Hummer H1 (1992-1998). Manual - part 44

2-140.24          Change 1

2 - 3 5 . 3 . (6.2L or 6.5L)  FUEL INJECTION PUMPS (DB2829-4523, DB2829-4879, or

DB2831-5149) CALIBRATION USING FUEL INJECTION PUMP TEST STA N D

(FTIS) MODEL A8022 (Cont’d)

8.

Disconnect tubing from male pipe fitting on fuel injection pump (1) and from calibration fluid push-
on connector (3) on front panel of test stand (5).

9.

Remove male pipe fitting from fuel injection pump (1).

10.

Disconnect rubber hose assembly from quick-connect plug on test adapter and from auxiliary
pressure quick-connect (11) on front panel of test stand (5).

11.

Remove quick-connect plug from test adapter.

12.

Remove test adapter, tab (9), washer (8), and O-ring (7) from transfer test port (6) of fuel injection
pump (1).

13.

Install O-ring (7), washer (8), tab (9), and screw (10) in transfer test port (6) of fuel injection
pump (1).

14.

Disconnect hose assembly from connector and calibration fluid supply quick-connect (4) on front
panel of test stand (5).

15.

Remove test adapter and connector from fuel inlet port (2) of fuel injection pump (1).

16.

Remove three 3/8-16x1 hex-head capscrews (20), 3/8-in. lockwashers (19), and 3/8-in. washers (18)
from slots and mounting holes on test stand drive coupling (12) and pump-mounted drive hub (17).

17.

Loosen two 3/8-16x1 hex-head capscrews (15) from flange mounting bracket (16) and bedplate (21). 

18.

Remove flange mounting bracket (16) and fuel injection pump (1) from test stand drive coupling (12)
and remove alignment gauge and barring tool.

19.

Remove three 5/16-18x1 hex-head capscrews (13), 5/16-in. washers (14), and fuel injection pump (1)
from adapter plate.

4

3

1

2

TUBING

MALE PIPE FITTING

TEST ADAPTER

CONNECTOR

HOSE ASSEMBLY

5

Change 1           2-140.25/(2-140.26 blank)

2 - 3 5 . 3 . (6.2L or 6.5L)  FUEL INJECTION PUMPS (DB2829-4523, DB2829-4879, or

DB2831-5149) CALIBRATION USING FUEL INJECTION PUMP TEST STA N D

(FTIS) MODEL A8022 (Cont’d)

BARRING TOOL

ALIGNMENT GAUGE

ADAPTER PLATE

TEST ADAPTER

QUICK-CONNECT PLUG

RUBBER

HOSE

ASSEMBLY

10

1

6

7

8

9

11

5

13

1

20

19

18

16

15

14

17

21

12

2-36. GLOW PLUG REPAIR

This task covers:

a. Cleaning

c. Testing

b. Inspection

INITIAL SETUP

Tools

Equipment Condition

General mechanic’s tool kit:

Engine disassembled

automotive (Appendix E, Item 1)

(para. 2-15).

Test Equipment

Multimeter (Appendix E, Item 32)

Mamual References

into subassemblies

 a. Cleaning 

Clean glow plug (1) in accordance with para. 2-9.

b. Inspection

NOTE

For general inspection instructions, refer to para. 2-10.

1. Inspect glow plug (1) for thread damage. Replace if threads are damaged.

2.

Inspect glow plug (1) for damage. Replace if damaged.

1. Using multimeter, check glow plug (1) internal resistance. Connect one test lead to terminal (2) and

other test lead to threaded area (3).

2. Glow plug (1) internal resistance should have continuity. If not, replace glow plug (1).

2-141

2-37. FUEL INJECTION NOZZLE REPAIR

This task covers:

a. Cleaning

c. Testing

b. Inspection

INITIAL SETUP:

Tools

General Safety Instructions

General mechanic’s tool kit:

● 

Do not place hands or arms near nozzle during

automotive (Appendix E, Item 1)

testing.

● 

Compressed air for cleaning purposes will not

Test Equipment

exceed 30 psi (207 kPa).

Nozzle tester (Appendix E, Item 31)

● 

Wear eyeshields when using compressed air.

Manual References

Equipment Condition

Engine disassembled into subassemblies
(para. 2-15).

Clean fuel injection nozzle (2) in accordance with para. 2-9.

NOTE

For general inspection instructions, refer to para. 2-10.

1. Inspect fuel injection nozzle (2) for thread damage. Replace if damaged.

2. Inspect fuel injection nozzle return nipples (1) for damage. Replace fuel injection nozzle (2)

if damaged.

3. Inspect fuel injection nozzle (2) for cracks and evidence of heat damage. Replace if cracked

or damaged.

1. Preparation.

(a) Connect fuel injection nozzle (2) to tester.
(b) Connect lines to return line nipples (1).

Do not place hands or arms near nozzle during testing.
Penetrating force of oil may cause serious injury or death.

(c) Close shutoff valve to pressure gauge on tester.

(d) 

Operate tester to prime nozzle (2).

2. Obtaining pressure check.

(a) Open shutoff valve to pressure gauge 1/4 turn.

(b) Depress lever on tester slowly. Note at what pressure the needle on pressure gauge stops.

Opening pressure must be between 1,500 psi (10,343 kPa) and 1,960 psi (13,514 kPa). Replace
nozzle (2) if opening pressure does not meet specifications.