Index Hummer Hummer H1 - service repair manual 2002 year

Content .. 262 263 264 265 ..

Hummer H1 (2002+). Manual - part 264

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Index 14-3

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05745159

Rear CTI Line Replacement   . . . . . . . . . . .  6-50
Rear Tube Connection Shield   . . . . . . . . . .  6-53
Spindle Extension and Seal  . . . . . . . . . . . .  6-54
Supply Line  . . . . . . . . . . . . . . . . . . . . . . . .  6-49
Troubleshooting  . . . . . . . . . . . . . . . . . . . . .  6-31
Tube Shield Replacement   . . . . . . . . . . . . .  6-51

Charging System

Alternator  . . . . . . . . . . . . . . . . . . . . . . . . .  12-22
Alternator Overhaul  . . . . . . . . . . . . . . . . .  12-23
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . .  12-28

Cigarette Lighter Replacement . . . . . .10-19, 12-68
Climate Control System

A/C Pressure Hose Replacement  . . . . . . .  11-18
Condenser Replacement . . . . . . . . . . . . . .  11-20
Control Head Replacement   . . . . . . . . . . .  11-16
Heater Hose Replacement  . . . . . . . . . . . .  11-22
Heater/A/C Diagnosis   . . . . . . . . . . . . . . . .  11-2
System Performance Checks . . . . . . . . . . .  11-2

Clutch Core Replacement   . . . . . . . . . . . .  11-32
Clutch Rotor and/or Bearing Replacement 11-30
Replacement . . . . . . . . . . . . . . . . . . . . . . .  11-28
Shaft Seal Replacement  . . . . . . . . . . . . . .  11-32

Converter Housing

Lower Cover Replacement . . . . . . . . . . . 5-135
Upper Cover Replacement . . . . . . . . . . . . 5-135

Bearing Replacement  . . . . . . . . . . . . . . . . .  2-42
Connecting Rod Journal Diameter . . . . . . .  2-97
Crankshaft and Main Bearings Removal  . .  2-60
End Play Check  . . . . . . . . . . . . . . . . . . . . .  2-81
Main Journal Diameter   . . . . . . . . . . . . . . .  2-97
Pulley Replacement  . . . . . . . . . . . . . . . . . .  2-20

Cruise Control Inoperative VIN Z . . . . . 12-135
Cruise Control Schematic . . . . . . . . . . . 12-137

Cruise Control Systems . . . . . . . . . . . . . . . . 12-134
CTIS

CTIS Compressor Inoperative  . . . . . . . . .  12-53
CTIS Exhaust Valve Inoperative  . . . . . . .  12-54
CTIS Front Inflate Valve Inoperative   . . .  12-55
CTIS Rear Inflate Valve Inoperative  . . . .  12-56
CTIS Schematic  . . . . . . . . . . . . . . . . . . . .  12-57

Customer Assistance

Hummer Service Hotline . . . . . . . . . . . . . . . 1-2
Service Manual Revisions . . . . . . . . . . . . . . 1-2

Cylinder Bore and Piston Measurement . . 2-62
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

Cylinder Head And Gasket Service  . . . . . .  2-37
Installation . . . . . . . . . . . . . . . . . . . . . . . . .  2-89
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-72
Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-55

D

Damper and Flywheel Service  . . . . . . . . . . . . .  2-76
Delco Compact Disc Changer Replacement  .  13-36
Diesel Fuel Injection System  . . . . . . . . . . . . . .  3-36
Digital Ratio Adapter . . . . . . . . . . . . . . . . . . 12-74.1
Dimmer Control Switch Replacement  . . . . . .  10-17
Door Glass

“Wind Noise” . . . . . . . . . . . . . . . . . . . . . . 10-43
Replacement . . . . . . . . . . . . . . . . . . . . . . . 10-41

Door Stop Strap Assembly Replacement . . . . 10-41
Doors

Disassembly, Replacement and Repair  . .  10-36
Door Glass  . . . . . . . . . . . . . . . . . . . . . . . .  10-41
Door Seals Replacement   . . . . . . . . . . . . .  10-41
Rear Vertical Door Replacement  . . . . . . .  10-74

Drainage Bracket Replacement . . . . . . . . . . . . 3-23
Dual Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . 13-35

E

Assembly and Adjustment  . . . . . . . . . . . . .  2-80
Block, Camshaft and Bearing Sizes . . . . . .  2-98
Cleaning Materials  . . . . . . . . . . . . . . . . . . . .  2-4
Compression Test . . . . . . . . . . . . . . . . . . . . .  2-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . .  2-2

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14-4

Index

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Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . 2-7
Engine Noise

Diagnosis Equipment . . . . . . . . . . . . . . . 2-6

Essential Tools  . . . . . . . . . . . . . . . . . . . . . .  2-99
Identification   . . . . . . . . . . . . . . . . . . . . . . . .  2-3
Identification Number  . . . . . . . . . . . . . . . . .  1-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . .  2-48
Lubricants/Sealants/Coolant

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . .  2-4
Engine Oil   . . . . . . . . . . . . . . . . . . . . . . .  2-3
Sealants   . . . . . . . . . . . . . . . . . . . . . . . . .  2-4

Mounting Bracket/Insulator  . . . . . . . . . . . .  2-19
Noise Diagnosis  . . . . . . . . . . . . . . . . . . . . . .  2-5
Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-45
Scan Tool Use   . . . . . . . . . . . . . . . . . . . . . . .  2-6
Service Piston and Cylinder Bore   . . . . . . .  2-97
Special Service Tools . . . . . . . . . . . . . . . . . .  2-3
Specifications . . . . . . . . . . . . . . . . . . . . . . .  2-96

Engine Access Cover . . . . . . . . . . . . . . . . . . . 10-20

Hold-Down Striker Replacement . . . . . . . 10-20
Inner Flexible Latch Replacement . . . . . . 10-20

Engine Access Cover Maintenance . . . . . . . . 10-20
Engine Assembly and Adjustment

Crankshaft and Main Bearing Installation . 2-80
Crankshaft Main Bearing Selection . . . . . . 2-80

Engine Cooling System

Description . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Diagnosis and Troubleshooting  . . . . . . . . . .  4-3
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-6

Engine Temperature Sender Replacement . . . . 3-40
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43

Air Intake Assembly Replacement . . . . . 11-45
Cycling Switch Replacement . . . . . . . . . . 11-45

Exhaust Manifold

Installation . . . . . . . . . . . . . . . . . . . . . . . . .  2-92
Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-51
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-35

Catalytic Converter Replacement   . . . . . . .  3-44
Crossover Pipe Replacement  . . . . . . . . . . .  3-44
Muffler Replacement  . . . . . . . . . . . . . . . . .  3-42

Extension Housing Bushing and Seal . . . . . . 5-169

F

Fan and Clutch Assembly Service  . . . . . . . . . .  4-16
Fan-Pulley-Damper Removal   . . . . . . . . . . . . .  2-50
Flexplate Replacement . . . . . . . . . . . . . . . . . .  5-139
Fluid Capacities  . . . . . . . . . . . . . . . . . . . . . . . .  1-10

Fuel/Fluids/Lubricants . . . . . . . . . . . . . . . . 1-24

Flushing Engine Cooler  . . . . . . . . . . . . . . . . . .  2-78
Flywheel Removal  . . . . . . . . . . . . . . . . . . . . . .  2-60
Former Assembly Replacement, “A” Pillar . .  10-60
Frame

Front Suspension Brace Replacement  . . . .  9-50
Front Suspension Front Crossmember . . . .  9-60
Front Suspension Rear Crossmember  . . . .  9-61
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .  9-64
Left Engine Mount Bracket  . . . . . . . . . . . .  9-54
Left Intermediate Body Mount Bracket . . .  9-57
Lifting Shackle Replacement . . . . . . . . . . .  9-47
Radiator Front Mount Bracket  . . . . . . . . . .  9-46
Rear Suspension Front Crossmember  . . . .  9-62
Rear Suspension Rear Crossmember  . . . . .  9-63
Rear-Front Tiedown Bracket  . . . . . . . . . . .  9-59
Rear-Rear Tiedown Bracket   . . . . . . . . . . .  9-58
Repairs  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-67
Right Engine Mount Bracket  . . . . . . . . . . .  9-55
Right Front Body Mount Bracket   . . . . . . .  9-55
Right Intermediate Body Mount Bracket . .  9-57
Transmission Crossmember Support  . . . . .  9-56
Transmission Mount Crossmember  . . . . . .  9-56
Transmission Mount Replacement   . . . . . .  9-56

Front Console Replacement . . . . . . . . . . . . . .  10-13
Front Cover and Baffle Installation  . . . . . . . . .  2-86
Front Cover and Oil Filler Tube   . . . . . . . . . . .  2-71
Front Cover And Timing Chain . . . . . . . . . . . .  2-23
Front Cover Oil Seal Replacement   . . . . . . . . .  2-22
Front Cover Removal . . . . . . . . . . . . . . . . . . . .  2-57
Front License Plate Bracket Replacement  . . .  10-62
Front Output Shaft

Bearing and Seal Replacement . . . . . . . . 5-166
Seal Replacement . . . . . . . . . . . . . . . . . . . 5-155

Front Striker Replacement . . . . . . . . . . . . . . . 10-61

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Index 14-5

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05745159

Fuel Filler Housing Replacement . . . . . . . . . 10-63
Fuel Filter

Drain Hose and Valve Replacement . . . . . 3-32
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Fuel Filter Warning Lamp . . . . . . . . . . . . . . . . . 2-4
Fuel Injection Line

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

Fuel Injection Pump

Fuel Supply and Return Line Removal  . . .  2-53
Installation . . . . . . . . . . . . . . . . . . . . . . . . .  2-87
Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-56

Fuel Injection Pump Boot Replacement . . . . . 3-33
Fuel Injection System

Injection Line Bracket and Clamp . . . . . . . 3-36

Fuel Lift Pump Service . . . . . . . . . . . . . . . . . . 3-33
Fuel System

Contamination  . . . . . . . . . . . . . . . . . . . . . .  3-41
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-6
Electronic Accelerator Pedal  . . . . . . . . . . . .  3-4
Electronic Injection Pump . . . . . . . . . . . . . .  3-3
Essential Tools  . . . . . . . . . . . . . . . . . . . . . .  3-45
Fuel Filter-Water Separator  . . . . . . . . . . . . .  3-3
Fuel Injectors  . . . . . . . . . . . . . . . . . . . . . . . .  3-4
Fuel Lift Pump  . . . . . . . . . . . . . . . . . . . . . . .  3-2
Fuel Lift Pump Inoperative  . . . . . . . . . . .  12-44
Fuel Lift Pump Schematic  . . . . . . . . . . . .  12-46
Fuel Manager Schematic . . . . . . . . . . . . .  12-50
Fuel Selector Valve  . . . . . . . . . . . . . . . . . .  3-30
Fuel Selector Valve Schematic   . . . . . . . .  12-49
Fuel Tank Selector System Inoperative  . .  12-47
Fuel Tanks, Lines, and Valves . . . . . . . . . . .  3-4
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . .  3-4

Auxiliary Fuel Tank . . . . . . . . . . . . . . . . . . 3-26
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Fuel Level Transmitter and Tank

Access Plate Service . . . . . . . . . . . . . . . . . 3-28

Fuel Tank Vent Line Service  . . . . . . . . . . .  3-29
Main Fuel Tank  . . . . . . . . . . . . . . . . . . . . .  3-24
Main/Auxiliary Tank Fuel Line  . . . . . . . . .  3-29
Vent Filter Replacement   . . . . . . . . . . . . . .  3-29

G

Input Seal Replacement  . . . . . . . . . . . . . . .  9-11
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-12
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .  9-8
Side Cover Replacement  . . . . . . . . . . . . . .  9-11
Spindle Bearing Adjustment   . . . . . . . . . . .  9-19
Spindle Seal Replacement . . . . . . . . . . . . .  9-17
Vent Line Replacement . . . . . . . . . . . . . . .  9-24

General Body Information . . . . . . . . . . . . . . . . 10-2
General Information

Auxiliary Power Point, Interior Fuse Box 12-10
Auxiliary Power Studs, Exterior

Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

Circuit Faults  . . . . . . . . . . . . . . . . . . . . . . .  12-4
Diagnostic Tests . . . . . . . . . . . . . . . . . . . . .  12-5
Fuse/Relay Location and Identification  . .  12-10
Ground Points   . . . . . . . . . . . . . . . . . . . . .  12-13
Preliminary Checks  . . . . . . . . . . . . . . . . . .  12-3

Glovebox Replacement . . . . . . . . . . . . . . . . . 10-19
Glow Plug

Glow Plug and Injection Nozzle   . . . . . . . .  2-90
Glow Plug Removal . . . . . . . . . . . . . . . . . .  2-54
Glow Plug Test   . . . . . . . . . . . . . . . . . . . . . .  2-6
Operation and Testing  . . . . . . . . . . . . . . . . .  2-6
Relay/Controller Replacement . . . . . . . . . .  3-40
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-35

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 12-40
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 12-43

H

Halfshaft Boot Replacement . . . . . . . . . . . . . . 9-21
Heated Glass

Both Heated Windshields Inoperative  . . .  12-92
Heated Windshield Schematic  . . . . . . . . .  12-93
Left Heated Windshield Inoperative  . . . .  12-90
Rear Window Defroster Inoperative  . . . .  12-94

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14-6

Index

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Rear Window Defroster Schematic . . . . . 12-95
Right Heated Windshield Inoperative . . . 12-91

Center Hood Stop Replacement . . . . . . . .  10-49
Front Hood Screen Replacement  . . . . . . .  10-50
Grille and Screen Replacement  . . . . . . . .  10-49
Guide Bracket Assembly Replacement  . .  10-50
Hood and Hinge Replacement  . . . . . . . . .  10-47
Hood Latch And Prop Rod   . . . . . . . . . . .  10-43
Hood Prop Rod and Bracket Replacement  10-45
Hood Release Cable Replacement  . . . . . .  10-44
Hood Retainer Bracket, L   . . . . . . . . . . . .  10-50
Hood Retainer Bracket, R   . . . . . . . . . . . .  10-50
Latch and Bracket Replacement   . . . . . . .  10-43
Outer Hood Seal Replacement . . . . . . . . .  10-48
Right Close-Out Seal and Retainer   . . . . .  10-51
Side Hood Stop Replacement   . . . . . . . . .  10-49

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-61

Horn Assembly Replacement   . . . . . . . . .  10-53
Horn Replacement  . . . . . . . . . . . . . . . . . .  12-61
Horn Schematic  . . . . . . . . . . . . . . . . . . . .  12-63
Horns Inoperative . . . . . . . . . . . . . . . . . . .  12-62
Mounting Bracket Replacement   . . . . . . .  10-53

Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30
Hummer Service Hotline . . . . . . . . . . . . . . . . . . 1-2
HVAC

Ambient Temperature Switch . . . . . . . . . 11-34
Auxiliary HVAC Unit

A/C Drain Tube(s) Replacement  . . . .  11-48
Blower Motor Replacement . . . . . . . .  11-49
Blower Switch Replacement  . . . . . . .  11-47
Evaporator/Heater Core Replacement  11-49
Expansion Valve Replacement   . . . . .  11-50
Heater Hose Replacement  . . . . . . . . .  11-47
High-Pressure Hose Replacement . . .  11-48
Low-Pressure Hose Replacement   . . .  11-49
Replacement . . . . . . . . . . . . . . . . . . . .  11-46

Blend Door Motor . . . . . . . . . . . . . . . . . . 11-42
Compressor

Description . . . . . . . . . . . . . . . . . . . . . . 11-1

Condenser . . . . . . . . . . . . . . . . . . . . . . . . 11-34
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36
Defrost Duct and Windshield

Nozzles Replacement . . . . . . . . . . . . . . . 11-26

Drain Tube Replacement  . . . . . . . . . . . . .  11-24
Essential Tools  . . . . . . . . . . . . . . . . . . . . .  11-51
Heater Hose Replacement  . . . . . . . . . . . .  11-22
High Pressure Cutoff Switch  . . . . . . . . . .  11-35
Low Pressure Cutoff Switch   . . . . . . . . . .  11-34
Main HVAC Unit . . . . . . . . . . . . . . . . . . .  11-37

Blower Motor . . . . . . . . . . . . . . . . . . .  11-38
Diverter Doors  . . . . . . . . . . . . . . . . . .  11-37
Evaporator  . . . . . . . . . . . . . . . . . . . . .  11-38
Expansion Valve   . . . . . . . . . . . . . . . .  11-38
Heat Unit Cowl Insulation

Replacement . . . . . . . . . . . . . . . . . . . 11-24

Heater Core   . . . . . . . . . . . . . . . . . . . .  11-38
High Pressure Cutoff Switch  . . . . . . .  11-38
Replacement . . . . . . . . . . . . . . . . . . . .  11-39
Thermostatic Cycling Switch . . . . . . .  11-38

Rear Console Replacement   . . . . . . . . . . .  11-46
Receiver Dryer Replacement  . . . . . . . . . .  11-21
Receiver/Dryer . . . . . . . . . . . . . . . . . . . . .  11-34
Receiver/Dryer Pressure Switch

Replacement . . . . . . . . . . . . . . . . . . . . . . 11-21

Special Tools  . . . . . . . . . . . . . . . . . . . . . .  11-52
Specifications . . . . . . . . . . . . . . . . . . . . . .  11-13
System Description   . . . . . . . . . . . . . . . . . .  11-1
System Diagnosis . . . . . . . . . . . . . . . . . . . .  11-8
System Performance Checks . . . . . . . . . . .  11-2
Unit Service  . . . . . . . . . . . . . . . . . . . . . . .  11-37
Vacuum Door Motor  . . . . . . . . . . . . . . . .  11-41
Water Control Valve   . . . . . . . . . . . . . . . .  11-22
Water Control Valve Replacement   . . . . .  11-23

HVAC Blower Schematic  . . . . . . . . . . . .  12-80
HVAC Compressor Inoperative . . . . . . . .  12-75
HVAC Compressor Schematic   . . . . . . . .  12-82
HVAC Main Blower Inoperative

ALL BUT High . . . . . . . . . . . . . . . . . . . 12-75

HVAC Temp Blend Door/Rear Blower . . 12-81
HVAC Temperature Door Inoperative . . 12-77

Bleeding the Hydro-boost System . . . . . . . 7-13
Hydro-Boost Replacement . . . . . . . . . . . . . 7-13

3-1-01

Content .. 262 263 264 265 ..