

rubber hose between the water pump discharge and the heat exchanger inlet (passenger’s side fitting). (See Figs. 7-a, 7-c, 7-h.)

O. Attach the short end of the supplied molded

90° rubber hose (7U038-012) to the straight fitting previously installed in the heat exchanger (driver’s side fitting). (See Fig. 7-a, 7-h.)

NOTE: Trim the hose as necessary.

P. Trim the long end of the previously installed

hose to about 1.5". Connect the long end of the formed 150° aluminum tube to the open end of the previously installed 90° molded hose. (See Figs. 7-f, 7-h.)

Q. Connect the long eng of the remaining 90°

rubber hose to the aluminum tube. Install the supplied hose union to the open end of the hose. Attach a section (approximately 36” long) of the supplied Ø3/4” heater hose to the previously installed union. Connect the open end of the Ø3/4” hose to the CAC inlet (top passenger side fitting). (See Fig. 7-e, 7-f & 7-h)

Fig. 7-d

Fig. 7-e

* Use pipe sealant on tapered pipe threads.

Fig. 7-f

7. CHARGE COOLER INSTALLATION, cont’d

R. Secure all hose connections at this time

using the supplied nylon ratchet clamps. Make sure that all hoses are routed and secured away from hot or moving parts.

S. Using the supplied butt connector, attach the

supplied length of wire to the poitive (green) wire on the water pump. Route the wire to the power distribution box (PDB) located on the driver side. Trim the wire so that it just reached the PDB. Connect the supplied fuse holder to the end of the wire. Attach the trimmed piece of wire to the opposite side of the fuse holder. Locate the fuel pump relay. Using the mini ATC fuse tap and the supplied femal spayed connector attach the wire to terminal #87 on the relay. (see Fig. 7-g)

T. Attach the supplied ring terminal to the water

pump ground wire. Secure the ground wire to the inner fender using the supplied M8 fastener.

U. Fill the CAC coolant using a 25%/75% anti-

freeze/water mix. Fill through the surge tank fill port located on the CAC.

Fig. 7-g

20OCT08 v2.0 08HummrH3(4GNv1.0)

P/N: 4GN020-015

CHARGE AIR COOLER

1/2 NPT TO 3/4” HOSE BARB (7P500-078)

(7U038-012) 90° A”X12”

FORMED HOSE

WATER PUMP (8F001-402)

MOUNTED WITH TWO ADEL

CLAMPS TO FAN SHROUD

3/4” HOSE (7U038-000)

CUT TO FIT

APPROXIMATELY 26”

3/4” HOSE (7U038-000)

CUT TO FIT

APPROXIMATELY 23”

(7U038-012)

90° A”X12” FORMED HOSE

(TRIMMED TO APPROX 4.5”X1.5’

(7U038-150)

150° MOLDED HOSE

(4GV014-010)

FORMED ALUMINUM

TUBE

WATER COOLER

(8N006-010)

90° 1/2 NPT TO 3/4”

HOSE BARB (7P500-026)

1/2 NPT TO 3/4” HOSE

BARB (7P500-026)

(8N010-240) HEAT EXCHANGER

MOUNTING BRACKET MOUNTED

BETWEEN CORE SUPPORT

AND HOOD LATCH SUPPORT

3/4” HOSE UNION

BARBED (7P375-075)

(FRONT VIEW)

7. CHARGE COOLER INSTALLATION, cont’d

Fig. 7-h

8. AIR INLET INSTALLATION

A. Locate the MAF mounting hole template in

this manual. Remove and cut the template as shown. Place the template on the passenger side inner fender and mark the three hole positions to be drilled. Drill the previously marked hole locations using a 1/4" drill.

B. Install the MAF meter into the air filter cover.

Place the supplied air filter on to the meter and secure. (See Fig. 8-a.)

C. Install the air filter assembly into the vehicle.

Secure the MAF meter and the sound suppressor shield to the previously drilled holes in the inner fender using the 1/4-20 hardware provided (the shield goes inside the fender opposite the MAF) (See Figure 8-d.).

D. Secure the forward edge of the air filter hous-

ing to the front core support using the supplied 90° bracket, 1/4-20 hardware and M6 Nyloc nut. (See Fig. 8-b).

E. Install the previously removed MAF electron-

ics into the supplied meter housing and secure using the supplied hardware. Connect the MAF electronics harness to the MAF. (See Figure 8-d)

F. Locate the 3.5” x 90° duct with bosses and

install the 3/8”NPT x 3/8” barb x 90° fitting. Secure the 3.5” x 90° duct to the supercharger inlet using the Ø3.5” x 2” sleeve and two #56 hose clamps provided. Secure the 90° duct w/out bosses to the previously installed MAF meter using the remaining Ø3.5" x 2" sleeve and two #56 hose clamps. (See Fig. 8-c, 8-d)

G. Connect the provided length of Ø3/8” hose to

the previously installed 3/8” barb x 90° fitting. Insert the supplied Ø3/8” hose union into the open end of the hose. Attach the factory 90° molded hose to the previously installed union. Connect the open of the 90° hose to the barb located on the passenger side valve cover. (See Fig. 8-c)

MAF METER

FACTORY

MOLDED

90°

Ø3.5" X 90°

DUCT

FILTER

COVER

AIR FILTER

Fig. 8-a

SUPPORT BRACKET

Fig. 8-b

Ø3/8" HOSE

3/8" NPT X

3/8" BARB

90°

Fig. 8-c

NOTE: Trim the 3/8" hose to the best fit.

Retain the extra hose to use in a later step.

H. Connect the two 90° inlet ducts using the

Ø3.5 x 10" flex hose and secure using the remaining #52 hose clamps provided. (See Fig. 8-d.)

I. Cut a piece of the supplied Ø1.0” rubber hose

approximately 4” long and secure it to the Ø1” port on the previously installed CAC using the #16 hose clamp provided.

3.5” 90° ELBOW w/ BOSSES

3.5” 90° ELBOW w/o BOSSES

Fig. 8-d

20OCT08 v2.0 08HummrH3(4GNv1.0)

MAF METER

P/N: 4GN020-015

This Page Left Intentionally Blank

EXISTING HOLE

DRILL THREE

1/4” HOLES

INNER FENDER

TEMPLATE

8. AIR INLET INSTALLATION “TEMPLATE”

20OCT08 v2.0 08HummrH3(4GNv1.0)

P/N: 4GN020-015

8. AIR INLET INSTALLATION, cont’d

K. Insert the inlet side of the supplied by-pass

valve into the open end of the previously installed hose and orient it so that the open end faces forward and secure using the #16 hose clamp provided. (the vacuum port should be facing down).

L. Using the remaining section of Ø1.0” rubber

hose connect the open end of the by-pass valve to the Ø1.0” barb on the previously installed Ø3.5” x 90° duct and secure using the remaining #16 hose clamps provided.

M. Connect the supplied piece of 5/32” vacuum

line to the vacuum port on the by-pass valve. Route the line up to the manifold. Locate the vacuum port on the passenger side of the manifold. Cut the sealing tab off the end of the factory vacuum port. Insure that the port is open and free of any debris left from the cutting process. Connect the open end of the previously installed vacuum line to the vacuum port. (See Fig. 8-e)

N. Reinstall the grill in the reverse order

removed, using the factory harware.

SEALING TAB

VACUUM PORT

Fig. 8-e

9. PCV VALVE INSTALLATION

A. Locate the valve cover vent hose attached

between the intake manifold and the rear of the valve cover.

B. Remove the factory 45° molded rubber elbow

from the valve cover end of the factory vent tube. (See Fig. 9-a)

C. Cut the factory vent tube just after the 90°

bend, leave enough straight section to install the PCV valve. (See Fig. 9-b)

D. Install the 3/8” end of the PCV valve into the

open end of the factory vent tube (heating the end of the tube slightly will make inserting the valve easier, use care not the melt the material). (See Fig. 9-b, 9-c)

E. Using the section of Ø5/8” hose provided,

attach the 5/8” x 3/8” reducer fitting to the end of the previously installed PCV valve. (See Fig. 9-b)

F. Attach the supplied section of Ø3/8” hose (left

over from the intake assembly) to the reducer fitting. Install the provided Ø3/8” hose union into the end of the Ø3/8” hose. Using the factory 45° molded rubber elbow connect the Ø3/8” hose to the barb on the drivers side valve cover. (See Fig. 9-a)

45° MOLDED ELBOW

Fig. 9-a

FACTORY TUBE

PCV VALVE

Ø5/8" HOSE

REDUCER UNION

Fig. 9-b

Fig. 9-c

Ø3/8" HOSE

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P/N: 4GN020-015

10. FINAL CHECK

NOTE: Once the Re-flashed ECU and TCM are received back from Vortech, reinstall them in the reverse order removed.

Take care not to damage the harness connectors or ECU/TCM connection pins. Re-secure the washer fluid/coolant reservoir assembly.

WARNING: Do not attempt to operate the

vehicle until all components are installed and all operations are completed including the final check.

A. If your vehicle has gone over 15,000 miles since

its last spark plug change, you will need to change the spark plugs now before test driving the vehicle.

B. Check all fitting, nuts, bolts and clamps for tight-

ness. Pay particular attention to oil and fuel lines around moving parts, sharp edges and exhaust system parts. Make sure all wires and lines are properly secured with clamps or tie-wraps.

C. Check all fluid levels, making sure that your

tank(s) is/are filled with 91 octane or higher fuel before commencing test drive.

D. Start the engine and allow to idle a few minutes,

then shut-off.

H.O. Charge Cooled Kits Only

NOTE: Check to see that CAC coolant is flowing

through the surge tank. If coolant is not flowing, remove the 3/4” rubber hose from the side of the CAC and apply light suction in an attempt to pass any trapped air in the system. Reconnect the hose and recheck coolant flow.

E. Recheck to be sure that no hoses, wires, etc. are

near exhaust headers or moving parts. Look also for any signs of fluid leakage.

F. PLEASE TAKE SPECIAL NOTE: operating the

vehicle without ALL the subassemblies completely and properly installed may cause FAILURE OF MAJOR COMPONENTS.

10. FINAL CHECK , cont’d

G. Test drive the vehicle.

H. Always listen carefully for engine detona-

tion. Discontinue heavy throttle usage if detonation is heard.

I. Read the STREET SUPERCHARGER

SYSTEM OWNER’S MANUAL AND RETURN THE WARRANTY REGISTRATION FORM within thirty (30) days of purchasing your supercharger system to qualify.

For internally lubricated V3 units only

This supercharger has been factory pre-lled with special Vortech synthetic lubricant. Oil does not need to be added to a brand new unit; however a uid level check should be performed.

Prior to operating the supercharger on the vehicle and after installation onto the vehicle:

Remove the factory installed at-head brass shipping plug (not the dipstick) from the top of the supercharger case. Replace the sealed shipping plug with the supplied “vented” plug. Do not operate the supercharger without it. Check the supercharger uid level.

Fluid level checking procedure:

1. Ensure that the .06” copper sealing washer is

located on the dipstick base.

2. Thread the clean dipstick into the unit until it seats.

3. Once the dipstick has seated, remove the dipstick from the unit. Fluid should register in the crosshatched area on the dipstick.

4. DO NOT OVERFILL!!! Drain excess uid from the unit if it is above the maximum level on the dipstick.

Check the uid level using the dipstick at least every 2,500 miles.

Initial supercharger uid change must be performed at 2,500 miles. The supercharger uid must be changed at least every 7,500 miles.

Drain the uid, rell the unit with 4 oz. of Vortech V3 lubricating uid and then conrm proper oil level using the dipstick. DO NOT OVERFILL!!!

WARNING: Use of any other uid other than the special Vortech lubricant will void the warranty and may cause component failure.

20OCT08 v2.0 08HummrH3(4GNv1.0)

P/N: 4GN020-015

ENGINEERING, LLC

1650 Pacific Avenue, Channel Islands CA 93033-9901 • Phone: 805 247-0226

Fax: 805 247-0669 • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST)

DP/N: 4GN020-015 - v2.0 10/20/08

Vortech Alpha H3 Hummer - 2008 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual