Hummer H1 (2002+). Manual - part 29

 

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 Engine  2-77

  

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05745159

 

Figure 2-146:   Torsional Damper Inspection Points

Figure 2-147:   Flywheel Inspection Points

 

OIL PUMP AND PUMP DRIVE SERVICE

 

The oil pump can be disassembled for inspection if desired but
not overhauled. The pump is serviced only as a complete as-
sembly. Individual pump parts are not available.

The pump shaft, pickup tube clamp and bolt, and pump mount-
ing stud are all available as service parts (Figure 2-148).

Replace the oil pump under the following conditions:

• Pressure test indicates low or no pump pressure

• High mileage overhaul

• Overhaul cause by oil pump failure

• Overhaul to correct problem that generated sludge, var-

nish

• Overhaul due to failure that produced chips, debris

• Repair caused by insufficient oil in engine

Inspect the oil pump drive gear and housing. Replace the drive
as an assembly if damaged in any way; only the drive O-ring
seal is replaceable.

The sensor on the oil pump drive is not serviceable. It is avail-
able only as part of the drive assembly.

 

Figure 2-148:   Oil Pump Serviceable Parts

SEAL

SURFACE

BOLT HOLES

INSULATOR

HUB BORE

KEYWAY

BODY

RING GEAR TEETH

HUB

PUMP SHAFT

OIL PUMP

(ASSEMBLY ONLY)

MOUNTING STUD

CLAMP

 

2-78

Engine

 

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OIL FILTER ADAPTER AND BYPASS VALVE 
SERVICE

Oil Filter Adapter

 

Inspect the adapter fitting and bolt for damaged threads
(Figure 2-149). Replace either fitting if damaged.

Inspect the filter adapter for stripped or crossed threads, cracks,
and chipped sealing surfaces. Replace the adapter if damaged.

Remove and discard the old O-rings and gasket from the bolts
(Figure 2-149). Install new O-rings and seal on the bolt and lu-
bricate them with engine oil.

 

Figure 2-149:   Filter Adapter and Bypass Valves

 

Bypass Valve 

 

Remove the two bypass valves  (Figure 2-149), and inspect
them carefully. Replace either valve if damaged, or filled with
shavings and/or debris. 

 

NOTE: 

 

The filter bypass and cooler bypass valves can be re-

moved with a small hook tool. 

 

FLUSHING ENGINE COOLER

 

Flush the engine oil cooler whenever a component failure con-
taminates the oil with metal or similar particles. The oil and fil-
ter should also be changed.

 

Cooler Flushing Procedure

 

1.

Remove oil cooler lines at engine and allow oil to drain 
into suitable container.

2.

With one line positioned in container, introduce air
pressure (no more than 20 psi (140 kPa)) into the other
line to force oil and contaminates out of cooler.

3.

When cooler is clear of oil, use pump or vacuum unit to
then either pump or draw solvent followed by fresh oil
through cooler. Continue until oil coming from cooler is
free of contaminants.

4.

Reconnect cooler lines to engine adapter fittings.

5.

Change engine oil and filter.

 

ROCKER COVER AND OIL PAN SERVICE

 

Clean the pan and covers in cleaning solvent. Use carb cleaner
on stubborn deposits if necessary.

Inspect rocker covers and oil pan for cracks, sealing surface
distortion, and dents. Repair minor dents. Replace either cover
if damaged (Figure 2-150).

 

Figure 2-150:   Rocker Arm Cover

OIL FILTER ADAPTER

ADAPTER

FITTING

ADAPTER BOLT

O-RINGS

GASKET

CUP PLUG

OIL FILTER 

COOLER 

OIL 

GALLERY

 PLUG

BYPASS 

VALVE

BYPASS VALVE

ROCKER ARM COVER

FLANGE

SEALING SURFACE

 

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 Engine  2-79

  

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05745159

Inspect the oil pan for cracks, sealing surface distortion, dents,
and damaged threads (Figure 2-151).

Small dents, not involving stretched metal, are not a cause for
replacement. Larger dents involving stretched or creased metal
will result in leaks.

Inspect the drainplug and pan for crossed or stripped threads
and burred flats. Discard the plug gasket. Replace the drain-
plug if damaged.

 

Figure 2-151:   Oil Pan Inspection Points

 

INTAKE AND EXHAUST MANIFOLDS

 

The manifolds can all be immersed in parts cleaning solvent.
Carbon buildup in the exhaust manifolds can be removed with
carb cleaner, wire brushing, or glass beading.

Check the manifold flange and gasket surfaces with a straight-
edge. Replace any manifold with warped, distorted surfaces.
Do not machine either type manifold in an attempt to salvage
it.

Minor scratches and nicks on gasket surfaces can be smoothed
with 80 grit emery cloth, an oil stone, or fine tooth file.

Inspect the manifolds for cracks on all surfaces. Check the ex-
haust manifolds and exhaust inlet pipes for splitting and flange
or joint separation. Although seriously damaged parts should
be replaced, minor damage on low mileage steel exhaust parts
can be repaired by welding.

Inspect manifold fittings and threads. Replace loose damaged
fittings and repair thread damage with a tap or helicoil insert.

 

Figure 2-152:   Crankshaft Journal Size Identification

DRAIN PLUG

PAN SEALING SURFACES

GASKET

A. MAIN BEARING  JOURNAL MARKINGS (BLUE, ORANGE/RED, OR WHITE)
B. ROD BEARING JOURNAL MARKINGS (YELLOW OR GREEN)

A

B

A

B

 

2-80

Engine

 

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ENGINE ASSEMBLY AND ADJUSTMENT

Crankshaft Main Bearing Selection

 

Main bearings are available in standard and two undersizes for
select fit purposes. Required bearing clearances are:

• 0.0017-0.003 in. (0.045-0.083 mm) at bearings 1 

through 4

• 0.002-0.0036 in. (0.055-0.093 mm) at number 5 rear 

main

There are three main journal diameter ranges. The ranges are
identified by a color code paint mark near one of the journals.
The size range color codes are blue, orange/red, and white.
Rod bearing journals are marked yellow or green. The color
codes indicate journal diameter and correspond to the Main
Bearing Selection Chart at the end of this section.

The main bearing bores in the block are also coded for size.
There are three ranges identified by the numbers 1, 2, or 3.
These numbers are stamped in the cylinder block pan rail. Re-
fer to the Main Bearing Selection chart at the end of this sec-
tion.

 

NOTE: 

 

Different bearings are used in turbo and NA diesel en-

gines. Do not interchange the main or rod bearings.

 

Crankshaft and Main Bearing Installation

 

1.

Measure main journal diameters, note color code on 
crankshaft, and size letter on engine pan rail. Select bear-
ings as needed. 0.0005 in. (0.013 mm) bearings are stan-
dard while 0.001 in. (0.026 mm) bearings are undersize.

2.

Identify and separate bearing halves before proceeding.
Bearing upper halves have oil grooves while lower halves
do not. Upper halves go in block while lower halves go in
bearing cap. Extra wide bearing is thrust bearing and is
installed in number 3 position.

3.

Install main bearing upper halves in block  (Figure 2-153).
Install bearing halves dry. Do not lubricate bearing saddle
in block or back of bearing. Be sure each bearing locating
tab is properly seated in notch machined in block. Also be
sure oil holes in bearing and block are aligned. Thrust
bearing half goes in #3 main bearing saddle.

4.

Install main bearing lower halves in bearing caps
(Figure 2-154). Install bearings dry and be sure each
bearing locating tang is seated in bearing cap notch. Thrust
bearing half goes in #3 main cap.

5.

Position crankshaft in block. Do not turn the shaft. Just
carefully seat it in bearing upper halves.

6.

Position length of plastigauge on each main bearing
journal (Figure 2-155). Cut plastigauge so it extends
across three quarters of journal. Position plastigauge so it
is parallel to crankshaft center line as shown.

 

Figure 2-153:   Installing Crankshaft and Main 

Bearing Upper Halves

Figure 2-154:   Assembling Main Caps and Bearing 

Lower Halves

CRANKSHAFT

TANG

BEARING
SADDLES

MAIN

BEARING

UPPER

HALVES

(GROOVED)

MAIN CAPS

MAIN BEARING
LOWER HALVES

(PLAIN)

TANG