Hummer H1 (1992-1998). Manual - part 54

2-41. ENGINE ASSEMBLY FROM SUBASSEMBLIES (Cont’d)

u. Fuel Supply and Return Lines

1. Install fuel supply line (8) on fuel pump (27) and finger tighten tube nut (26).

2. Install fuel return line (17) on timing gear cover (25) with clamp (13), washer (12), and

capscrew (11). Finger tighten capscrew (11).

3. Install return line (17) to valve cover stud (21) with clamp (20), washer (19), and nut (18). Tighten

nut (18) to 13-20 lb-ft (18-27 N•m).

4, Install supply line (8) and return line (17) to cylinder block (29) with two clamps (28), washer (24),

and stud (23). Tighten stud (23) and capscrew (11) to 25 lb-ft (34 N•m).

5. Tighten tube nut (26).
6. Connect three rubber hoses (16) to front fuel injection nozzles (22) and fuel injection pump (14)

with, three clamps (15).

7. Connect fuel filter inlet hose (10) to fuel supply line (8) with hose clamp (9).

2-41. ENGINE ASSEMBLY FROM SUBASSEMBLIES (Cont’d)

v. Fuel Injection Lines

1. Install number 1 and 3 injection lines (7) and connect t

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fuel injection pump (1) and fuel injection

nozzles (4).

2. Using crowfoot wrenches, tighten four nuts (3) and fuel injection lines (7) on fuel injection nozzles (4)

and fuel injection pump (1) to 20 lb-ft (27 N•m).

3. Repeat steps 1 and 2 for each set of remaining fuel injection lines (7), number 5 and 7, number 6

and 8, and number 2 and 4.

4. Install four clamps (5) securing fuel injection lines (7) to support brackets (2) with four screw-

aesembled washers (6).

5. Install boot (8) onto fuel injection pump (1) and tighten clamp (9).

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2-41. ENGINE ASSEMBLY FROM SUBASSEMBLIES (Cont’d)

 w. Water Crossover 

1. Install two gaskets (11) and water crossover (16) on cylinder heads (15).

2. Install four capscrews (10) on water crossover (16) and cylinder heads (15). Tighten capscrews (10) t

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25-37 lb-ft (34-50 N•m).

3. Connect thermostat bypass hose (12) to nipple (14) and tighten hose clamp (13).

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2-41. ENGINE ASSEMBLY FROM SUBASSEMBLIES (Cont’d)

x. Intake Manifold

1. Install two gaskets (2) and intake manifold (1) on cylinder heads (3).

2. Install injection line clip (10), three injection line clips (5), and fuel supply line clamp (11) on

intake manifold (1), following assembly diagram shown.

NOTE

Perform step 3 for 6.2L engines. Perform step 4 for 6.5L engines.

3. Install four long studs (6), long capscrew (9), six studs (7), five capscrews (8), and sixteen

washers (4), following assembly diagram shown.

4. Install four long studs (6), long capscrew (9), seven studs (7), four capscrews (8), and sixteen washers (4),

following assembly diagram.

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