Hummer H1 Service Manual page 68

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Right Side Cover Installation
1. Clean cover mounting surface of cylinder head with brake
or contact cleaner and shop towels. This product will
remove residue from the surface and ensure proper adhe-
sion of new sealer.
2. If new rocker arm cover is being installed, clean seal
surface with brake or contact cleaner.
3. Apply sealer to rocker arm cover sealing surface. Make
sealer bead 3/16 in. wide by 1/16 in. thick. Use Loctite
599, Permatex Ultra Copper, or similar quality silicone
sealer. Allow sealer to cure slightly (skin over) before
installation.
4. Align and install rocker arm cover on cylinder head.
5. Install rocker arm cover attaching studs and bolts
(Figure 2-34). Tighten cover fasteners evenly to 13-25 lb-
ft (18-34 N¥m) torque. Start at center and work toward
ends when tightening.
6. Remove protective covering from injectors and lines.
Then connect lines to injectors and to pump, if removed.
Tighten line fittings to 20-22 lb-ft (27-30 N¥m) torque.
7. Install intake manifold and new gaskets. A gasket dressing
such as, perfect seal, or Permatex High Tack, can be used
to hold gaskets in place. Tighten manifold bolts and studs
to 31 lb-ft (42 N¥m) torque in sequence (Figure 2-35).
8. Install fuel injector line clamps and wire harness brackets
on manifold studs. Tighten retaining nuts to 26 lb-ft (35
N¥m) torque.
9. Install CDR valve and hose.
10. Install bolt that secures transmission fill tube to cylinder
head.
11. Install water control valve and hoses.
12. Install surge tank.
13. Refill cooling system
14. Start engine and check cover for leaks. Then bleed each
injector by loosening fuel line fitting (at injector), just
enough to purge any trapped air. Stop engine when
complete.
15. Install air cleaner, inlet hose, and air horn.
16. Install engine cover and front console.
17. Top off engine coolant and oil levels if required.
05745159
Left Side Cover Removal
1. Remove front console and engine cover.
2. Drain engine coolant.
3. Remove driver side splash shield.
4. Remove air inlet hose and air horn.
5. Disconnect radiator upper hoses at thermostat housing and
radiator. Then remove hoses and inlet tube as assembly.
6. Disconnect fuel pump, remove it from clamp and move
pump aside for working clearance.
7. Remove nuts attaching harness and sensor brackets to
intake manifold studs.
8. Remove nuts attaching water valve and bracket. Then
move valve and bracket aside for working clearance.
9. Remove nuts and washers attaching fuel injection line
clamps to manifold studs. Remove and retain clamps and
fasteners.
10. Remove studs and bolts attaching intake manifold to
cylinder heads. Remove manifold and gaskets. Cover
cylinder head intake ports with shop towels to prevent dirt
entry (Figure 2-35).
11. Remove screws attaching oil dipstick and tube to cover.
Then rotate tube away from engine for working clearance.
12. Disconnect fuel lines at driver side injectors. Then loosen
(or remove) lines at pump. Rotate lines aside for working
clearance. Cover lines and injectors to prevent dirt entry.
CAUTION: Do not bend the fuel injector lines. The internal
coating could fracture, peel off, and clog the injectors.
13. Remove rocker arm cover attaching bolts and studs. Then
tap cover with rubber mallet to break sealer bead. Do not
pry cover loose.
14. Remove rocker arm cover.
15. Clean cover in parts cleaning solvent and scrape all traces
of old silicone sealer off cover seal surfaces. Final clean
cover seal surfaces with brake or contact cleaner. This is
necessary to remove residue from cleaning solvent, and
ensure proper adhesion of new sealer.
16. Clean gasket surfaces of intake manifold and cylinder
heads. Be sure surfaces are clean and smooth. Remove
minor nicks or scratches with 220 grit emery cloth.
Engine 2-31