Hummer H1 (1992-1998). Manual - part 2

CHAPTER 2

ENGINE MAINTENANCE

Section I. REPAIR PARTS, SPECIAL TOOLS, TEST, MEASUREMENT, AND

DIAGNOSTIC EQUIPMENT (TMDE), AND SUPPORT EQUIPMENT

2-1. COMMON TOOLS AND EQUIPMENT

Refer to Modified Table of Organization and Equipment (MTOE) for authorized common tools and
equipment applicable to your unit.

2-2. SPECIAL TOOLS AND SUPPORT EQUIPMENT

Special tools and support equipment are listed in Appendix E of this manual and illustrated in TM 9-2815-
237-34P.

2-3. TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE)

Calibrate all measuring and test equipment used to determine equipment conformance in accordance with
TB 43-180.

 2-4. REPAIR PARTS 

Section Il. SERVICE UPON RECEIPT

2-5. ENGINE INSPECTION

a. Inspect for any damage done to engine during its removal from the vehicle. Refer to TM 9-2320-280-34

for engine removal procedure.

b. Upon receipt of engine, ensure that all components are present and that no engine subassemblies have

been removed. Refer to TM 9-2320-280-34 for engine dress after removal.

c. If the engine has been transferred to you from another DS/GS maintenance facility, check the equip-

ment against the packing slip to see if the shipment is complete. Report all discrepancies in accordance with

the instructions of DA Pam 738-750.

Section III. TROUBLESHOOTING

2-6. GENERAL

Information in this section is for use of support maintenance personnel in conjunction with, and as a
supplement to, troubleshooting procedures in TM 9-2320-280-20 and TM 9-2320-280-34.

2-7. ENGINE TROUBLESHOOTING

CAUTION

Operation of a deadlined engine without preliminary inspection

will cause further damage.

Information to be used for troubleshooting the engine is contained in TM 9-2320-280-20 and

TM 9-2320-280-34.

a. Excessive oil consumption is generally caused by leaky gaskets or loose line connections.
b. Always check the easiest and most obvious things first. This simple rule saves time and trouble.

c. Double check before disassembly. The source of most engine problems can be traced to more than one

part in a system. For example:

(1) Excessive fuel consumption may not be caused by the fuel pump alone. Instead, the trouble could

be a clogged air cleaner, or a restricted exhaust passage causing severe back pressure.

(2) Engines very often are disassembled in search of a complaint and the real evidence of the problem

is destroyed. Check again to be sure an easier solution to the problem has not been overlooked.

d. Before correcting a problem, diagnose the cause of the problem. Do not allow the same failure to

occur again.

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Section IV. GENERAL MAINTENANCE INSTRUCTIONS

2-8. GENERAL MAINTENANCE INSTRUCTIONS TASK SUMMARY

TASK

PARA,

PROCEDURES

PAGE

NO.

2-9.

Cleaning

2-3

2-10.

Inspection

2-4

2-11.

Repair

2-5

2-12.

Assembly

2-6

 2-9. CLEANING

a. General Instructions. Cleaning procedures will be the same for the majority of parts and compo-

nents which make up engine subassemblies. General cleaning procedures are detailed in “b” through “i”.

b. The Importance of Cleaning. Great care and effort are required in all cleaning operations. The

presence of dirt and foreign material is a constant threat to satisfactory engine operation and maintenance.
The following will apply to all cleaning operations:

(1) Hands must be kept free of any accumulation of grease which can collect dust and grit.
(2) Clean all parts before inspection, after repair, and before assembly.
(3) After cleaning, all parts must be covered or wrapped in plastic or paper to protect them from dust

and/or dirt.

WARNING

Compressed air used for cleaning purposes will not exceed 30 psi
(207 kPa). Use only with effective chip guarding and personal
protective equipment (goggles/shield, gloves, etc.).

c. External Engine Cleaning.  All electrical equipment and other parts that could be damaged by steam

cleaning or moisture must be removed, and all openings covered before cleaning. Dry with compressed air.

d. Disassembled Parts Cleaning. Place all disassembled parts in wire baskets for cleaning.

(1) Dry and cover all cleaned parts.
(2) Place on or in “racks” and hold for inspection or repair.
(3) All parts subject to rusting must be lightly oiled and wrapped.

(4) Keep all related parts and components together. Do not mix parts.

Improper cleaning methods and use of unauthorized cleaning
solutions will injure personnel and damage equipment. See
TM 9-247 for correct information.

e. Castings.

(1)  Clean inner and outer surfaces of castings and all areas subject to grease and oil with cleaning

solvents. Refer to TM 9-247.

(2) Use a stiff brush to remove sludge and gum deposits.
(3) Use compressed air to blow out all tapped capscrew holes and dry castings after cleaning.

f. Oil Passages. Particular attention must be given to all oil passages in castings and machined parts.

Oil passages must be clean and free of any obstructions.

(1) Clean passages with wire probes to breakup any sludge or gum deposits.
(2) Wash passages by flushing with solvents. See TM 9-247,
(3) Dry passages with compressed air.

CAUTION

Do not allow drycleaning solvents to come in contact with seals,
cables, or flexible hoses. These cleaners cause leather, rubber, and
synthetic materials to dry out, rot, and lose pliability making them
unserviceable.

g. Nonmetallic Parts. Clean hoses and other nonmetallic parts with soap and water.
h. Bearings.

WARNING

Do not use compressed air to dry bearings. Spinning a dry bearing

with compressed air may cause injury to personnel or damage to

equipment.

(1) Bearings require special cleaning. After removing surface oil and gum deposits, place bearings in

hot oil, 140°F (60•C), to loosen congealed oil and grease. Wipe bearings dry with a Iint-free cloth; do not use

compressed air.

(2) See TM 9-214 for information and care of bearings.

i. Electrical Components.

(1) Clean electrical components with clean cloth dampened with drycleaning solvent. Care must be

taken not to damage protective insulation.

WARNING

Compressed air used for cleaning purposes will not exceed 30 psi
(207 kPa). Use only with effective chip guarding and personaI

protective equipment (goggles/shield, gloves, etc.).

(2)  Use compressed air oa dry electrical components.

2-10. INSPECTION

a. General Instructions.  Procedures for inspections will be the same for many parts and components

which make up the engine subassemblies. General procedures are detailed in “b” through “k”, Dimensional

standards for parts have been fixed at extremely close tolerances, so use specification tables. Use specified
inspection equipment for inspection where cracks and other damage cannot be spotted visually. Exercise
extreme care in all phases of inspection. Repair or replace all unserviceable components; refer to para. 2-11.

b. Castings.

(1) Inspect all ferrous and nonferrous castings for cracks. See MIL-I-6866, Inspection, Penetrant

Methods, and MIL-I-6868, Inspection Process, Magnetic Particles. Particularly check areas around studs,
pipe plugs, threaded inserts, and sharp comers. Replace cracked castings.

(2) Inspect machined surfaces for nicks, burrs, and raised metal. Mark damaged areas for repair

or replacement.

(3) Inspect all pipe plugs, pipe plug openings, capscrews, and capscrew openings for damaged and

stripped threads. Replace if damaged or threads are stripped.

(4) Check all gasket mating surfaces, flanges on housings, and supports for warpage with a straight

edge or surface plate. Inspect mating flanges for discolorations which may indicate leakage. Replace if
warped.

(5) Check all castings for conformance to applicable repair standards.

2-4