Hummer H1 (2002+). Manual - part 43

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 Fuel, Emissions, and Exhaust  3-33

®

5745159

FUEL LIFT PUMP SERVICE

Fuel Lift Pump Replacement

Removal

1.

Disconnect fuel pump wiring harness (Figure 3-43).

2.

Disconnect fuel pump hoses.

3.

Loosen clamp and remove pump.

4.

Remove adapters and O-rings from fuel pump. Discard O-
rings.

Figure 3-43:   Fuel Pump Attachment 

Installation

1.

Install O-rings and adapters on fuel pump (Figure 3-43). 
Use new O-rings.

2.

Install fuel pump in clamp and tighten clamp securely.

3.

Connect hoses to fuel pump.

4.

Connect wiring harness to pump.

5.

Start engine and check fuel pump and hoses for leaks.

Fuel Tank-To-Filler Neck Hose Replacement

Removal

1.

Drain fuel tank.

2.

Remove filler tube housing bolts.

3.

Disconnect filler tube vent hose.

4.

Loosen clamps and remove hose from tank and filler
(Figure 3-44).

Figure 3-44:   Filler Tube-To-Tank Attachment

Installation

1.

Install hose on tank and filler tube and tighten hose 
clamps.

2.

Install filler tube and housing.

3.

Fill fuel tank and check for leaks.

00-S13-003

WIRING

HARNESS

BRACKET

HOSE

FUEL

PUMP

O-RING

HOSE

CONNECTOR

ADAPTER

ADAPTER

FILLER TUBE

TANK

FILLER TUBE

-TO-

TANK HOSE

 INLET 

TUBE

3-34

Fuel, Emissions, and Exhaust

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®

Diesel Injection Pump Fuel Hose or Tube Replacement

Removal

1.

Remove supply hose.

2.

Remove return hose from injection pump and tube
(Figure 3-45).

3.

Remove tube-to-injector hose.

4.

Remove injector connecting hoses (Figure 3-46).

5.

Remove nozzle cap from rear nozzle nipple.

Installation

1.

Install cap on rear injector nipple (Figure 3-46).

2.

Install injector connecting hose.

3.

Install tube-to-injector hose (Figure 3-45).

4.

Install fuel return hoses on tube and injection pump.

5.

Install supply hose.

6.

Start engine and check for fuel leaks.

Figure 3-45:   Diesel Fuel Injection Return Hose and Tube Routing

Figure 3-46:   Injector-To- Injector Return Hose Connection

DRAIN RETURN

HOSE

INJECTION PUMP

INJECTOR

RETURN HOSES

RETURN TUBE

RETURN HOSE

SUPPLY HOSE

CONNECTING

HOSE (TYPICAL)

INJECTORS

CAP

NIPPLE

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 Fuel, Emissions, and Exhaust  3-35

®

5745159

GLOW PLUG SERVICE

Glow Plug Tip Removal
(Damaged or Broken)

1.

Remove fuel injector from necessary cylinder.

2.

Using torsional damper bolt (Figure 3-47),rotate crankshaft
to bring affected piston to TDC position.

3.

Using pliers, reach through injector nozzle port
(Figure 3-48), break off expanded tip, and remove from
prechamber.

4.

Remove glow plug.

Figure 3-47:   Torsional Damper Bolt Location

5.

Direct stream of low-pressure compressed air into glow
plug port. This will expel any remaining pieces of broken
tip through injector port.

NOTE: If the preceding methods fail to remove glow plug tip
remains from the prechamber, the cylinder head must be re-
moved to clear the broken pieces. 

6.

Install new glow plug.

7.

Install fuel injector.

Figure 3-48:   Glow Plug and Injector  Port Locations

Glow Plug Replacement

Removal

1.

Disconnect wire from glow plug with tool J–39083.

2.

Remove glow plug from cylinder head (Figure 3-49).

Figure 3-49:    Glow Plug Removal/Installation

Installation

1.

Install glow plug in cylinder head. Tighten plug to 8-12 lb-
ft (11-16 N•m) torque.

2.

Connect wire to glow plug.

TORSIONAL DAMPER BOLT

GLOW PLUG PORT

INJECTOR PORT

GLOW PLUG

WIRE

3-36

Fuel, Emissions, and Exhaust

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®

DIESEL FUEL INJECTION SYSTEM

Diesel Injection Line Bracket And Clamp 

Removal

1.

Remove console and engine covers.

2.

Remove air horn.

3.

Remove bracket (Figure 3-50).

4.

Remove bracket from valve cover studs.

5.

Remove line clamps if necessary.

Figure 3-50:   Injection Line Bracket Removal/

Installation 

Installation 

1.

Install clamps on lines if removed.

2.

Install bracket on valve cover studs (Figure 3-51). Tighten
bracket nuts to 13-20 lb-ft (18-27 N•m).

3.

Install air horn.

4.

Install console and engine cover.

Figure 3-51:   Injection Line Bracket Removal/

Installation (Driver-Side)

VALVE COVER

STUDS

INJECTOR

LINE

BRACKET

LINE CLAMP

LINE

CLAMP

VALVE COVER

STUDS

INJECTOR

LINE

BRACKET

OIL

DIPSTICK

TUBE