Hummer H3-Alpha 2008 Intercooled Supercharger System PDF Installation Instructions

Tools Required
Safety glasses
Metric wrench set
1/4” drill bit
1/4”, 3/8”, & 1/2” drive metric socket set (standard and deep)
8mm hex (Allen) wrench
3/8” and 1/2” drive, foot pound and inch pound torque wrenches
Belt tensioner wrench or 1/2” breaker bar
7/32” socket
Drill and 5/16” drill bit
Phillips and flat head screwdrivers
Fuel quick disconnect tools (included in kit)
E5 internal Torx socket
Small or angled 3/8” drill motor
Drain pan
Compressed air

First off, refer to the included Flashpak manual and flash the Hummer’s computer with the updated calibration for the supercharged system. Should you receive an error code, contact us before proceeding. With a 10mm wrench disconnect the negative (-) battery cable and wrap the terminal end with electrical tape. Ensure that the cable is far enough away from the battery, that it does not accidentally touch the battery and make contact during the installation.

On the right (passenger) side of the intake manifold, locate the fuel pressure test port. CAUTION! The fuel in the system is under pressure! Relieve the pressure in the fuel system by depressing the check valve with a screwdriver and collecting the fuel with a shop towel. Magnuson Products recommends that you wear eye protection to avoid injury.

… With the fuel rail disconnect tool supplied, remove the fuel lines form the fuel rail. USE CAUTION! The system may be under pressure. Avoid open flame or other sources of ignition. As recommended earlier, Magnuson Products recommends use of eye protection. …As it will be necessary to drain the cooling system and the H3 has no drain on the radiator, loosen the two bolts that secure the thermostat assembly with a 10mm socket wrench. Catch the coolant in a drain pan for reuse. Re-tighten the thermostat bolts after draining is complete.

It will be necessary to make clearance on the alternator mount casting for the new manifold to fit properly. The new manifold should not touch the alternator mount. These modifications can be easily done with the mount in place. For clarity this mount is shown removed from the engine. Using a marking pen and a straight edge, mark a line as shown on the top surface of the of the alternator mount. Start the line at the drivers (left) rear corner of the idler mount and then to the right rear corner of the alternator mount. Continue the line at an angle for a distance of about 1-1/4” to the back edge of the casting behind the alternator mount. Using a suitable grinder and eye protection, remove the material up to the
line..

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