Hummer H1 (2002+). Manual - part 21

 

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 Engine  2-45

  

®

 

05745159

 

OVERHAUL SERVICE INFORMATION

 

Anaerobic and RTV type sealers are both used during engine
re-assembly. Anaerobic sealer such as Loctite gasket maker
(515 or 510) is used on the timing chain cover. RTV sealers
such as Permatex Ultra Copper, Ultra Blue, or Loctite 599, are
used on the oil pan and rocker covers.

Thread locking chemicals such as Loctite 242 are specified
wherever necessary. In addition, Permatex dielectric com-
pound can be used on electrical connections to prevent corro-
sion.

Do not use substitute fasteners unless they are of the correct
size and hardness grade. When replacement bolts/nuts are re-
quired, it is recommended that parts catalog items be used.
This ensures that correct grade fasteners are used.

 

ENGINE REMOVAL

 

1.

Remove front console attaching screws. Move console 
rearward and disconnect console harness connector and 
radio harness. Then remove console.

2.

Disconnect Digital Ratio Adapter and Keyless Entry
Module. Remove inner engine cover.

3.

Remove hood with aid of helper as follows:

• Unlatch and lower brushguard, if equipped.

• Unlatch and raise hood.

• Remove clip that attaches hood harness to driver side of 

frame.

• Disconnect hood harness from cowl top harness.

• Remove bolts attaching prop and bracket to driver side 

air lift bracket. Do not remove prop rod from hood. 
Leave rod attached. Tape rod to hood if desired.

• Remove hood hinge pins.

• Remove hood with aid of helper.

4.

Disconnect and remove batteries and cables.

5.

Remove battery tray.

6.

Remove driver and passenger side splash shields.

7.

Drain engine coolant and engine oil.

8.

Discharge A/C system with recovery machine set in
recovery mode.

9.

Disconnect radiator upper and lower hoses at the radiator.

10. Drain fluid in power steering pump using a suction gun.

11. Disconnect oil lines at transmission and power steering

coolers. Cap lines to prevent dirt entry Figure 2-52.

12. Disconnect engine cooler lines for engine oil cooler. Cap

lines to prevent dirt entry.

13. Disconnect A/C lines at condenser. Cap or tape lines and

fittings to prevent dirt entry.

14. Remove rubber/sponge pads from air lift brackets.

15.  Remove return hoses from power steering pump.

16. Remove surge tank hose from radiator.

17. Remove bolts attaching radiator and shroud assembly to

frame and brackets. Then (with aid of helper), remove
radiator, shroud, condenser, and oil coolers as an assembly
Figure 2-53.

 

.

 

Figure 2-52:   Covering Open Ends of Oil 

Cooler Lines

Figure 2-53:   Radiator, Cooler, Fan Shroud 

Removal/Installation

 

18. Remove air horn from turbocharger and air cleaner hose

(Figure 2-54).

19. Disconnect radiator hose at thermostat housing and at

radiator upper and lower outlets.

20. Remove the engine oil dipstick and tube

21. Loosen tensioner and remove serpentine belt.

22. Using the spanner wrench and ratchet adapter, remove

cooling fan and clutch from water pump.

COVER OPEN ENDS

OF ALL COOLER LINES

WITH DUCT TAPE

6-S02-009

 

2-46

Engine

 

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23. Disconnect A/C hoses at compressor. Move hoses aside

for working clearance. Cap open ends to prevent dirt entry
(Figure 2-55).

 

Figure 2-54:   Air Horn and Hose Removal/Installation

Figure 2-55:   Suction/Discharge Hose Assembly 

Mounting

 

24. Disconnect bypass hose at water crossover.

25. Disconnect heater hoses at water crossover and water

pump.

26. Disconnect and remove generator, belt tensioner, idler

pulley and bracket as assembly (Figure 2-56).

 

Figure 2-56:   Alternator, Pulleys, and Bracket 

Removal/Installation

 

27. Remove brackets/retainers that secure wire harnesses to

intake manifold and heads.

28. Disconnect AMG wiring harness from starter, glow plug

controller and cowl top harness, then remove.

29. Disconnect wires at all glow plugs.

30. Remove fuel pump from retaining clamp.

31. Disconnect fuel hose from injector pump line at underside

of manifold. Cap all open hose ends.

32. Disconnect injection pump and engine harness connectors.

Move wire harnesses aside for removal clearance.

33. Disconnect glow plug relay wires and cables.

34. Disconnect exhaust pipe at the turbocharger.

35. Remove any remaining brackets and clips securing wire

harnesses to engine.

36. Disconnect oil lines from power steering pump to hydro

boost at hydro boost housing. Cap lines and hydro boost
outlets to prevent dirt entry. Move lines aside for
clearance.

37. Remove turbocharger heat shield and disconnect vacuum

actuator hose.

38. Remove air intake manifold crossover. Tape openings to

prevent dirt entry.

39. Remove intake manifold runners.

9-S03-002

AIR

HORN

AIR

CLEANER

  HOSE 

SEAL

WASHER (2)

SUCTION/ DISCHARGE

HOSE ASSEMBLY

COMPRESSOR

ALTERNATOR/

IDLER/TENSIONER

AND BRACKET

ASSEMBLY

SUPPORT

BRACKET

 

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 Engine  2-47

  

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05745159

40. Working under vehicle, loosen, disconnect, or remove

following:

• Remove skid plate.

• Remove starter and shield (with aid of helper).

• Remove exhaust pipe. Also loosen and move heat shield 

aside.

• Remove converter housing access cover and gasket.

• Remove oil filter and disconnect lines to oil cooler.

• Remove transmission fill tube Figure 2-58.

• Remove torque converter attaching bolts Figure 2-57.

• Remove nuts attaching engine mount insulators to frame 

brackets.

41. Remove turbocharger.

42. Support transmission with floor jack. Position wood

blocks between transmission and jack saddle.

 

Figure 2-57:   Converter Bolt Removal/Installation

Figure 2-58:   Transmission Dipstick Tube

 

43. Remove bolts/studs attaching transmission to engine

block.

44. Attach lifting sling to engine (Figure 2-59).

 

Figure 2-59:   Lifting Bracket to Cylinder Head 

Attachment

 

45. Raise engine with hoist and remove it from engine bay.

 

CAUTION: 

 

Make sure all electrical wires, harnesses, and

fluid lines are disconnected and clear of engine assembly. Do
this before removal to avoid damage.

 

46. Mount engine on heavy duty engine stand or cradle.

Engine stand should have minimum capacity of 1500 lb
(680 kg).

TORQUE

CONVERTER

CONVERTER

BOLT

FLYWHEEL

TRANSMISSION

SEAL

TRANSMISSION FILL/DIPSTICK TUBE

LIFTING BRACKET

FRONT

OF 

SLING

RIGHT SIDE

CYLINDER

HEAD (FRONT)

PIN

LIFTING BRACKET

LEFT SIDE

CYLINDER

HEAD

LIFTING 

SLING

J–33139

 

2-48

Engine

 

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Figure 2-60:   Engine Mounted on Repair Stand

 

ENGINE INSTALLATION

 

1.

If new engine is being installed, transfer mounting brack-
ets and insulators, generator, power steering pump, A/C 
compressor, drive plate (flywheel), turbocharger, and nec-
essary mounting brackets, shields, damper pulleys, sensors 
and fittings, from old to new engine.

2.

Attach lifting bracket to engine.

3.

Attach hoist to lifting bracket. Raise engine and guide it
into engine bay with aid of helper.

4.

Align and seat engine on transmission. Be sure converter
pilot hub is seated in crankshaft and that transmission is
seated on engine block dowels. Install 2-3 transmission
attaching bolts (finger tight) to hold engine and
transmission in place.

5.

Align and seat engine mounting bracket insulators on
frame brackets. Be sure insulator studs are fully seated in
frame brackets before proceeding.

6.

Apply Loctite 242 to transmission, converter, and engine
mount nuts/bolts. Then install and tighten nuts and bolts to
following torque:

• Converter bolts to 32 lb-ft (43 N•m)

• Transmission bolts to 35 lb-ft (47 N•m)

• Insulator stud nuts to 90 lb-ft (122 N•m)

7.

Install converter housing access cover. Tighten cover
attaching screws to 60 lb-in. (7 N•m) torque.

8.

Connect engine oil cooler lines to fittings at rear of engine
block.

9.

Install turbocharger.

10. Install starter motor and shield with aid of helper. Tighten

starter mounting bolts to 30-40 lb-ft (41-54 N•m) torque. Do
not connect cable and solenoid wire to starter at this time.

11. Install exhaust pipe and heat shield, if removed and

connect exhaust pipe to turbocharger. Tighten attaching
nuts to 37 lb-ft (50 N•m) torque.

12. Install new oil filter.

13. Install intake manifolds and crossover.

14. Install/connect following:

• Wire harness brackets and clamps

• Injection pump, engine harness, sensor wires

• Turbocharger actuator vacuum hose

• Torbocharger heat shield

• Transmission and engine dipstick tubes

• AMG engine harness

15. Install fuel pump in clamp at driver side of engine bay.

16. Connect fuel lines to injection pump.

17. Install CDR valve and hose if removed.

18. Route hydraulic lines from power steering pump to hydro-

boost unit and connect lines. Be sure lines are clear of hot
or rotating components and are not kinked at any spot.

PIN

LIFTING SLING

AND BRACKET

LEFT

CYLINDER HEAD

J–33139

7-S02-015