Engine Installation - Hummer H1 Service Manual

_____________________________________________________________________
2-48 Engine
LIFTING SLING
AND BRACKET
J–33139
LEFT
CYLINDER HEAD
Figure 2-60: Engine Mounted on Repair Stand

ENGINE INSTALLATION

1. If new engine is being installed, transfer mounting brack-
PIN ets and insulators, generator, power steering pump, A/C
compressor, drive plate (flywheel), turbocharger, and nec-
essary mounting brackets, shields, damper pulleys, sensors
and fittings, from old to new engine.
2. Attach lifting bracket to engine.
3. Attach hoist to lifting bracket. Raise engine and guide it
into engine bay with aid of helper.
4. Align and seat engine on transmission. Be sure converter
pilot hub is seated in crankshaft and that transmission is
seated on engine block dowels. Install 2-3 transmission
attaching bolts (finger tight) to hold engine and
transmission in place.
5. Align and seat engine mounting bracket insulators on
frame brackets. Be sure insulator studs are fully seated in
frame brackets before proceeding.
6. Apply Loctite 242 to transmission, converter, and engine
mount nuts/bolts. Then install and tighten nuts and bolts to
7-S02-015
following torque:
• Converter bolts to 32 lb-ft (43 N•m)
• Transmission bolts to 35 lb-ft (47 N•m)
• Insulator stud nuts to 90 lb-ft (122 N•m)
7. Install converter housing access cover. Tighten cover
attaching screws to 60 lb-in. (7 N•m) torque.
8. Connect engine oil cooler lines to fittings at rear of engine
block.
9. Install turbocharger.
10. Install starter motor and shield with aid of helper. Tighten
starter mounting bolts to 30-40 lb-ft (41-54 N•m) torque. Do
not connect cable and solenoid wire to starter at this time.
11. Install exhaust pipe and heat shield, if removed and
connect exhaust pipe to turbocharger. Tighten attaching
nuts to 37 lb-ft (50 N•m) torque.
12. Install new oil filter.
13. Install intake manifolds and crossover.
14. Install/connect following:
• Wire harness brackets and clamps
• Injection pump, engine harness, sensor wires
• Turbocharger actuator vacuum hose
• Torbocharger heat shield
• Transmission and engine dipstick tubes
• AMG engine harness
15. Install fuel pump in clamp at driver side of engine bay.
16. Connect fuel lines to injection pump.
17. Install CDR valve and hose if removed.
18. Route hydraulic lines from power steering pump to hydro-
boost unit and connect lines. Be sure lines are clear of hot
or rotating components and are not kinked at any spot.
®