Vortech Alpha H3 Hummer - 2008 User Manual

®

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: [phone]

Fax: [phone] • 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-

T

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 [phone] 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.

All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated

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

P/N: 4GN020-015
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
20OCT08 v2.0 08HummrH3(4GNv1.0)

©2008 VORTECH ENGINEERING, LLC

ii

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

©2008 Vortech Engineering, LLC

iii

All Rights Reserved, Intl. Copr. Secured

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 [phone] 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.

P/N: 4GN020-015
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
20OCT08 v2.0 08HummrH3(4GNv1.0)

iv

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

©2008 Vortech Engineering, LLC

v

All Rights Reserved, Intl. Copr. Secured

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

P/N: 4GN020-015
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
20OCT08 v2.0 08HummrH3(4GNv1.0)

vi

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

©2008 Vortech Engineering, LLC

1

All Rights Reserved, Intl. Copr. Secured

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

P/N: 4GN020-015
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
20OCT08 v2.0 08HummrH3(4GNv1.0)

2

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.

3

2 5/8"

1.5"

Fig. 2-c

Fig. 2-d

©2008 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured

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

P/N: 4GN020-015