Vortech H3 I-5 Hummer - 2006-2008 User Manual

®

GM I-5

H3 HUMMER

Supercharger System

2006 - 2008 Model Years

Installation Instructions

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

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: 4GN020-010 - 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 limit-

ed 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: 4GN020-010
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
20OCT08 v2.0(4GNv2.0)

©2007 VORTECH ENGINEERING, LLC

ii

TABLE OF CONTENTS

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

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

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

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

PARTS LIST (2006 - 2008 H3 HUMMER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

PARTS LIST (2008 H3 I-5 HUMMER) .........................................vii

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

2. POWER STEERING PUMP MODIFICATIONS ............................ 3

3. OIL DRAIN INSTALLATION ........................................... 4

4. OIL FEED INSTALLATION ............................................ 5

5. FUEL INJECTOR REPLACEMENT ..................................... 6

6. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION ............. 7

7. CHARGE COOLER INSTALLATION ....................................12

8. AIR INLET INSTALLATION ............................................16

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

10. FINAL CHECK .....................................................22

©2008 Vortech Engineering, LLC

iii

All Rights Reserved, Intl. Copr. Secured

P/N: 4GN020-010

20OCT08 v2.0(4GNv2.0)

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.

P/N: 4GN020-010
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
20OCT08 v2.0(4GNv2.0)

iv

GM 2006-2008 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 vehi-
cle. 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

P/N: 4GN020-010

20OCT08 v2.0(4GNv2.0)

GM 2006-2008 H3 Hummer

®

Part No. 4GL218-010SQ

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.

008110 SMALL SILVER DIE-CUT DECAL 2
008130 LICENSE PLATE FRAME, VORTECH 1
008444 A/C STREET INFO PKG ASY VORTECH 1
2A046-140 BELT, 6-RIB X 114.00 EFFECT. L 1
2E228-480 S/C, V2 SC-TRM, CW, CUR, STN, H3 1
4GN020-010 INSTR MANL, 3.7L, H3 HUMMR 1
4GN102-001 INJECT AND HARNESS ASY, H3 1

8F060-060 FUEL INJ. 60 LB, STD. PENCIL 5
4GN002-001 HARNESS, H3 INJ. MOD. 1

4GN110-010 P/S RES. RELOC ASY. 2007 H3 1

4GN010-010 BRKT, P/S RES. FTG RETAINER 1
4GN010-020 RETAINER, P/S PUMP FITTING 1
7P500-071 FITTING, P/S RES. RETRN, H3 1
7P500-073 FITTING, P/S PUMP RETRN H3 1
7A250-051 1/4-20 x .50" HHCS ZINC PLTD 1
7A250-101 1/4-20 x 1" HHCS ZINC PLTD 5
7J006-094 6mm WASHER, SS 10
7F250-021 1/4-20 NYLOCK NUT, ZINC PLTD 5
7U032-020 HOSE, 3/8"ID, P/S RET 8"
7R001-004 #4 HOSE CLAMP 2
7P375-050 3/8" HOSE UNION, BRASS 1
7U030-036 1/2" OIL DRAIN HOSE 1
7R001-006 #6 STNLS HOSE CLAMP, NARROW 2
7U100-114 O-RING, -114, H3 P/S 1

4GN111-044 S/C MTG BRKT ASY, 3.7L H3 1

4GN111-033 ASY, BRKT H3 S/C MNT 1
4GN010-040 BRACE, S/C BRKT SPRT, H3 1
7C080-045 M8-1.25 x 45mm HXHD 3
7K375-030 3/8"AN FLAT WASHERS SS 7
7A375-225 3/8-16 x 2-1/4" HXHD G8 4
1210517 ASY, IDLER PLY, SMOOTH 6-RIB 1
2A017-044 SPACER, IDLER, .509" 1
2A017-016 PILOT, 6203/5 BRG, 3/8" SCREW 1
7F375-017 3/8-16 NYLOCK NUT 1
7F006-093 6mm NYLOCK NUT 1
7J006-093 6mm WASHER, PLATED 1
7A375-227 3/8-16 x 2.25" BTN SCKT HD CAP 1
7J250-001 1/4" WASHER, SAE PLTD 2
7F250-021 1/4-20 NYLOCK NUT, ZINC, PLTD 1
7A250-101 1/4-20 x 1" HHCS, PLTD 1
7A375-208 3/8-16 x 2" G8 HXHD 1

4GN112-010 AIR INLET ASY. 3.7L H3 1

4GN013-010 AIR CLEANER COVER, H3 1
4GN013-020 BRACKET, AIR FILTER CVR SPRT 1
4FA012-012 INTAKE ELBOW, 90° w/o BOSSES 1
4FA012-013 INTAKE ELBOW, 90° w/BOSSES 1
7S350-200 SLEEVE, 3-1/2" x 2" BLUE 2
8H040-235 AIR FILTER, 4.0" FLG x 7.0L 1
7P750-102 3/4"NPT x 1" x 90° HSE FITTING 1
7R002-056 #56 SAE TYPE “F” SS HOSE CLAMP 4
8A002-031 MAF, Ø3.25"ID, '07 H3 3.7L 1
7A250-074 1/4-20 x .75" HHCS PLTD 2
7J250-001 1/4" WASHER, SAE, PLTD 6
7A250-101 1/4-20 x 1" HHCS, ZINC PLTD 1
7U035-001 3-1/2" FLEX-HOSE .75'
7R002-052 #52 SAE TYPE “F” SS HOSE CLAMP 2
7A250-063 1/4-20 x .63" HHCS SS 2
7C040-008 M4-.7x8mm SCHD SS 2
7U030-036 1/2" OIL DRAIN HOSE 1.25'
7P375-055 3/8"NPT x 90° x 1/2" HOSE BARB 1
7P500-001 1/2" HOSE UNION 1
7F006-093 6mm NYLOCK NUT 1

4GN130-026 OIL FEED ASY, 3..7L H3 1

7P250-016 M16 x 1.5mm MALE, TO -4 JIC MALE ST 1
7P125-004 1/8"NPT x 90° x -4 JIC FTG STL 1
7U250-090-240 OIL FEED HOSE, 24" x -4 x 90° 1

7U100-055 TIE-WRAP, 7.5" NYLON 4

4GN130-036 OIL DRAIN ASY, 3.7L H3 1

4GN100-010 TUBE NUT ASY, HUMMR H3 1
7P375-042 3/8"NPT MALE x .5" FEM. INV FLARE 1
7U030-036 1/2" OIL DRAIN HOSE 1.83'
7R001-006 #6 STNLS HOSE CLAMP, NARROW 2
7T560-001 CUTTER, 9/16" ROTABROACH 1
7T560-002 ARBOR, ROTABROACH 1

4GN139-096 PCV MOD ASY, H3 3.7L 1

7R001-006 #6 STNLS HOSE CLAMP, NARROW 2
7R004-002 STEPLESS CLAMP, 17.0-70 2
7U030-036 1/2" OIL DRAIN HOSE 0.125'
7U032-016 3/8" EFI FUEL HOSE, HI-PRESSURE .146'
7P375-113 PCV VALVE, VIPER, 3/8" x 1/2" BA 1

8N201-320 CHARGE COOLER ASY, 3.7L H3 1

8N101-320 WELDED CORE ASY, H3 1
7S335-275 SILICONE, ELBOW H3 3.35" x 2.75" 1
8N010-230 BRKT, UPR SPRT SETRAB H3 1
8N010-240 BRKT, SETRAB MNT H3 1
7A250-074 1/4-20 x .75" HHCS PLTD 5
7F250-021 1/4-20 NYLOCK NUT, ZINC PLTD 6
7J250-001 1/4" WASHER, SAE PLTD 10
7S275-200 SLEEVE, Ø2.75" x 2.00"L BLUE 1
8N055-050 PLASTIC CAP, SURGE TANK 1
8N006-010 WATER COOLR, SETRAB SINGLE PASS 1
8F001-402 PUMP, WATER, PIERBURG 1
7R003-027 ADEL CLAMP, 1-11/16" 2
4GL014-010 WATER, TUBE, GTO 1
4GV014-010 WATER PIPE, L-BEND 1
7U133-100 HOSE, ELBOW, 90° x 1"ID, MOLDED 1
7R002-016 #16 SAE TYPE “F” SS HOSE CLAMP 4
8D001-001 STD COMPRESS BYPASS VALVE 1
7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 3
7R002-052 #52 SAE TYPE “F” SS HOSE CLAMP 1
7R003-016 ADEL CLAMP, 1.0" 1
7U038-012 HOSE, Ø3/4" x 90° x 4"/12" LEGS 1
7R007-001 NYLON RATCHET CLAMP 1-1/8" 10
7P500-078 1/2"NPT x 3/4" HOSE FITTING STRT 3
7U100-055 TIE-WRAP, 7.5" NYLON 10
7U030-046 5/32" VACUUM LINE 5'
7P500-026 1/2"NPT x 3/4" BARB x 90°, BRASS 1
7P250-033 1/4" x 5/32" RED. UNION 1
7U030-030 1/4" VACUUM HOSE 0.20'
7U030-036 1/2" OIL DRAIN HOSE 1'
7P500-251 1/2" x 1/4" BARB HOSE UNION 1
7R004-687 CLAMP, 13/16" ONE EAR 2
5W001-015 FUSE, BLADE TYPE 20AMP 1
5W001-071 FUSE HOLDER, 16GA WIRE 1
5W018-020 18GA STRD WIRE, BLK, UL1015 4'
5W001-024 MINI ATC FUSE TAP 1
5W001-025 FEM SLIDE, INSUL. MINI, 22-16AWG 1
5W001-012 18-22GA, BUTT CONN RED INSUL. 1
5W001-011 16-14GA RING TERM. .26" HOLE 1
7U038-000 3/4" HEATER HOSE 3.67'
7U038-150 HOSE, 3/4" x 150° MOLDED HOSE 1
7E010-049 #10 x 3/4" HXHD, SLF DRL SHT MTL 2

P/N: 4GN020-010
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
20OCT08 v2.0(4GNv2.0)

vi

GM 2008 H3 I-5 Hummer

®

Part No. 4GL218-030L

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.

008110 SMALL SILVER DIE-CUT DECAL 2
008130 LICENSE PLATE FRAME, VORTECH 1
008444 A/C STREET INFO PKG ASY VORTECH 1
2A046-140 BELT, 6-RIB x 114.00 EFFECT. L 1
2F338-020 V3 S/C ASY, SC--TRIM H3 I5 HUMR 1
4GN020-010 INSTR MANL, 3.7L, H3 HUMMR 1
4GN102-003 INJECT AND HARNESS ASY, 42LB, H3 1

8F060-044 FUEL INJ. 42 LB, STD. PENCIL 5
4GN002-001 HARNESS, H3 INJ. MOD. 1

4GN110-010 P/S RES. RELOC ASY. 2007 H3 1

4GN010-010 BRKT, P/S RES. FTG RETAINER 1
4GN010-020 RETAINER, P/S PUMP FITTING 1
7P500-071 FITTING, P/S RES. RETRN, H3 1
7P500-073 FITTING, P/S PUMP RETRN H3 1
7A250-051 1/4-20 x .50" HHCS ZINC PLTD 1
7A250-101 1/4-20 x 1" HHCS ZINC PLTD 5
7J006-094 6mm WASHER, SS 10
7F250-021 1/4-20 NYLOCK NUT, ZINC PLTD 5
7U032-020 HOSE, 3/8"ID, P/S RET 8"
7R001-004 #4 HOSE CLAMP 2
7P375-050 3/8" HOSE UNION, BRASS 1
7U030-036 1/2" OIL DRAIN HOSE 1
7R001-006 #6 STNLS HOSE CLAMP, NARROW 2
7U100-114 O-RING, -114, H3 P/S 1

4GN111-044 S/C MTG BRKT ASY, 3.7L H3 1

4GN111-033 ASY, BRKT H3 S/C MNT 1
4GN010-040 BRACE, S/C BRKT SPRT, H3 1
7C080-045 M8-1.25 x 45mm HXHD 3
7K375-030 3/8"AN FLAT WASHERS SS 7
7A375-225 3/8-16 x 2-1/4" HXHD G8 4
1210517 ASY, IDLER PLY, SMOOTH 6-RIB 1
2A017-044 SPACER, IDLER, .509" 1
2A017-016 PILOT, 6203/5 BRG, 3/8" SCREW 1
7F375-017 3/8-16 NYLOCK NUT 1
7F006-093 6mm NYLOCK NUT 1
7J006-093 6mm WASHER, PLATED 1
7A375-227 3/8-16 x 2.25" BTN SCKT HD CAP 1
7J250-001 1/4" WASHER, SAE PLTD 2
7F250-021 1/4-20 NYLOCK NUT, ZINC, PLTD 1
7A250-101 1/4-20 x 1" HHCS, PLTD 1
7A375-208 3/8-16 x 2" G8 HXHD 1

4GN112-010 AIR INLET ASY. 3.7L H3 1

4GN013-010 AIR CLEANER COVER, H3 1
4GN013-020 BRACKET, AIR FILTER CVR SPRT 1
4FA012-012 INTAKE ELBOW, 90° w/o BOSSES 1
4FA012-013 INTAKE ELBOW, 90° w/BOSSES 1
7S350-200 SLEEVE, 3-1/2" x 2" BLUE 2
8H040-235 AIR FILTER, 4.0" FLG x 7.0L 1
7P750-102 3/4"NPT x 1" x 90° HSE FITTING 1
7R002-056 #56 SAE TYPE “F” SS HOSE CLAMP 4
8A002-031 MAF, Ø3.25"ID, '07 H3 3.7L 1
7A250-074 1/4-20 x .75" HHCS PLTD 2
7J250-001 1/4" WASHER, SAE, PLTD 6
7A250-101 1/4-20 x 1" HHCS, ZINC PLTD 1
7U035-001 3-1/2" FLEX-HOSE .75'
7R002-052 #52 SAE TYPE “F” SS HOSE CLAMP 2
7A250-063 1/4-20 x .63" HHCS SS 2
7C040-008 M4-.7x8mm SCHD SS 2
7U030-036 1/2" OIL DRAIN HOSE 1.25'
7P375-055 3/8"NPT x 90° x 1/2" HOSE BARB 1
7P500-001 1/2" HOSE UNION 1
7F006-093 6mm NYLOCK NUT 1

4GN139-096 PCV MOD ASY, H3 3.7L 1

7R001-006 #6 STNLS HOSE CLAMP, NARROW 2
7R004-002 STEPLESS CLAMP, 17.0-70 2
7U030-036 1/2" OIL DRAIN HOSE 0.125'
7U032-016 3/8" EFI FUEL HOSE, HI-PRESSURE .146'
7P375-113 PCV VALVE, VIPER, 3/8" x 1/2" BA 1

8N201-320 CHARGE COOLER ASY, 3.7L H3 1

8N101-320 WELDED CORE ASY, H3 1
7S335-275 SILICONE, ELBOW H3 3.35" x 2.75" 1
8N010-230 BRKT, UPR SPRT SETRAB H3 1
8N010-240 BRKT, SETRAB MNT H3 1
7A250-074 1/4-20 x .75" HHCS PLTD 5
7F250-021 1/4-20 NYLOCK NUT, ZINC PLTD 6
7J250-001 1/4" WASHER, SAE PLTD 10
7S275-200 SLEEVE, Ø2.75" x 2.00"L BLUE 1
8N055-050 PLASTIC CAP, SURGE TANK 1
8N006-010 WATER COOLR, SETRAB SINGLE PASS 1
8F001-402 PUMP, WATER, PIERBURG 1
7R003-027 ADEL CLAMP, 1-11/16" 2
4GL014-010 WATER, TUBE, GTO 1
4GV014-010 WATER PIPE, L-BEND 1
7U133-100 HOSE, ELBOW, 90° x 1"ID, MOLDED 1
7R002-016 #16 SAE TYPE “F” SS HOSE CLAMP 4
8D001-001 STD COMPRESS BYPASS VALVE 1
7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 3
7R002-052 #52 SAE TYPE “F” SS HOSE CLAMP 1
7R003-016 ADEL CLAMP, 1.0" 1
7U038-012 HOSE, Ø3/4" x 90° x 4"/12" LEGS 1
7R007-001 NYLON RATCHET CLAMP 1-1/8" 10
7P500-078 1/2"NPT x 3/4" HOSE FITTING STRT 3
7U100-055 TIE-WRAP, 7.5" NYLON 10
7U030-046 5/32" VACUUM LINE 5'
7P500-026 1/2"NPT x 3/4" BARB x 90°, BRASS 1
7P250-033 1/4" x 5/32" RED. UNION 1
7U030-030 1/4" VACUUM HOSE 0.20'
7U030-036 1/2" OIL DRAIN HOSE 1'
7P500-251 1/2" x 1/4" BARB HOSE UNION 1
7R004-687 CLAMP, 13/16" ONE EAR 2
5W001-015 FUSE, BLADE TYPE 20AMP 1
5W001-071 FUSE HOLDER, 16GA WIRE 1
5W018-020 18GA STRD WIRE, BLK, UL1015 4'
5W001-024 MINI ATC FUSE TAP 1
5W001-025 FEM SLIDE, INSUL. MINI, 22-16AWG 1
5W001-012 18-22GA, BUTT CONN RED INSUL. 1
5W001-011 16-14GA RING TERM. .26" HOLE 1
7U038-000 3/4" HEATER HOSE 3.67'
7U038-150 HOSE, 3/4" x 150° MOLDED HOSE 1
7E010-049 #10 x 3/4" HXHD, SLF DRL SHT MTL 2

©2008 Vortech Engineering, LLC

vii

All Rights Reserved, Intl. Copr. Secured

P/N: 4GN020-010

20OCT08 v2.0(4GNv2.0)

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P/N: 4GN020-010
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
20OCT08 v2.0(4GNv2.0)

viii

1. PREPARATION/REMOVAL

A. Disconnect the negative battery cable.

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 evaporative canister vent

hose from the air filter assembly and canister
and set aside. (See Fig. 1-a.)

C. Disconnect the MAF electronics harness con-

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

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

clamp securing the inlet duct to the throttle
body.

E. Remove the two 13mm headed screws

securing the lower portion of the air filter
enclosure to the inner fender. Remove the
two 10mm headed screws securing the inter­mediate ducting to the cylinder head.
Remove the air filter assembly and set aside.

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-b.)

G. Using a 3/8" ratchet, de-tension the accesso-

ry belt tensioner and remove the factory belt.

H. Remove the power steering pulley using the

appropriate pulley puller. Set the pulley aside
to be re-installed in a later step.

I. Remove the hose from the bottom of the

power steering fluid reservoir. Drain the
power steering fluid into a clean container
and set aside. Once the fluid is drained, dis­connect the power steering pressure line from
the bottom of the pump. (There may be resid-
ual fluid in this line.) (See Fig. 1-c.)

POWER STEERING

RESERVOIR

P/S PRESSURE

LINE

Fig. 1-a

Fig. 1-b

POWER STEERING

PULLEY

Fig. 1-c

©2008 Vortech Engineering, LLC

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All Rights Reserved, Intl. Copr. Secured

P/N: 4GN020-010

20OCT08 v2.0(4GNv2.0)

1. PREPARATION/REMOVAL, cont’d

J. Using a 13mm socket remove the three

screws retaining the power steering pump to
the pump bracket. Set the pump on a clean
flat surface. (See Figs. 1-d, 1-e.)

K. Remove the two reservoir retaining clips hold-

ing the plastic reservoir to the power steering
pump. Set the clips aside and detach the res­ervoir from the pump. Be careful not to lose
the rubber O-ring on the reservoir. Set the
reservoir with O-ring aside. (See Fig. 1-e.)

L. 2007 Models Only: Locate the stud on the

passenger’s side inner fender (previously
retained the lower portion of the factory air
box). Cut the stud off flush with the inner
fender surface, using an appropriate cutter.
(See Fig. 1-f.)

NOTE: It is a good idea to dress (either with paint or

other means) any bare metal that may have
been exposed as a result of the cutting pro-

cess.

Fig. 1-d

POWER STEERING

RESERVOIR

CLIPS

Fig. 1-e

AIR BOX STUD

PASSENGER’S SIDE

INNER PENDER

Fig. 1-f

P/N: 4GN020-010
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
20OCT08 v2.0(4GNv2.0)

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