Hummer H1 (2002+). Manual - part 33

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 Engine  2-93

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05745159

TORSIONAL DAMPER AND CRANKSHAFT 
PULLEY INSTALLATION

1.

Install damper key in crankshaft (Figure 2-186).

2.

Lubricate crankshaft hub, damper seal contact surface, and
damper hub bore with engine oil or chassis grease.

3.

Align and install damper on crankshaft.

4.

Install washer and damper bolt. Tighten bolt 200 lb-ft (270
N•m) torque. Have helper prevent crankshaft from turning
with holding tool installed on flywheel.

Figure 2-186:   Torsional Damper Installation

Fan and Pulley Installation

1.

Install crankshaft pulley and bolts (Figure 2-187).

2.

Slide fan onto clutch and install bolts finger tight.

3.

Install fan and clutch assembly on water pump shaft.

4.

Hold water pump shaft with spanner J–41240-1 and
tighten clutch nut to 80-100 lb-ft (108-135 N•m) with
wrench J–41240-5A.

5.

Torque fan bolts to 15-20 lb-ft (20-27 N•m).

Figure 2-187:   Fan and Pulley Installation.

TURBOCHARGER AND INTAKE MANIFOLD 
INSTALLATION

1.

Apply Permatex High Tack to manifold gaskets and posi-
tion gaskets on cylinder heads.

2.

Install left/right side manifold halves. Tighten attaching
bolts/studs to 31 lb-ft (42 N•m) torque.

3.

Mount turbocharger or cylinder block, and install
attaching bolts, nuts, and brackets. Tighten attaching bolts/
nuts to 43 lb-ft (58 N•m) torque.

4.

Connect exhaust inlet tubes to exhaust manifolds and
turbocharger (Figures 2-8 and 2-9). Tighten exhaust tube
flange clamps to 7 lb-ft (10 N•m) torque.

NOTE: Do not install the intake manifold crossover housing at
this time. The housing will not be installed until after the en-
gine is installed in the vehicle.

5.

Install alternator mounting brackets, and idlers on right
side cylinder head.

6.

Install power steering pump and mounting brackets.

7.

Install A/C compressor and braces.

8.

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

9.

Install water pump pulley, if not installed before this.

10. Install fan and clutch assembly. Tighten attaching bolts/

nuts to 15-20 lb-ft (20-27 N•m) torque.

11. Install serpentine belt.

12. Install glow plugs, if not previously installed. Tighten

plugs to 13 lb-ft (18 N•m) torque.

13. Install wire harness and hose brackets.

TORSIONAL

DAMPER

DAMPER KEY

SEAL SURFACE

CRANKSHAFT

FAN

CLUTCH

SPANNER

WRENCH

PULLEY

2-94

Engine

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REPROGRAMMING TDC OFFSET

TDC offset must be reprogrammed whenever the PCM, front
cover, timing gears, timing chain, crankshaft position sensor,
or other components affecting timing are replaced. The proce-
dure for reprogramming TDC offset is as follows:

1.

Verify that vehicle batteries are fully charged.

2.

Start and run engine at curb idle speed.

3.

Continue running engine at curb idle speed until coolant
reaches normal operating temperature. 

4.

Connect Tech 1 scan tool to data link/diagnostic
connector. 

5.

Select FO: OUTPUT TESTS from Miscellaneous Test
menu. 

6.

Select FO: INJ PUMP. 

7.

Select TDC OFFSET LEARN.

8.

Press Up Arrow key and PCM will learn engine top dead
center offset value. This requires approximately 20
seconds.

9.

Correct learned TDC Offset value should be between
minus 0.25 and minus 0.75. If value is not within specified
range, loosen injection pump and rotate it to correct value
as follows:

• If value is between plus 1.0 and minus 0.25, rotate pump 

toward driver side to achieve specified value. 

• If value is between minus 0.75 and minus 2.0, rotate 

pump toward passenger to achieve specified value.

NOTE:  1 mm pump movement in either direction results in
approximately 2 degrees change. 

+1.0

+.5

0

-.75

-1.0

-1.5

-2.0

-.25

When the timing is in
this region, rotate pump
toward driver side to
achieve target zone. 

When the timing is in this
region, rotate pump toward
passenger side to achieve
target zone. 

Target

Zone

 

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 Engine  2-95

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05745159

TORQUE SPECIFICATIONS

Item

Lb-Ft.

Lb-In.

N•m

Block drainplugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Camshaft gear bolt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Camshaft thrust plate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Connecting rod nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Coolant crossover/thermostat housing bolts . . . . . . . . . . . . . . . . . . . 

Crankshaft pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Exhaust manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Flywheel bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Front cover bolts/studs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Glow plugs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Hydraulic lifter guide plate and clamp bolts. . . . . . . . . . . . . . . . . . . 

Intake manifold bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Injection line fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Injector nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Injection pump driven gear bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Injection pump mounting nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Oil filter adapter bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Main bearing cap bolts — Inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Outer 12 mm  . . . . . . . . . . . . . . . . . . . . . 

Outer 10 mm  . . . . . . . . . . . . . . . . . . . . . 

Oil pan bolts (all except rear two bolts) . . . . . . . . . . . . . . . . . . . . . . 

(rear two bolts)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Oil pump mounting stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Oil pan drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Oil pump drive, clamp bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Rocker cover bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Rocker shaft bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Torsional damper bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Air horn bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Oil filler neck nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Water pump-to-adapter bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Water pump-to-front cover bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Turbocharger mounting bolts/nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . 

Turbocharger inlet tube clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Starter bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Splash shield screws:

5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Hose/wire harness brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Engine mount-to-block bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Exhaust U-bolt clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Insulator  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

*Tighten bolts in sequence an additional 1/4 turn.

16

126

17

48

31

30

55*

25

66

33

13

19

31

19

59

17

31

47

55*

48*

30

—

17

66

20

31

16

41

200

—

17

20

20

43

—

35

—

—

12

30-40

5

90

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

89

—

—

—

—

—

—

—

45-65

—

—

—

—

90

—

90-130

45-65

—

—

—

—

22

171

23

65

42

41

75

34

89

45

18

26

42

26

80

23

42

64

75

65

40

10

23

89

27

42

22

56

270

5-7

23

28

28

58

10

47

10-15

5-7

16

41-54

7

122

2-96

Engine

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ENGINE SPECIFICATIONS

General Data: 

Displacement

6.5L/395 c.i.d.

Type

4 Cycle, Diesel, Liquid-Cooled

Bore

4.06 in. (103 mm)

Stroke

3.82 in. (97 mm)

Compression Ratio 

20.2:1

Firing Order

1-8-7-2-6-5-4-3

Oil Pressure

6 psi (69 kPa) at idle (hot); 

30 psi (552 kPa) at 2000 RPM

Cylinder Bore

Diameter (Refer to Service Piston and Bore Specifications)

Out-of-Round (Maximum) . . . . . . . .0.0008 in. (0.02 mm)
Taper (Thrust Side) (Maximum) . . . .0.0008 in. (0.02 mm)

Piston to Bore Clearance

1

:

Bores 1 through 6  . .  0.0037-0.0047 in. (0.094-0.120 mm)
Bores 7 and 8. . . . . . . .  0.004-0.005 in. (0.107-0.133 mm)

Piston Ring:

Groove Clearance:

Top  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Keystone Ring
Second . . . . . . . . . . . . 0.0015-0.0031 in. (0.039-0.079mm)
Oil . . . . . . . . . . . . . .  0.0016-0.0035 in. (0.040-0.090 mm)

End Gap

2

:

Top  . . . . . . . . . . . . . . . . .  0.010-0.020 in. (0.26-0.51 mm)
Second . . . . . . . . . . . . . . .  0.029-0.039 in. (0.75-1.00 mm)
Oil . . . . . . . . . . . . . . . . . .  0.010-0.020 in. (0.25-0.51 mm)

Piston Pin:

Diameter

1.220-1.221 in. (30.9961-31.0039 mm)

Fit in Piston

0.00039-0.0006 in. (0.010-0.0153 mm)

Fit in Rod

0.0003-0.001 in. (0.0081-0.0309 mm)

Crankshaft:

Journal Diameter 
(Refer to Main and Rod Journal Specification Charts)

Journal Taper (Maximum). . . . . . . .0.0002 in. (0.005 mm)
Journal Out-of-Round (Maximum) .0.0002 in. (0.005 mm)

Main Bearing Clearance

No. 1, 2, 3, 4  . . . . . . .  0.0018-0.003 in. (0.045-0.083 mm)
No. 5  . . . . . . . . . . . . .  0.002-0.0037 in. (0.055-0.093 mm)

Crankshaft End Play

0.0039-0.0098 in. (0.10-0.25 mm)

Rod Bearing Clearance (Select Fit)

0.0017-0.0039 in. 

(0.045-0.100 mm)

Rod Side Clearance

 0.007-0.025 in. (0.17-0.63 mm)

Camshaft:

Lobe Lift ± 0.05

Intake. . . . . . . . . . . . . . . . . . . . . . . . .0.281 in. (7.133 mm)
Exhaust  . . . . . . . . . . . . . . . . . . . . . . .0.281 in. (7.133 mm)
Camshaft End Play  . . .  0.002-0.012 in. (0.051-0.305 mm)

Journal Diameter (Refer to Camshaft Specifications Chart)

1

NOTE: Add 0.0005 in. (0.013 mm) to cylinder bore diameters

to determine proper bore size for cylinders no. 7 and no. 8.

2

NOTE: Ring end gap specifications are for new bores; worn

bores will generate larger ring end gaps.

Valve Train:

Lifter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Roller
Rocker Arm Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5:1
Valve Lash (Intake and Exhaust) . . . . . . . . . . .  Not Adjustable
Valve Recess Depth:

Intake. . . . . . . . . . . . . . . . . . . . . . . .0.0013 in. (0.034 mm)
Exhaust  . . . . . . . . . . . . . . . . . . . . . .0.0018 in. (0.048 mm)

Face Angle (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . 45°
Seat Angle (Intake and Exhaust)  . . . . . . . . . . . . . . . . . . . . . 46°
Seat Runout (Intake and Exhaust)  . . . . . .0.0019 in. (0.05 mm)
Seat Width

Intake. . . . . . . . . . . . . . . .  0.035-0.060 in. (0.89-1.53 mm)
Exhaust  . . . . . . . . . . . . . .  0.062-0.093 in. (1.57-2.36 mm)

Stem Clearance

Intake. . . . . . . . . . . . .  0.001-0.0027 in. (0.026-0.069 mm)
Exhaust  . . . . . . . . . . .  0.001-0.0027 in. (0.026-0.069 mm)

Valve Spring Pressure

Closed . . . . . . . . . . .  80 lb at 1.81 in. (356 N @ 46.0 mm)
Open  . . . . . . . . . .  230 lb at 1.39 in. (1025 N @ 35.3 mm)

Installed Height  . . . . . . . . . . . . . . . . . . . . . . . . 1.8 in. (46 mm)
Timing Chain Free Play

New Chain. . . . . . . . . . . . . . . . . . . . . .0.500 in. (12.7 mm)
Used Chain  . . . . . . . . . . . . . . . . . . . . .0.800 in. (20.3 mm)