Hummer H1 (2002+). Manual - part 15

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 Engine  2-21

¨

05745159

Installation

1.

Clean face of torsional damper with brake cleaner. Smooth 
surface with Þle, or 280 grit paper, if necessary.

2.

Install pulley on damper and install pulley bolts. Tighten
bolts until snug.

3.

Install serpentine belt on all pulleys except belt tensioner
(Figure 

2-16). Turn tensioner counterclockwise with

breaker bar and slide belt onto tensioner. Then release
breaker bar so tensioner can rotate clockwise to adjust
belt.

4.

Tighten crankshaft pulley bolts to 48 lb-ft (65 N¥m)
torque.

Figure 2-16:   Serpentine Belt Installation

TORSIONAL DAMPER

Removal

1.

Remove crankshaft pulley and serpentine belt. Refer to 
procedure in this section.

2.

Remove damper bolt and washer (Figure 2-17).

3.

Remove torsional damper with tool J

Ð

23523-F

(Figure 2-18).

4.

Remove and inspect crankshaft keys. Replace keys if
worn, chipped, or distorted.

Figure 2-17:   Torsional Damper and Crankshaft Pul-

ley Mounting

Figure 2-18:   Torsional Damper Removal

Installation

1.

Check seal contact surface of damper. Surface must be 
clean and smooth to avoid damaging timing cover seal. 
Smooth surface with 180 grit emery if necessary. Then 
polish surface with 220 grit emery coated with engine oil.

2.

Inspect condition of front cover seal. Replace seal if worn,
cut, cracked, or hardened. Use pry tool to remove oil seal
and tool J

Ð

22102 to install new seal.

3.

Install damper drive key in crankshaft. Be sure keys are
fully seated in crankshaft key slots.

4.

Lubricate crankshaft nose, front cover seal, and seal
surface of torsional damper with engine oil.

5.

Install torsional damper on crankshaft. Be sure drive key is
not displaced during damper installation.

6.

Install damper washer and bolt. Tighten bolt to 160-200
lb-ft (217-270 N¥m) torque.

7.

Install crankshaft pulley. Tighten pulley bolts to 48 lb-ft
(65 N¥m) torque.

8.

Install serpentine belt (Figure 2-16).

A/C COMPRESSOR

OR IDLER PULLEY

WATER PUMP

PULLEY

SERPENTINE 

BELT

POWER

STEERING

PUMP

PULLEY

CRANKSHAFT

PULLEY

VACUUM

PUMP

PULLEY

ALTERNATOR

PULLEY

TENSIONER

PULLEY

CRANKSHAFT
KEY

CRANKSHAFT

DAMPER
SEAL SURFACE

DAMPER BOLT

AND WASHER

PULLEY

TORSIONAL

DAMPER

TOOL J

Ð

23523-F

2-22

Engine

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¨

FRONT COVER OIL SEAL REPLACEMENT

1.

Remove crankshaft pulley and torsional damper. Refer to 
procedures in this section.

2.

Remove oil seal front cover with tool J

Ð

22102 or pry tool

(Figure 2-19).

3.

Clean seal contact surface of torsional damper. Smooth
surface, if necessary, with 180 grit emery. Then polish
with 220 grit emery coated with engine oil. Seal surface
must be smooth to avoid damaging new seal.

4.

Install new seal in cover with tool J

Ð

22102. Open end of

seal goes toward interior of cover.

5.

Lubricate new seal and seal surface of torsional damper,
with engine oil.

6.

Install keys in crankshaft. Then align and install torsional
damper. Install damper belt and washer. Tighten bolt to
140-160 lb-ft (190-217 N¥m).

7.

Install crankshaft pulley and serpentine belt. Refer to
procedure in this section.

Figure 2-19:   Front Cover Oil Seal Location

OIL PUMP DRIVE

Removal

1.

Remove engine cover/console for access to rear of engine.

2.

Remove the turbocharger as described in this section.

3.

Clean surface of drive, block and drive clamp with carb
cleaner.

4.

Remove bolt that secures oil pump drive clamp to block
(Figure 2-20).

5.

Remove oil pump drive with turn and lift motion. Use
channel lock or use grip pliers to remove drive.

6.

Remove gasket from block or drive.

7.

Cover pump drive opening in block to prevent dirt entry.

Installation

1.

Install new gasket on oil pump drive.

2.

Position and insert oil pump drive in block. Turn drive
back and forth to seat it as needed.

3.

Install drive clamp and bolt. Tighten bolt to 25-37 lb-ft
(34-50 N¥m) torque.

4.

Install turbocharger as described in this section.

5.

Install engine console/cover.

Figure 2-20:   Oil Pump Drive Removal/Installation

FRONT COVER

OIL SEAL

TOOL

J22102

OIL PUMP DRIVE

GASKET

CLAMP

ENGINE SPEED 
SENSOR

S02-012.2

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 Engine  2-23

¨

05745159

FRONT COVER AND TIMING CHAIN

Cover Removal

1.

Disconnect and remove batteries and tray.

2.

Drain engine coolant.

3.

Remove radiator upper and lower hoses.

4.

Loosen crankshaft pulley belts.

5.

Remove left and right splash shields.

6.

Disconnect hood harness then remove hood with aid of
helper. Place hinge pins in hinges after removal to avoid
losing them.

7.

Remove A/C condenser oil coolers, radiator, and fan
shroud as assembly (Figure 2-21).

8.

Loosen and remove serpentine drive belt. Use 1/2 in. drive
breaker bar to rotate belt tensioner counterclockwise to
loosen belt (Figure 2-15).

9.

Disconnect heater, bypass and inlet hoses at water pump
and coolant crossover (Figure 2-22).

10. Remove oil filler neck and coolant crossover

(Figure 2-22).

Figure 2-21:   Condenser, Oil Coolers, Radiator and Fan Shroud Removal as an Assembly

RADIATOR

LOWER

MOUNT

FRAME

BRACKET

FAN SHROUD

REAR SUPPORT BRACKET

OIL COOLERS

CONDENSER

RIGHT SIDE

AIR LIFT BRACKET

2-24

Engine

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¨

Figure 2-22:   Upper Radiator Hose Connections 

11. Remove fan and fan clutch.

12. Remove crankshaft pulley (Figure 2-14).

13. Remove torsional damper attaching bolt and washer

(Figure 2-17).

14. Remove torsional damper with tool J

Ð

23523-F

(Figure 2-18).

15. Remove drive keys from crankshaft. Replace keys if worn,

chipped, or distorted.

16. Remove water pump and adapter plate as assembly

(Figure 2-23).

17. Remove bolts that attach front cover to oil pan

(Figure 2-24).

18. Rotate crankshaft by hand until timing marks on sprockets

and gears are aligned and number one piston is at TDC.

19. Remove injection pump driven gear (Figure 2-24).

20. Remove baffle from front cover (Figure 2-24).

21. Remove nuts and washers attaching fuel injection pump to

studs on front cover (Figure 2-24).

NOTE: There are timing marks on the front cover and injec-
tion pump. Note position of these marks for installation refer-
ence.

22. Remove bolts that attach front cover to engine block. Then

break sealer bead with putty knife and remove cover.

23. Cover oil pan opening to prevent dirt entry.

24. Check timing chain deflection with dial indicator.

Measure deflection mid-way between crankshaft and cam
sprockets. Maximum allowable deflection is 0.810 in.
(20.5 mm). Replace chain and sprockets if deflection is
greater than specified.

25. Check camshaft end play with dial indicator. Maximum

allowable end play is 0.012 in. (0.3 mm). Replace cam
thrust plate and spacer if end play is greater than specified.

NOTE: Note position of timing marks on drive gear and crank
and cam sprocket for installation reference.

26. Remove bolt and washer attaching injection pump drive

gear to camshaft. Then remove gear (Figure 2-25).

27. Slide timing chain and sprockets off camshaft and

crankshaft (Figure 2-25).

28. Remove drive keys from camshaft and crankshaft.

Replace keys if chipped, cracked, or distorted. Minor burrs
can be removed with a stone or fine tooth file.

29. Clean all old sealer off engine block, front cover, and

water pump/adapter plate with scraper.

Figure 2-23:   Water Pump and Adapter Plate Removal/Installation

CROSSOVER

HOSE

OIL

FILLER

NECK

FRONT COVER

WATER PUMP

ADAPTER PLATE