Hummer H1 (2002+). Manual - part 30

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 Engine  2-81

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05745159

Figure 2-155:   Gauging Plastic Position on 

Crankshaft Main journal

7.

Install main bearing caps and old bolts retained from
disassembly operations. Tighten inner cap bolts to 55 lb-ft
(75 N•m), outer bolts on main caps 1 and 5 to 48 lb-ft (65
N•m) and main caps 2, 3, and 4 to 30 lb-ft (40 N•m) to
compress gauging plastic.

8.

Remove main bearing caps and measure plastigauge with
graduated scale on gauge envelope (Figure 

2-156).

Measure widest point of compressed plastic.

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If clearances are correct, proceed to next step.

•

If clearances are insufficient, try standard bearings.
Or, if clearances are too large, try undersize bearings.
In some cases, a combination of standard and under-
size bearings will be needed to obtain required clear-
ance. Note that under size bearings refer to crankshaft
diameter.

9.

Carefully remove crankshaft and clean plastic off journals.
Then lubricate main bearings and crankshaft with 40W
engine oil or a quality assembly lube, and reinstall
crankshaft.

10. Reinstall main bearing caps. Be sure caps are properly

aligned. Bearing notches should be aligned and direction
arrows toward front.

11. Apply Permatex High Temp silicone sealer to rear main

bearing cap seat in block (Figure 2-157).

12. Install new inner and outer bearing cap bolts finger tight

only. Bolts will not be tightened until after crankshaft end
play check.

Figure 2-156:   Measuring Gauging Plastic to 

Determine Bearing Clearance

Figure 2-157:   Sealer Application Points in Rear Main 

Bearing Cap Seat

CRANKSHAFT END PLAY CHECK

1.

Tighten bolts in main cap number 3 to approximately 10 
lb-ft (14 N•m) torque.

2.

Tap crankshaft rearward then forward to align thrust
bearing. Use lead hammer or rawhide mallet to tap
crankshaft.

3.

Tighten long inner number 3 main cap bolts to 55 lb-ft (75
N•m) and shorter outer bolts to 30 lb-ft (40 N•m) torque.

4.

Verify that crankshaft can be rotated freely without bind
or drag.

5.

Pry and hold crankshaft forward. Measure clearance
between crankshaft and number 3 main bearing with feeler
gauge (Figure 2-158). Clearance should be 0.004-0.010 in.
(0.10-0.25 mm). If clearance is incorrect, thrust bearing is
incorrect size or not seated, or crankshaft thrust surface is
worn. Correct as necessary. If clearance is OK, continue
with assembly.

CRANKSHAFT MAIN

BEARING JOURNAL

GAUGING

PLASTIC

COMPRESSED

GAUGING

PLASTIC

ENVELOPE SCALE

APPLY RTV-TYPE

SEALER HERE

REAR MAIN

BEARING CAP SEAT

(IN BLOCK)

2-82

Engine

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CRANKSHAFT MAIN CAP TORQUE SEQUENCE

1.

Tighten the inner 12 mm bolts to 55 lb-ft (75 N.m).

2.

Retighten the inner 12 mm bolts to 55 lb-ft (75 N.m).

3.

Tighten the inner 12 mm bolts an additional 90 degrees.

4.

Tighten the outer 12 mm bolts (crankshaft bearing caps 1
and 5) to 48 lb-ft (65 N.m).

5.

Retighten the outer 12 mm bolts (crankshaft bearing caps
1 and 5) to 48 lb-ft (65 N.m).

6.

Tighten the outer 12 mm (crankshaft bearing caps 1 and 5)
an additional 90 degrees.

7.

Tighten the outer 10 mm bolts (bearing caps 2, 3, and 4) to
30 lb-ft (40 N.m).

CAUTION:  DO NOT tighten the outer 10 mm bolts an addi-
tional 90 degrees!

8.

Check the crankshaft for proper rotation.

NOTE: If crankshaft does not rotate freely or binds in spots,
problem may be: misaligned main caps, bearing incorrectly in-
stalled, foreign material on bearing or journal, wrong bearing
size.

Figure 2-158:   Measuring Crankshaft End Play

REAR MAIN SEAL INSTALLATION

1.

Lubricate new rear main seal lip with chassis grease or 
petroleum jelly.

2.

Apply sealer such as Permatex #2 to outer circumference
of new seal.

3.

Install seal with tool J–39084 (Figure 2-159). Be sure seal
is flush with block and bearing cap as shown

Figure 2-159:   Rear Main Seal Installation

#3 MAIN CAP

FEELER GAUGE

MAIN BEARING CAP

CRANKSHAFT

SEAL

BLOCK

BLOCK

SEAT SEAL FLUSH

CRANKSHAFT

SEAL

MAIN BEARING CAP

J–39084

SEAL INSTALLER

WITH BLOCK

AND BEARING CAP

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 Engine  2-83

®

05745159

PISTON/CONNECTING ROD INSTALLATION 
AND BEARING FIT

Verify correct piston and rod assembly. Be sure piston crown relief
and notches in rod for bearing inserts are aligned (Figure 2-160).

Install only one piston and connecting rod assembly at a time.
This is necessary because rod bearing clearance must be
checked with the bearing inserts dry. Check bearing clearance
at each rod as it is installed.

Make sure the connecting rod caps are matched to their respec-
tive rods and are properly aligned. Failure to match and align
the rod caps can result in premature bearing failure.

Standard and undersize bearing inserts can be combined in one
rod to obtain desired clearance. Just be sure to install the un-
dersize insert in the rod cap.

CAUTION:  Rod bearing clearance must be checked with the
bearings dry (no lubrication). For this reason, the crankshaft
must not be rotated during the measuring procedure. Other-
wise, bearing damage will occur.

1.

Lubricate cylinder wall, piston rings, and all surfaces of 
piston (except crown), with engine oil.

2.

Verify that piston ring ends are properly spaced. Refer to
spacing diagram  (Figure 2-127).

3.

Insert rod bearing halves in rod end and bearing cap.
Install bearing dry. They will not be lubricated until after
clearance check with plastic gauging material.

4.

Install lengths of rubber hose on each connecting rod bolt.
Hose will prevent cylinder wall scratches and nicks during
piston installation  (Figure 2-160).

5.

Compress piston rings on #1 piston with compressor tool
(Figure 2-161).

6.

Rotate crankshaft until rod journal for number one piston
is accessible.

7.

Start number one piston in cylinder. Position rod end so it
is aligned with crankshaft journal. Also be sure relief in
piston crown is toward outside of engine.

8.

Press piston downward into cylinder with hammer handle
(Figure 2-161). Guide rod end onto crankshaft journal at
same time.

9.

Check rod bearing clearance as follows:

a.

Place strip of plastic gauging material on crankshaft
rod journal (Figure 2-162).

b.

Install rod cap and bearing and tighten rod bolt nuts to
65 N•m (48 lb-ft).

c.

Remove rod cap and measure gauging material with
graduated scale on plastigauge envelope (Figure 2-162).
Clearance should be 0.0017-0.0039 in. (0.045-0.100 mm).

d.

If clearance is OK, proceed to next step. If clearance is
not OK, use new standard or undersize rod bearings to
obtain correct clearance. If combination of standard
and undersize bearing inserts are required, install
undersize insert in rod cap. Note that standard bearings
provide more clearance than under size bearings.

10. Remove rod cap. Clean gauging material off crankshaft

journal. Lubricate rod bearing halves and crankshaft journal
with engine oil or assembly lube. Then reinstall rod cap and
tighten new rod cap nuts to 48 lb-ft (65 N•m) torque.

11. Install remaining piston and connecting rod assemblies as

described in steps 1. through 10.

Figure 2-160:   Piston and Rod Assembly

Figure 2-161:   Piston Installation

PISTON AND ROD 

ROD BOLT

BEARING SHELL

PROTECTIVE RUBBER HOSE

(ON ROD BOLTS)

BEARING SHELL

BEARING CAP

ROD NUT

ASSEMBLY

RING COMPRESSOR

TOOL 

HAMMER HANDLE

2-84

Engine

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Figure 2-162:   Measuring Connecting Rod Bearing 

Clearance with Plastic Gauging material

12. Check connecting rod side play with feeler gauge

(Figure 2-163). Insert gauge between connecting rods on
same journal. Clearance should be 0.007-0.025 in. (0.17-
0.63 mm).

NOTE: If side clearance is incorrect, rod caps or rod and pis-
ton may be installed in wrong position.

Figure 2-163:   Checking Connecting Rod Side 

Clearance

OIL PUMP, OIL PAN, FLYWHEEL INSTALLATION

1.

Pour 2-3 ounces engine oil into pump and rotate pump 
shaft to lubricate pump gears.

2.

Install retainer and pump shaft in oil pump. Apply high
temp bearing grease to upper end of shaft.

3.

Install oil pump. Be sure pump is seated on rear main cap.
Refer to Oil Pump Drive Removal in this section for more
information. 

4.

Install pump mounting stud. Tighten stud to 59-74 lb-ft
(80-100 N•m).

5.

Seat pump pickup tube bracket on mounting stud. Tighten
bracket nut to 35 lb-ft (47 N•m) torque. Tighten screw that
secures bracket to pump pickup tube to 12 lb-ft (16 N•m)
torque.

6.

Apply silicone sealer, such as Permatex High Temp, Ultra
Blue, or Ultra Black to surfaces of oil pan mounting flange
surfaces (Figure 2-164).

7.

Apply sealer to pan rear seal (Figure 2-164). Then press
seal into place on oil pan. Coat seal ends with sealer as
well.

8.

Apply silicone sealer around two holes in right side panel
rail on block (Figure 2-164).

9.

Align and position oil pan on engine block pan rails.
Tighten larger diameter bolts at rear of pan to 17 lb-ft (23
N•m) torque. Tighten remaining bolts/studs to 89 lb-in.
(10 N•m) torque.

Figure 2-164:   Oil Pan and Seal Installation

NOTE:  Be sure pan rear seal was not displaced during pan in-
stallation.

10. Clean crankshaft flange and flywheel mounting surfaces.

11. Install flywheel on flange (Figure 

2-165). Be sure

converter bolt pads are facing out and away from engine.

12. Apply 1-2 drops Loctite 242 to new flywheel bolts (but

only if new bolts do not have pre-applied thread locker).
Then install and tighten bolts 65 lb-ft (88 N•m) torque.

ROD CAP AND

BEARING INSERT

PLACE GAUGING STRIP

ON ROD JOURNAL

AS SHOWN

CONNECTING ROD

MEASURE WIDEST POINT

OF COMPRESSED

GAUGING STRIP WITH

SCALE ON ENVELOPE

FEELER GAUGE

OIL PAN

MOUNTING

FLANGE

DRAINPLUG

GASKET

PAN
RAIL

HOLES

PAN REAR SEAL