Hummer H1 Service Manual

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H1 HUMMER

SERVICE

MANUAL

COMMERCIAL

HUMMER

AM GENERAL CORPORATION

408 South Byrkit Avenue

P.O. Box 728

Mishawaka, Indiana 46546-0728

AM General Number 05745159

2002

TABLE OF CONTENTS

General Information

Engine

Fuel, Emissions and Exhaust

Cooling System

Transmission/Transfer Case

Wheels and Tires/

Central Tire Inﬂation System

Brake System

Steering System

Axles/Suspension and Frame

Body

Heating/Ventilation/

Air Conditioning (HVAC)

Electrical

Accessories

Index

Table of Contents

Chapters

Table of Contents

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Questions and answers

Tom Sturtevant

April 19, 2025

Is there a fuse block for the generator 1992 24v

Summary of Contents for Hummer H1

Page 1 TABLE OF CONTENTS H1 HUMMER SERVICE General Information Engine MANUAL Fuel, Emissions and Exhaust Cooling System Transmission/Transfer Case COMMERCIAL HUMMER ® Wheels and Tires/ Central Tire Inﬂation System Brake System Steering System Axles/Suspension and Frame Body Heating/Ventilation/ Air Conditioning (HVAC)
Page 2: Table Of Contents
Transmission Identification ......1-4 Hummer Service Hotline ....... .1-2 U.S./Metric Conversions and Equivalents .
Page 3: P.o. Box
ABOUT THIS MANUAL 1-315-432-4110 . This service manual contains instructions for maintaining the commercial HUMMER. Spend some time looking through this manual. Features to improve the usefulness of this manual and increase your efficiency are: Accessing Information - These include: tabulated sections for quick reference, extensive troubleshooting guides for specific systems, and step-by-step directions for service repairs.
Page 4: Emission Control Information Label
________________ General Information, Lubrication and Maintenance ¨ EMISSION CONTROL INFORMATION LABEL The vehicle emission control label contains engine information such as curb idle rpm, engine displacement, catalytic converter type, fuel rate, and vacuum hose routing. This label is affixed to the air cleaner housing (Figure 1-1). Figure 1-1: Emission Control Information Label Information 05745159...
Page 5: Safety Certification Label
(GVWR), Gross Axle Weight Ratings (GAWR), and wheel and tire information. For more information on the GVWR and GAWR, refer to ÒVEHICLE LOADING INFORMATIONÓ in the Hummer OwnerÕs Manual. Figure 1-3: Safety Certification Label for 10,300 lb GVWR Vehicles Figure 1-4: Safety Certification Label for...
Page 6: Engine Identification
________________ General Information, Lubrication and Maintenance ¨ EPA NOISE EMISSION CONTROL INFORMA- TRANSFER CASE SERIAL NUMBER TION LABEL (ON ID PLATE) The EPA noise emission control information label is located on the passenger side B-pillar (door latch post). The label is re- quired by the EPA and includes a tamper-proof feature.
Page 7 _________________ 1-6 General Information, Lubrication and Maintenance ® 000001 Digit 12 Digit 1 through 17 Manufacturing Sequential, Country Assigned Serial Number Digit 2 Company/Make Digit 11 Plant Code Digit 3 Vehicle Type Digit 10 Model Year Digit 4 Engine Type Digit 9 Check Digit Digit 5...
Page 8: Component Data
________________ General Information, Lubrication and Maintenance ¨ COMPONENT DATA Engine: Manufacturer ................................. GM Powertrain Model ................................... 6.5 L (395 in. Type.........................Four Cycle, Turbocharged Diesel, Liquid-Cooled Power Output: ..................... 195 HP @ 3400 rpm/430 ft lb. Torque @ 1800 rpm Engine Dimensions: Length....................................
Page 9: Transfer Case
_________________ 1-8 General Information, Lubrication and Maintenance ¨ Thermostat: Starts to Open ................................190¡ F (88¡ C) Fully Open................................212¡ F (100¡ C) Generator: Manufacturer ....................................Delco Output ..............................124 AMP @ 1842 Engine RPM Rated Voltage .................................. 13.35 -15.9 V Batteries: Manufacturer ................................Johnson Controls Type..................................
Page 10 Refrigerant....................................R-134a Capacity (system + 2 oz. of oil) ..........................3.2 lb. (1.45 kg) Winch: Manufacturer ....................................Warn Model ..............................12,000 lb., 12VDC HUMMER Type............................Electric Drive, Thermal Cutoff Switch Capacity................................. 12,000 lb (5,448 kg) Wheels and Tires: Manufacturer ..........................Goodyear Tire Size 37 in. X 12.5R-16.5 Wheel Type: Standard ..................................
Page 11: Fluid Capacities
________________ 1-10 General Information, Lubrication and Maintenance ¨ FLUID CAPACITIES Cooling System .................................. 26 qt (25 L) Engine: Crankcase (oil pan) only .............................. 7 qt (6.6 L) Crankcase and Filter..............................8 qt (7.6 L) Fuel Tank...................................25 gal. (95 L) Auxiliary Fuel Tank ...............................17 gal. (64.3 L) Axle (front/rear) ................................
Page 12: Vehicle Dimensions
_______________ General Information, Lubrication and Maintenance 1-11 ¨ Turbo Diesel Engine -- (12,100 lb. (5,489 kg) GVWR Vehicles -- Fleet Vehicles Only Curb Weight (12,100 GVWR): Two-Door Enlarged Cab (Hard Top) (XLC2) ....................6,720 lb (3,048 kg) Four Door Hard Top (HMC4).......................... 7,120 lb (3,230 kg) Four-Door Station Wagon (HMCS).........................
Page 13: Abbreviations
________________ 1-12 General Information, Lubrication and Maintenance ¨ ABBREVIATIONS ABS ......Antilock Brake System lhÊ...
Page 14: Bolt Identification And Torque Limits (Dry*)
_______________ General Information, Lubrication and Maintenance 1-13 ¨ BOLT IDENTIFICATION AND TORQUE LIMITS (DRY*) Bolt Head ID Marks and SAE GRADE * A phosphate and oil bolt is considered dry BOLT SAE GRADE SAE GRADE SAE GRADE SAE GRADE SIZE NO.
Page 15: Bolt Identification And Torque Limits (Wet*)
________________ 1-14 General Information, Lubrication and Maintenance ¨ BOLT IDENTIFICATION AND TORQUE LIMITS (WET*) Bolt Head ID Marks and SAE Grade *A cadmium plated bolt is considered wet. BOLT SAE GRADE SAE GRADE SAE GRADE SAE GRADE SIZE NO. 1 OR 2 NO.
Page 16: U.s./Metric Conversions And Equivalents
_______________ General Information, Lubrication and Maintenance 1-15 ¨ U.S./METRIC CONVERSIONS AND EQUIVALENTS Metric Conversions MULTIPLY TO GET INCHES 2.54 CENTIMETERS FEET 0.305 METERS MILES 1.609 KILOMETERS SQUARE INCHES 6.451 SQUARE CENTIMETERS CUBIC INCHES 16.39 CUBIC CENTIMETERS FLUID OUNCES 29.573 MILLILITERS PINTS 0.473 LITERS...
Page 17: Paint And Trim Colors
________________ 1-16 General Information, Lubrication and Maintenance ¨ PAINT AND TRIM COLORS Interior trim colors are tan and gray. Seating materials are available in cloth and vinyl. Soft top colors and codes are: Tan (T) and Black (B). Exterior paint colors and codes are outlined in the following chart.
Page 18: Towing, Lifting, Jump Starting
Vehicle Hoisting Vehicle jacking points are shown in Figure 1-11. The vehicle Hummer vehicles can be raised on a hoist for service access. can be raised with a floor jack at any of the indicated positions. Drive-on and swivel arm hoists are both acceptable. Hoist ca- Jacking can be performed at the front, rear, or at any one pacity and width are important.
Page 19 ¨ Towing Recommendations Flat Bed/Wheel Lift Towing Procedures Hummer vehicles can be towed with wheel lift, sling-type, or Flat bed/wheel lift tow vehicles are highly recommended. They flat bed tow equipment. keep all of the towed vehicle wheels off the pavement. This is important with full time four wheel drive vehicles.
Page 20: Conventional Towing Procedures
Recreational Towing Loop sling chain around frame rails adjacent to rear cross- Hummer vehicles can be towed behind an RV if desired. A member and secure to tow sling (Figure 1-15). low-boy style vehicle trailer is best for this purpose. Flat tow- Insert 4Ó...
Page 21: Jump Starting
________________ 1-20 General Information, Lubrication and Maintenance ¨ Jump Starting Hummer vehicles can be jump started when necessary. Starting BATTERY can be performed with a portable starting unit, separate booster POSITIVE TERMINAL batteries, or the battery in another vehicle. Certain Cautions and Warnings must be observed when jump starting a vehicle.
Page 22: Maintenance Schedule
¥ Check CDR valve for oil saturation. page 1Ð22 . To keep track of the hours of severe operation, an optional hourmeter can be installed at your Hummer dealer. ¥ Inspect condition of control arms, springs, and shock absorb- ers.
Page 23: Scheduled Maintenance Chart
________________ 1-22 General Information, Lubrication and Maintenance ® Maintenance Inspection Group B: SCHEDULED MAINTENANCE CHART • Inspect fuel injection pump, lines, and ﬁttings for leaks or 3,000 Miles (4,800 km) 100 hrs normal use or 50 hrs severe operation damage. •...
Page 24 Drain & replace brake ﬂuid. NOTE: Some maintenance requires specialized know- ledge or equipment and may be best handled by qualiﬁed service technicians at your nearest HUMMER dealer. NOTE: After your vehicle has been driven for 63,000 miles (101,400 km) repeat the schedule indicated in this section, starting at 3,000 miles (4,800 km).
Page 25: Recommended Fuel/Fluids/Lubricants/Capacities
¥ 7.7 qts (7.3L) for the transmission (during fluid drain/re- WEATHER fill) °F °C Brake Fluid Recommended brake fluid for all Hummer vehicles is DOT 3 +100 brake fluid. Master cylinder approximate capacity is 1.64 pints (0.78L). Brake system approximate capacity is 3.1 pints (1.5L). SAE 30W...
Page 26: Lubrication And Maintenance Items
_______________ General Information, Lubrication and Maintenance 1-25 ¨ A/C Refrigerant and Compressor Oil Engine Oil and Filter Change The only refrigerant that can be used is R-134a. No other re- The oil filter is located on the driver side of the engine frigerant is recommended.
Page 27: Transfer Case Fluid
________________ 1-26 General Information, Lubrication and Maintenance ¨ Fuel Filter Service Check transmission fluid level at least once each month. Proce- dure is as follows: Replace the filter element every 6,000 mi (9,600 km), or annu- Drive vehicle until transmission ßuid is at normal operating ally, whichever occurs first (Figure 1-21).
Page 28: Axle And Geared Hub
_______________ General Information, Lubrication and Maintenance 1-27 ¨ Axle and Geared Hub Universal and Slip Joint Lubrication Check axle and hub lubricant condition and level every 3,000 Lubricate U-joints with a multipurpose, NLGI-LB grade chas- mi (4,800 km) or semiannually, whichever occurs first. sis grease.
Page 29 ________________ 1-28 General Information, Lubrication and Maintenance ¨ Steering and Suspension Lubrication Points Lubricate steering and suspension components every 3,000 mi. IDLER ARM (4 800 km), or semiannually, whichever occurs first. If operat- FITTINGS ing conditions are severe, service at 1,000 mi. (1 600 km) inter- vals.
Page 30: Master Cylinder Fluid Level Check
_______________ General Information, Lubrication and Maintenance 1-29 ¨ Power Steering Fluid Master Cylinder Fluid Level Check Check the fluid level in the power steering reservoir monthly CAUTION: Use DOT 3 brake fluid only. Failure to use the and adjust level as necessary. If fluid is hot, level should be be- proper fluid may affect brake performance or damage brake tween ÒHOTÓ...
Page 31: Body Lubrication Points
________________ 1-30 General Information, Lubrication and Maintenance ¨ CDR Valve Clean the CDR valve with parts solvent and allow to dry. Re- place the valve if oil soaked, or if it wonÕt sustain vacuum/at- mospheric pressure testing, see ÒCDR ValveÓ in Section 3 for pressure testing instructions.
Page 32: Fuel, Emissions And Exhaust
_______________ General Information, Lubrication and Maintenance 1-31 ¨ ESSENTIAL TOOLS NOTE: See page 1-1 of the Service Parts Catalog for information on ordering Kent-Moore tools. Engine Tool No. Description JÐ23523-F Harmonic Balancer Remover/Installer Set JÐ26999-30 Compression Gauge Adapter JÐ22102 Front Crankshaft Seal Installer JÐ26999 Compression Gauge JÐ39084...
Page 33 ________________ 1-32 General Information, Lubrication and Maintenance ¨ Wheels, Tires and CTIS Tool No. Description JÐ42557 Cam Socket Brakes Tool No. Description Ð Disc Brake Tool Kit 42553 Steering Tool No. Description JÐ24319-B Steering Linkage and Tie-Rod Puller JÐ25033-C Pump Pulley Installer JÐ33141 Adapter Fittings (used with J-25323) JÐ25034-C...
Page 34: Miscellaneous Essential Tools
Tech 1 Test Lead, part of TK-O-A TAÐ1190-A Tech 1 OperatorÕs Manual, part of TK-O-A JÐ35616-A Connector Test Adapter Set JÐ42645-C HUMMER Mass Storage Cartridge Kit JÐ43160 Adapter Cable, Tech 1A (14/16 pin) 7000041 Vehicle Interface Module (VIM) JÐ44237 ABS, DLC Jumper JÐ24538-B...
Page 35: Special Tools
________________ 1-34 General Information, Lubrication and Maintenance ¨ SPECIAL TOOLS Engine Tool No. Description JÐ29834 Valve Lifter Removal Tool JÐ8080 Main Bearing Shell Remover/Installer (In-Vehicle) JÐ6098-10 Camshaft Bearing Remover/Installer (use with JÐ33049) JÐ8062 Valve Spring Compressor JÐ33042 Static Timing Mark Gauge JÐ33049 Camshaft Bearing Replacement Set (Universal) JÐ24270...
Page 36 _______________ General Information, Lubrication and Maintenance 1-35 ¨ Axles/Suspension and Frame Tool No. Description JÐ33142 Axle Shaft and Seal Installer JÐ21786 Pinion Rear Bearing Cup Remover JÐ21787 Pinion Front Bearing Cup Remover JÐ8611-01 Rear Pinion Bearing Race Installer JÐ29162 Rear Retaining Seal Installer JÐ8608 Rear Pinion Bearing Race Installer JÐ39524...
Page 37 ________________ 1-36 General Information, Lubrication and Maintenance ¨ THIS PAGE INTENTIONALLY BLANK.
Page 38 ________________________________________________________________________________ ¨ Section 2 Engine INTRODUCTION This section contains general information, diesel engine diagno- located. Use the contents tables to avoid random searches for sis, turbocharger service, and diesel engine repair and overhaul. needed information. A table of contents is provided that lists the various repair Specifications for diesel engines are located at the end of this items and the section page number where repair information is section for quick reference.
Page 39: Cooling System
Rocker Cover Installation ......2-91 ENGINE DESCRIPTION A turbocharged diesel engine is used in Hummer vehicles. It is dead center on the intake and power strokes. The extra oil pres- a liquid cooled, four-stroke, 90¡...
Page 40: Engine Oil
Recommended engine oil for the GM built, diesel engines used crease boost, or closes it to increase boost. Waste gate position in Hummer vehicles, is API classification CF-4 (Figure 2-3). is controlled by the PCM. Base stock or synthetic oils are equally acceptable.
Page 41: Cleaning Materials
RTV sealants will be applied. This type of solvent does not leave a residue that interferes with sealer cure or adhesion. All Hummer models are equipped with a fuel filter warning Carbon deposits can be emulsified by some spray type gasket lamp.
Page 42: Piston And Connecting Rod
_____________________________________________________________________ Engine ¨ ROAD TESTING seems to make a greater frequency noise. This is because the bearing may knock at both ends of piston travel. The purpose of road testing is basically to confirm or deny the existence of an engine fault. Procedure is as follows: Piston and Connecting Rod Note condition of wheels/tires before test.
Page 43: Diagnosis Equipment
______________________________________________________________________ 2-6 Engine ¨ Diesel Fuel Knock or Rattle just below the injector nozzle (Figure 2-5). The tip of each plug extends into a pre-chamber which concentrates the fuel/air The rattling sound unique to diesel engine is normal. It is a mixture prior to combustion.
Page 44: General Information
_____________________________________________________________________ Engine ¨ AMMETER IGNITION SWITCH FUSE FUSE IGNITION SWITCH STARTER POS. STUD FUSIBLE 00-S02-001 LINK Figure 2-6: Checking Current at Each Glow Plug OIL PUMP PRESSURE TEST Connect the pressure test gauge to the transmitter fitting in the valley of the block. Pressure should be a minimum of 6 psi (41 kPa) at hot idle and increase to 30 psi (207 kPa) at 2000 rpm.
Page 45 ______________________________________________________________________ 2-8 Engine ¨ Engine Diagnosis PROBLEM POTENTIAL CAUSE CORRECTION Hard Starting 1. InsufÞcient cranking speed (below 100 rpm 1. Check, repair cables or connections. Recharge bat- cold or 180 rpm hot). teries if low. Replace batteries if shorted, sul- Caused by: phated, damaged.
Page 46 _____________________________________________________________________ Engine ¨ Engine Diagnosis PROBLEM POTENTIAL CAUSE CORRECTION Hard Starting 1. Wrong fuel or poor quality fuel. 1. Drain and reÞll tank. Purge rest of fuel system and When Hot bleed injectors. 2. Air leaks in fuel supply (suction) lines. 2.
Page 47 _____________________________________________________________________ 2-10 Engine ¨ Engine Diagnosis PROBLEM POTENTIAL CAUSE CORRECTION Engine Will Not 5. Starter or solenoid problem. 5. Check for bad or loose connections at starter and Crank - solenoid. If OK, note if starter surges when current (Continued) is applied.
Page 48 ____________________________________________________________________ Engine 2-11 ¨ Engine Diagnosis PROBLEM POTENTIAL CAUSE CORRECTION Low Power, 1. Vehicle overloaded. 1. Lighten vehicle load. Poor Accelera- tion 2. Low grade diesel fuel. 2. Drain tank and refuel. 3. Sludge or wax buildup in fuel Þlter (low fuel 3.
Page 49 _____________________________________________________________________ 2-12 Engine ¨ Engine Diagnosis PROBLEM POTENTIAL CAUSE CORRECTION White Smoke 1. Low quality fuel. 1. Drain and reÞll tank with better quality fuel. 2. Injection pump/engine timing is retarded. 2. Check and correct timing. 3. Engine coolant entering combustion chamber 3.
Page 50 ____________________________________________________________________ Engine 2-13 ¨ Engine Diagnosis PROBLEM POTENTIAL CAUSE CORRECTION Excessive Oil 1. Prolonged high speed, high load, or overload 1. Reduce overload, or speed as needed. Consumption operation. 2. Incorrect oil grade used for high ambient 2. Switch to SG, SH-CD oil with SAE viscosity rat- temperature operation.
Page 51 _____________________________________________________________________ 2-14 Engine ¨ Engine Diagnosis PROBLEM POTENTIAL CAUSE CORRECTION Overheating Failed thermostat or radiator cap. 5. Check thermostat and cap operation. Replace (continued) either part if inoperative. Fan clutch inoperative. 6. Replace clutch. Water pump inoperative. 7. Check coolant ßow and replace pump if necessary. Blown head gasket.
Page 52 ____________________________________________________________________ Engine 2-15 ¨ TURBOCHARGER SERVICE AND DIAGNOSIS WASTEGATE VACUUM Description ACTUATOR The turbocharger used on 6.5L diesel engines is a Borg- MANIFOLD Warner model 1H1 (Figure 2-7). Lubrication is by engine oil CROSSOVER from the engine lubrication system. HOUSING Boost is monitored by the PCM and controlled by the waste- gate and electronic accelerator pedal.
Page 53: Turbocharger Operation
_____________________________________________________________________ 2-16 Engine ¨ TURBOCHARGER OPERATION The position sensor is a potentiometer that operates like a TPS. It signals pedal position to the PCM. At boost detent position, The wastegate valve controls boost. It is operated by the vac- the potentiometer signal causes the PCM to close the wastegate uum actuator.
Page 54 ____________________________________________________________________ Engine 2-17 ¨ Turbocharger Removal Turbocharger Installation Remove front console, rear console, engine cover, and dis- Install new O-ring seal on turbocharger manifold outlet. connect related wiring and A/C ducting. Do not reuse old O-ring as leakage may occur. Remove turbocharger heat shielding.
Page 55 _____________________________________________________________________ 2-18 Engine ¨ Turbocharger Diagnosis PROBLEM POTENTIAL CAUSE CORRECTION Low Power Poor Lean fuel mixture caused by insufÞcient fuel 1. Problem is in fuel delivery system. Check fuel Acceleration volume or pressure. supply pump pressure, look for leaks in lines and (Black smoke not at Þttings, plugged fuel Þlter, accelerator cable evident at 1/2 to...
Page 56 ____________________________________________________________________ Engine 2-19 ¨ DIESEL ENGINE IN-VEHICLE SERVICE 10. Remove nut securing engine bracket to stud on starter motor (Figure 2-12). General Information 11. Raise engine enough to remove insulator, or bracket (Figure 2-12). The repair procedures described in this section cover engine service that can be performed in the vehicle.
Page 57 _____________________________________________________________________ 2-20 Engine ¨ CRANKSHAFT PULLEY ENGINE BRACKET Removal 1. Loosen (but do not remove) crankshaft pulley bolts (Figure 2-14). 2. Remove serpentine accessory drive belt as follows: Loosen drive belt by rotating belt tensioner in counterclockwise direction (Figure 2-15). Use 1/2 in. drive breaker bar to rotate pulley.
Page 58: Torsional Damper
____________________________________________________________________ Engine 2-21 ¨ Installation Clean face of torsional damper with brake cleaner. Smooth surface with Þle, or 280 grit paper, if necessary. Install pulley on damper and install pulley bolts. Tighten TORSIONAL bolts until snug. DAMPER Install serpentine belt on all pulleys except belt tensioner (Figure 2-16).
Page 59: Front Cover Oil Seal Replacement
_____________________________________________________________________ 2-22 Engine ¨ FRONT COVER OIL SEAL REPLACEMENT OIL PUMP DRIVE 1. Remove crankshaft pulley and torsional damper. Refer to Removal procedures in this section. 1. Remove engine cover/console for access to rear of engine. Ð 2. Remove oil seal front cover with tool J 22102 or pry tool 2.
Page 60: Front Cover And Timing Chain
____________________________________________________________________ Engine 2-23 ¨ FRONT COVER AND TIMING CHAIN Cover Removal Disconnect and remove batteries and tray. Remove A/C condenser oil coolers, radiator, and fan shroud as assembly (Figure 2-21). Drain engine coolant. Loosen and remove serpentine drive belt. Use 1/2 in. drive Remove radiator upper and lower hoses.
Page 61 _____________________________________________________________________ 2-24 Engine ¨ 19. Remove injection pump driven gear (Figure 2-24). HOSE CROSSOVER 20. Remove baffle from front cover (Figure 2-24). 21. Remove nuts and washers attaching fuel injection pump to studs on front cover (Figure 2-24). NOTE: There are timing marks on the front cover and injec- tion pump.
Page 62 ____________________________________________________________________ Engine 2-25 ¨ FUEL INJECTION INJECTION PUMP PUMP DRIVE GEAR FRONT PUMP COVER GASKET BAFFLE INJECTION PUMP DRIVEN GEAR FRONT SEAL Figure 2-24: Drive Gear, Baffle, and Front Cover Removal CAMSHAFT KEY TIMING CHAIN CAMSHAFT CAMSHAFT SPROCKET INJECTION PUMP DRIVE GEAR CRANKSHAFT TIMING MARKS...
Page 63 _____________________________________________________________________ 2-26 Engine ¨ Front Cover Installation Ð 6. Install new seal in front cover with tool J 22102. 7. Apply sealer to front cover as follows: 1. Install new camshaft thrust plate and spacer if required. ¥ Use anerobic sealer, such as Loctite 510, on cover 2.
Page 64 ____________________________________________________________________ Engine 2-27 ¨ INJECTION PUMP FRONT COVER DOWEL BAFFLE PUMP FRONT INJECTION PUMP GASKET COVER DRIVEN GEAR TIMING MARK DOWEL Figure 2-29: Baffle and Pump Driven Gear Installation 17. Install torsional damper. Then install damper attaching washer and bolt. Tighten bolt to 140-160 lb-ft (190-217 Figure 2-28: Front Cover Mounting N¥m) torque.
Page 65 _____________________________________________________________________ 2-28 Engine ¨ 22. Install fan pulley, fan, and fan clutch. Tighten attaching nuts to 15-20 lb-ft (20-27 N¥m). 23. Install serpentine drive belt. 24. Connect heater and bypass hoses at water pump and crossover. Then attach radiator upper inlet hoses to inlet tube.
Page 66: Rear Main Oil Seal Replacement
____________________________________________________________________ Engine 2-29 ¨ REAR MAIN OIL SEAL REPLACEMENT CAUTION: Do not nick or scratch crankshaft seal surface when removing old seal (Figure 2-32). Remove transmission and transfer case assembly. Using small screwdriver or seal puller, remove old seal Remove flywheel. from cylinder block and main bearing cap cavity.
Page 67 _____________________________________________________________________ 2-30 Engine ¨ ROCKER ARM COVER SERVICE Right Side Cover Removal 1. Remove front console and engine cover. 13. Remove studs and bolts attaching rocker arm cover to cylinder head (Figure 2-34). 2. Remove air horn and inlet hose. Then remove air cleaner assembly.
Page 68 ____________________________________________________________________ Engine 2-31 ¨ Right Side Cover Installation Left Side Cover Removal Clean cover mounting surface of cylinder head with brake Remove front console and engine cover. or contact cleaner and shop towels. This product will Drain engine coolant. remove residue from the surface and ensure proper adhe- Remove driver side splash shield.
Page 69 _____________________________________________________________________ 2-32 Engine ¨ Left Side Cover Installation 1. Clean cover mounting rails on cylinder head with brake or 8. Install fuel injector line clamps and harness and sensor contact cleaner and shop towels. This product will remove brackets on manifold studs. Tighten retaining nuts to 26 residue from surface and ensure proper adhesion of new lb-ft (35 N¥m) torque.
Page 70 ____________________________________________________________________ Engine 2-33 ¨ ROCKER ARM, SHAFT, AND PUSHROD SERVICE Removal Remove one or both rocker arm covers as needed. Refer to Lift and remove each rocker arm and shaft assembly procedures in this section. (Figure 2-36). Do not intermix assemblies if they will be reused.
Page 71 _____________________________________________________________________ 2-34 Engine ¨ Cleaning and Inspection Clean the valve train components in parts cleaning solvent. 8. Install rocker covers and intake manifold as described in Carb cleaner or a spray type gasket remover can be used to re- this section. move stubborn deposits.
Page 72 ____________________________________________________________________ Engine 2-35 ¨ EXHAUST MANIFOLD SERVICE Right Exhaust Manifold Heat Shield Replacement Removal Remove console and engine access cover. Install heat shield and exhaust manifold on cylinder head and tighten capscrews to 25 lb-ft (34 N¥m). Remove right exhaust manifold rear heat shield screws and locknuts (Figure 2-38).
Page 73 _____________________________________________________________________ 2-36 Engine ¨ Right Exhaust Manifold Rear Heat Shield Replacement 1. Remove console and engine access cover. 2. Detach rear heat shield from transmission fill tube clamp (Figure 2-39). 3. Remove rear heat shield. 4. Install rear heat shield. 5.
Page 74 ____________________________________________________________________ Engine 2-37 ¨ CYLINDER HEAD AND GASKET SERVICE 12. Remove intake manifold and gaskets. Note attaching stud and bolt locations for reinstallation reference. Cylinder Head (Left Side) 13. Disconnect driver side fuel injector lines at pump and injectors and remove lines. Cover injectors with duct tape Removal to prevent dirt entry.
Page 75 _____________________________________________________________________ 2-38 Engine ¨ Cylinder Head (Left Side) 8. Install rocker arm and shaft assemblies. Be sure pushrods are properly seated in lifter and rocker arms. Do this Installation before tightening shaft retainer bolts. Install shaft retainers 1. Clean gasket surface of cylinder block with scraper if nec- and bolts.
Page 76 ____________________________________________________________________ Engine 2-39 ¨ 12. Install fuel injector lines. Tighten line fittings at pump and ¥ Glow plug relay and bracket injector to 19 lb-ft (26 N¥m) torque. ¥ Engine wire harness clips and ground wires 13. Install intake manifold and gaskets. Tighten manifold ¥...
Page 77 _____________________________________________________________________ 2-40 Engine ¨ Cylinder Head (Right Side) 10. Apply sealer to rocker arm cover. Make sealer bead 3/16 inch wide by 1/16 inch thick. Use RTV-type silicone, Installation adhesive-sealer such as Loctite 592, or Permatex High Temp, Ultra Copper, or Ultra Blue. Allow sealer to cure 1.
Page 78 ____________________________________________________________________ Engine 2-41 ¨ VALVE LIFTER REPLACEMENT BODY The 6.5L diesel engines are equipped with roller-type hydrau- lic lifters. The lifters are not repairable. A failed lifter must be replaced as an assembly. Service access to the lifters requires removal of one or both ROLLER cylinder heads.
Page 79 _____________________________________________________________________ 2-42 Engine ¨ Stroke lifter plunger with pushrod to pump fluid and reinstall rod cap. Tighten new cap nuts to 44-52 through lifter. lb-ft (60-71 N¥m) torque. d. Remove lifter from container and wipe it dry with lint 7. Replace main bearings as follows: free cloth or paper.
Page 80: Intake Manifold
Section 2 Engine ____________________________________________________________________ Engine 2-43 ® INTAKE MANIFOLD MAIN BEARING UPPER BEARING TANG HALF (IN BLOCK) Service CRANKSHAFT A three-piece intake manifold is used on turbocharged diesel MAIN engines (Figure 2-49). It consists of left and right manifold BEARING JOURNAL halves and a center manifold.
Page 81 _____________________________________________________________________ 2-44 Engine ® EXHAUST MANIFOLDS Removal Clean old gasket material off cylinder head and manifold with scraper and wire brush. 1. Remove consoles and engine cover for access to turbo- charger inlet pipes. For information regarding inlet pipes, Installation refer to Section 3.
Page 82 ____________________________________________________________________ Engine 2-45 ® OVERHAUL SERVICE INFORMATION 17. Remove bolts attaching radiator and shroud assembly to frame and brackets. Then (with aid of helper), remove Anaerobic and RTV type sealers are both used during engine radiator, shroud, condenser, and oil coolers as an assembly re-assembly.
Page 83 _____________________________________________________________________ 2-46 Engine ® 23. Disconnect A/C hoses at compressor. Move hoses aside ALTERNATOR/ for working clearance. Cap open ends to prevent dirt entry IDLER/TENSIONER AND BRACKET (Figure 2-55). ASSEMBLY SUPPORT BRACKET HORN CLEANER HOSE Figure 2-56: Alternator, Pulleys, and Bracket Removal/Installation 27.
Page 84 ____________________________________________________________________ Engine 2-47 ® 40. Working under vehicle, loosen, disconnect, or remove 43. Remove bolts/studs attaching transmission to engine following: block. • Remove skid plate. 44. Attach lifting sling to engine (Figure 2-59). • Remove starter and shield (with aid of helper). LIFTING BRACKET FRONT •...
Page 85: Engine Installation
_____________________________________________________________________ 2-48 Engine ® ENGINE INSTALLATION LIFTING SLING AND BRACKET If new engine is being installed, transfer mounting brack- J–33139 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.
Page 86 ____________________________________________________________________ Engine 2-49 ® 19. Remove protective tape from A/C suction/discharge hose 36. Install battery tray and batteries. Connect positive and adapter and connect it to compressor. Install new seal washers. negative cables to batteries. 37. Install seals and cover plates on air lift brackets. Notched HOSE ADAPTER side of seals face engine.
Page 87: A/C Compressor Removal
_____________________________________________________________________ 2-50 Engine ® Fan and Pulley Removal ALTERNATOR OIL FILLER NECK 1. Insert spanner J–41240-1 in holes in water pump pulley (Figure 2-62). 2. Use spanner to hold water pump shaft and wrench J– 41240-5A to loosen nut securing fan clutch to water pump. 3.
Page 88 ____________________________________________________________________ Engine 2-51 ® Power Steering Pump and Bracket Removal 1. Remove bolts/nuts attaching pump mounting bracket to block and cylinder head and remove pump and bracket as assembly. 2. If pump requires service, remove pump attaching bolts and remove pump from bracket (Figure 2-67). MOUNTING BRACKET PUMP PULLEY POWER...
Page 89: Turbocharger And Center Manifold Removal
_____________________________________________________________________ 2-52 Engine ® Intake Manifold Removal CENTER MANIFOLD O-RING 1. Remove bolts and studs attaching each manifold half to cylinder head. 2. Tap each manifold half with rawhide mallet to loosen it. GASKET Lift and remove manifold halves and gaskets (Figures 2-70 GASKET and 2-71).
Page 90: Fuel Supply And Return Line Removal
____________________________________________________________________ Engine 2-53 ® Fuel Injection Line Removal Fuel Supply and Return Line Removal Loosen clamp and remove fuel supply hose from fuel NOTE: Mark or tag fuel injection lines for installation refer- injection pump (Figure 2-76). ence. Loosen clamps and remove fuel return hose from injection 1.
Page 91: Glow Plug Removal
_____________________________________________________________________ 2-54 Engine ® Rocker Arm Cover Removal Fuel Injector Removal 1. Remove injection line support bracket from studs Remove fuel return hoses and clamps from injectors (Figure 2-77). (Figure 2-79). 2. Remove cover attaching bolts and studs. Remove fuel injectors and gaskets (Figure 2-79). Remove rocker arm cover.
Page 92 ____________________________________________________________________ Engine 2-55 ® Cylinder Head Removal CLAMP PLATE 1. Remove cylinder head bolts (Figure 2-81). LIFTER REMOVER J–29834 2. Remove cylinder head from block. 3. Remove cylinder head gasket. Discard gasket afterward. VALVE LIFTER 4. Repeat procedure for opposite cylinder head. CYLINDER HEAD HEAD BOLTS (17 PER HEAD)
Page 93 _____________________________________________________________________ 2-56 Engine ® Water Pump/Adapter Plate/Oil Fill Tube Removal 1. Remove oil ﬁll tube from adapter plate (Figure 2-83). OIL FILL TUBE ADAPTER PLATE ADAPTER PLATE GASKET WATER PUMP Figure 2-85: Water Pump, Adapter Plate, and Gasket Disassembly WATER PUMP Fuel Injection Pump Removal Remove electrical connections, fuel inlet and return lines from pump.
Page 94: Front Cover Removal
____________________________________________________________________ Engine 2-57 ® Front Cover Removal INJECTION PUMP 1. Remove bafﬂe from front cover (Figure 2-87). DRIVE GEAR DRIVE KEYS 2. Remove bolts attaching front cover to oil pan. 3. Remove bolts attaching front cover to engine block. CRANKSHAFT 4.
Page 95: Oil Pan Removal
_____________________________________________________________________ 2-58 Engine ® STUDS DRAINPLUG GASKET SEAL SEAL OIL PAN ADAPTER SEALS WASHER Figure 2-92: Oil Pan Removal BOLT OIL FILTER Oil Pump and Drive Removal Figure 2-90: Oil Filter and Adapter Removal Remove nut from pump mounting stud (Figure 2-93). Loosen bracket clamp screw and rotate bracket off mounting stud.
Page 96 ____________________________________________________________________ Engine 2-59 ® CLAMP OIL PUMP DRIVE CYLINDER BLOCK THRUST PLATE CAMSHAFT SPACER GASKET Figure 2-95: Camshaft Removal Piston and Connecting Rod Removal Remove ridge at top of each cylinder bore with ridge reamer J–24270. Remove shavings - chips afterward. Paint mark pistons for assembly reference.
Page 97: Flywheel Removal
_____________________________________________________________________ 2-60 Engine ® Flywheel Removal NO. 3 NO. 4 NO. 5 1. Remove six capscrews and ﬂywheel from crankshaft NO. 2 (THRUST) (REAR MAIN) NO.1 (Figure 2-97). (FRONT) 2. Remove flywheel attaching bolts with impact wrench and suitable size socket. REAR 3.
Page 98 ____________________________________________________________________ Engine 2-61 ® Inspection NOTE: Be sure to inspect the piston cooling oil tubes in turbo diesel blocks. Verify that the tubes are clear (Figure 2-101). Check all of the block surfaces for nicks, scratches, cracks, damaged threads, or evidence of porosity at any point. Minor nicks and scratches can be smoothed with a fine tooth file or CAM BEARING AND BORE LOCATIONS...
Page 99: Cylinder Bore And Piston Measurement
_____________________________________________________________________ 2-62 Engine ® Check the pipe plugs at the sides and front of the block Check condition of the cylinder head and front cover dowel (Figure 2-103). Replace any plugs that are loose or leaking. pins (Figure 2-104). Remove and replace any pins that are Coat replacement plug threads with Permatex #2, or high temp loose.
Page 100 ____________________________________________________________________ Engine 2-63 ® Measure piston skirt diameter at the centerline of the piston pin but at a right angle (opposite) to the pin. Refer to the “Service Piston and Cylinder Bore Specifications” data at the end of this section for dimensions. Remove the piston rings, insert the piston in the bore, and BORE GAUGE check piston-to-bore clearance with a feeler gauge.
Page 101 _____________________________________________________________________ 2-64 Engine ® Cylinder Boring and Honing Information CAMSHAFT BEARING REPLACEMENT Camshaft bearing tool set J–33049 plus adapters J–6098-11 Check the ID letters stamped on the cylinder block pan rails. and J–6098-12 and tool set J–6098-01 are required for bearing These letters identify the production standard piston grade size replacement.
Page 102 ____________________________________________________________________ Engine 2-65 ® J–6098-01 J–6098-01 ADAPTER J–6098-12 DRIVER DRIVER HANDLE HANDLE ADAPTER NO. 5 BEARING J–6098-12 NO. 1 J–6098-01 DRIVER OIL HOLE (1) HANDLE NO. 1BEARING NO. 5 ADAPTER FROM ADAPTER FROM J–33049 BEARING SET J–33049 SEAM AT 11 O’CLOCK Figure 2-110: Removing Cam Bearings 1 and 5 J–6098-01 DRIVER...
Page 103 _____________________________________________________________________ 2-66 Engine ® CRANKSHAFT SERVICE Crankshaft runout should not exceed 0.0002 - 0.0008 in. (0.005 - 0.020 mm). Replace the crankshaft if runout is greater than Clean the crankshaft with solvent and clear the journal oil specified. Do not attempt to straighten a cast iron crankshaft. holes with a wire brush if necessary.
Page 104: Section 2 Engine
Section 2 Engine ____________________________________________________________________ Engine 2-67 ® PISTON/CONNECTING ROD OVERHAUL TOP COMPRESSION RING Remove and discard the old piston rings. Use a remover/in- staller tool similar to parallel jaw type tool shown (Figure 2-116). Discard rings after removal. BOTTOM Use a ring groove tool to remove carbon and oil deposits from COMPRESSION the ring grooves.
Page 105 _____________________________________________________________________ 2-68 Engine ® the pin bore centerline as shown. Replace the pistons if wear is such that piston-to-bore clearance would be greater than: • 0.004 in. (0.120 mm) for cylinder 1-6 and • 0.005 in. (0.133 mm) for cylinder 7 and 8 2.57 in.
Page 106 ____________________________________________________________________ Engine 2-69 ® • If a cylinder bore only requires honing to correct a prob- lem, use the next grade size piston. Avoid going to the largest oversize piston unless absolutely necessary. INSTALLER TOOL • Verify that a new piston is properly aligned on the con- J–39507 necting rod.
Page 107 _____________________________________________________________________ 2-70 Engine ® PISTON RING FEELER GAUGE INSTALLER TOOL J–39507 RETAINING RING TOOL TAB Figure 2-126: Checking Piston Ring End Gap Figure 2-125: Seating Piston Pin Retainer Ring 3. Install rings in sequence: oil ring first, bottom compression ring second, and top compression ring last. Piston Ring Installation Use ring expander tool J–42525 to install the rings.
Page 108: Front Cover And Oil Filler Tube
____________________________________________________________________ Engine 2-71 ® CAMSHAFT, TIMING CHAIN, SPROCKET, AND FRONT COVER AND OIL FILLER TUBE DRIVE GEAR SERVICE Inspect the cover for cracks, scratches/nicks on the sealing sur- faces, or damaged threads. Remove minor scratches/nicks with Clean the camshaft and geartrain parts in solvent. Wipe the 180 grit emery.
Page 109 _____________________________________________________________________ 2-72 Engine ® Remove valve retainer, shield and spring. Remove stem seal from valve and slide valve out of guide and head. OIL FILLER TUBE Remove shim. On exhaust valve, also remove nylon stem and guide seal (Figure 2-134). Remove remaining valve assemblies in same manner.
Page 110 ____________________________________________________________________ Engine 2-73 ® INTAKE VALVE VALVE SPRING AND VALVE STEM SEAL DAMPER ASSEMBLY SHIM RETAINER SHIELD VALVE STEM SEAL LOCKS EXHAUST VALVE VALVE STEM AND SHIM GUIDE SEAL VALVE SPRING AND DAMPER ASSEMBLY SHIELD RETAINER/ROTATOR Figure 2-134: Intake and Exhaust Valve Components Cleaning and Inspection PRE-COMBUSTION CHAMBER Clean the cylinder heads and valve components in parts clean-...
Page 111 _____________________________________________________________________ 2-74 Engine ® Check the valve stems for wear, scoring, or distortion. Inspect the faces for pitting, cracks, or burnt segments. Also inspect ACCEPTABLE the lock grooves at the stem top. Be sure the grooves are free of CRACK LENGTH cracks, worn or broken lands, or chipped spots.
Page 112 ____________________________________________________________________ Engine 2-75 ® Cylinder Head Reassembly LOCKS (2) 1. Scuff sand all gasket surfaces with 180 grit paper. 2. Clean the valvetrain parts and cylinder head with solvent RETAINER and dry with compressed air. Install new freeze plugs in heads if necessary. Apply RETAINER/ Permatex #2 or high temp adhesive/sealer to edges of ROTATOR...
Page 113: Lifter, Pushrod, Rocker Arm Service
_____________________________________________________________________ 2-76 Engine ® LIFTER, PUSHROD, ROCKER ARM SERVICE Clean the rocker arms, shafts, pushrods, guides, clamps, and ROCKER SHAFT lifters in parts cleaning solvent. RETAINER AND BOLT Immerse the lifters in solvent and use a pushrod to stroke the lifter plunger.
Page 114 ____________________________________________________________________ Engine 2-77 ® OIL PUMP AND PUMP DRIVE SERVICE The oil pump can be disassembled for inspection if desired but not overhauled. The pump is serviced only as a complete as- sembly. Individual pump parts are not available. The pump shaft, pickup tube clamp and bolt, and pump mount- HUB BORE ing stud are all available as service parts (Figure 2-148).
Page 115: Flushing Engine Cooler
_____________________________________________________________________ 2-78 Engine ® OIL FILTER ADAPTER AND BYPASS VALVE Bypass Valve SERVICE Remove the two bypass valves (Figure 2-149), and inspect them carefully. Replace either valve if damaged, or filled with Oil Filter Adapter shavings and/or debris. Inspect the adapter fitting and bolt for damaged threads NOTE: The filter bypass and cooler bypass valves can be re- (Figure 2-149).
Page 116 ____________________________________________________________________ Engine 2-79 ® INTAKE AND EXHAUST MANIFOLDS Inspect the oil pan for cracks, sealing surface distortion, dents, and damaged threads (Figure 2-151). The manifolds can all be immersed in parts cleaning solvent. Small dents, not involving stretched metal, are not a cause for Carbon buildup in the exhaust manifolds can be removed with replacement.
Page 117: Engine Assembly And Adjustment
_____________________________________________________________________ 2-80 Engine ® ENGINE ASSEMBLY AND ADJUSTMENT CRANKSHAFT Crankshaft Main Bearing Selection Main bearings are available in standard and two undersizes for select fit purposes. Required bearing clearances are: • 0.0017-0.003 in. (0.045-0.083 mm) at bearings 1 through 4 TANG MAIN •...
Page 118 ____________________________________________________________________ Engine 2-81 ® CRANKSHAFT MAIN COMPRESSED BEARING JOURNAL GAUGING PLASTIC GAUGING PLASTIC ENVELOPE SCALE Figure 2-155: Gauging Plastic Position on Figure 2-156: Measuring Gauging Plastic to Crankshaft Main journal Determine Bearing Clearance 7. Install main bearing caps and old bolts retained from disassembly operations.
Page 119 _____________________________________________________________________ 2-82 Engine ® CRANKSHAFT MAIN CAP TORQUE SEQUENCE 1. Tighten the inner 12 mm bolts to 55 lb-ft (75 N.m). 2. Retighten the inner 12 mm bolts to 55 lb-ft (75 N.m). 3. Tighten the inner 12 mm bolts an additional 90 degrees. 4.
Page 120 ____________________________________________________________________ Engine 2-83 ® PISTON/CONNECTING ROD INSTALLATION 10. Remove rod cap. Clean gauging material off crankshaft journal. Lubricate rod bearing halves and crankshaft journal AND BEARING FIT with engine oil or assembly lube. Then reinstall rod cap and Verify correct piston and rod assembly. Be sure piston crown relief tighten new rod cap nuts to 48 lb-ft (65 N•m) torque.
Page 121 _____________________________________________________________________ 2-84 Engine ® OIL PUMP, OIL PAN, FLYWHEEL INSTALLATION ROD CAP AND BEARING INSERT Pour 2-3 ounces engine oil into pump and rotate pump shaft to lubricate pump gears. Install retainer and pump shaft in oil pump. Apply high temp bearing grease to upper end of shaft.
Page 122: Timing Chain-Sprocket-Gear Installation
____________________________________________________________________ Engine 2-85 ® TIMING CHAIN-SPROCKET-GEAR INSTALLATION CONVERTER BOLT PADS FLYWHEEL Rotate crankshaft so #1 piston is at TDC. Install sprocket drive keys in camshaft and crankshaft (Figure 2-167). THRUST WASHER FLYWHEEL AND BOLT BOLTS (6) TIMING MARK INJECTION LOCATIONS PUMP DRIVE GEAR...
Page 123: Front Cover And Baffle Installation
_____________________________________________________________________ 2-86 Engine ® FRONT COVER AND BAFFLE INSTALLATION 1. Install new seal in front cover with installer tool J–22102. 2. Apply sealer to front cover as follows: • Use anaerobic sealer such as Loctite 510 on cover sur- faces that contact block (Figure 2-168). •...
Page 124 ____________________________________________________________________ Engine 2-87 ® FUEL INJECTION PUMP INSTALLATION WATER PUMP AND ADAPTER PLATE INSTALLATION 1. Install injection pump gasket on front cover studs. Apply Permatex #2 to both sides of gasket and install gas- 2. Mount injection pump on front cover studs (Figure 2-169). ket and water pump on adapter plate (Figure 2-171).
Page 125 _____________________________________________________________________ 2-88 Engine ® VALVE LIFTER INSTALLATION 1. Prime valve lifters in kerosene then engine oil. Immerse lifter in kerosene ﬁrst and oil last. Then pump plunger with ADAPTER PLATE FRONT pushrod to force solution through lifter. COVER 2. Lubricate lifters with oil and install in cylinder block. Position guide plates on lifters.
Page 126: Cylinder Head Installation
____________________________________________________________________ Engine 2-89 ® CYLINDER HEAD INSTALLATION HEAD BOLT CYLINDER HEAD Important: • Make sure that the block and head gasket surfaces are clean. • The head gasket material is soft. Handle the gasket with care and make sure the gasket surface is not creased or HEAD dented.
Page 127: Pushrod, Rocker Arm And Shaft Installation
_____________________________________________________________________ 2-90 Engine ® GLOW PLUG AND INJECTION NOZZLE PUSHROD, ROCKER ARM AND SHAFT INSTALLATION INSTALLATION 1. Install glow plugs in each cylinder head (Figure 2-178). NOTE: The rocker arm end of each pushrod is identified with Tighten plugs to 8-12 lb-ft (11-16 N•m). a paint stripe.
Page 128: Rocker Cover Installation
____________________________________________________________________ Engine 2-91 ® ROCKER COVER INSTALLATION RETAINER PUSHROD 1. Clean mounting ﬂanges on both rocker covers and cylin- der heads. Wipe ﬂange sealing surfaces off with isopropyl alcohol to prepare surface for sealer application. 2. Apply RTV-type sealer to cover sealing surfaces. 3.
Page 129 _____________________________________________________________________ 2-92 Engine ® FUEL INJECTOR LINE INSTALLATION WATER CROSSOVER INSTALLATION Flush injector lines with fresh diesel fuel and compressed air. Apply Permatex #2 to crossover gaskets and position gas- kets on cylinder heads (Figure 2-185). 2. Attach fuel lines to injectors and pump. Verify line routing and connection (Figures 2-183 and 2-184).
Page 130 ____________________________________________________________________ Engine 2-93 ® TORSIONAL DAMPER AND CRANKSHAFT TURBOCHARGER AND INTAKE MANIFOLD PULLEY INSTALLATION INSTALLATION 1. Install damper key in crankshaft (Figure 2-186). Apply Permatex High Tack to manifold gaskets and posi- tion gaskets on cylinder heads. 2. Lubricate crankshaft hub, damper seal contact surface, and damper hub bore with engine oil or chassis grease.
Page 131 _____________________________________________________________________ 2-94 Engine ® 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.
Page 132: Torque Specifications
____________________________________________________________________ Engine 2-95 ® TORQUE SPECIFICATIONS Item Lb-Ft. Lb-In. N•m Block drainplugs ........—...
Page 133: Engine Specifications
_____________________________________________________________________ 2-96 Engine ® ENGINE SPECIFICATIONS Camshaft: Lobe Lift ± 0.05 General Data: Intake......0.281 in. (7.133 mm) Displacement 6.5L/395 c.i.d.
Page 134 ____________________________________________________________________ Engine 2-97 ® SERVICE PISTON AND CYLINDER BORE SPECIFICATIONS (MM) NOTE: Cylinders #7 and #8 require 0.013 mm (0.005 in.) additional clearance (piston to bore). Engine Bore Diameter Bore Diameter Piston Grade Skirt Diameter Displacement 1 thru 6 7 & 8 6.5L Production Std.—JT 102.865-102.880...
Page 135 _____________________________________________________________________ 2-98 Engine ® BLOCK, CAMSHAFT AND BEARING SIZES (MM) 6.5L Engines 55.025 55.025 55.025 55.025 51.025 Camshaft Journal Diameter O.D 54.970 54.970 54.970 54.970 50.970 (Diameter Tolerance 0.55 mm) Finished Cam Bearing ID 55.088 55.088 55.088 55.088 51.083 (Diameter tolerance 0.038 mm) 55.050 55.050 55.050...
Page 136 ____________________________________________________________________ Engine 2-99 ® ESSENTIAL TOOLS J–26999-30 J–23523-F J–26999 J–22102 J–23951 J–34116 J–39084 J–33139 J–41240-5A J–35555 J–41240-1 Tool No. Description J–23523-F Harmonic Balancer Remover/Installer Set J–26999-30 Compression Gauge Adapter J–22102 Front Crankshaft Seal Installer J–26999 Compression Gauge J–39084 Rear Main Seal Installer J–33139 Engine Lifting Sling and Bracket J–23951...
Page 137 ____________________________________________________________________ 2-100 Engine ® SPECIAL TOOLS J–8062 J–33042 J–6098-10 J–29834 J–8080 J–33049 J–39507 J–29134-8 J–24270 J–8087 J–25087-C J–8037 J–8089 J–8358 Tool No. Description J–29834 Valve Lifter Removal Tool J–8080 Main Bearing Shell Remover/Installer (In-Vehicle) J–6098-10 Camshaft Bearing Remover/Installer (use with J–33049) J–8062 Valve Spring Compressor J–33042...
Page 138 ________________________________________________________________________________ ® Section 3 Fuel, Emissions, and Exhaust TABLE OF CONTENTS Air Cleaner Assembly Fuel Filter-Water Separator ......3-3 Air Cleaner Filter Element Service .
Page 139: Fuel Lift Pump
_____________________________________________ 3-2 Fuel, Emissions, and Exhaust ® FUEL INJECTION FUEL PUMP LINES TANK SELECTOR INJECTORS ELECTRIC TANK AUXILIARY FUEL FUEL MAIN TANK FILTER/ LIFT WATER PUMP SEPARATOR Figure 3-1: Fuel Supply System Fuel Lift Pump The electrical circuit for the lift pump involves several main components (Figure 3-3).
Page 140: Fuel Filter-Water Separator
____________________________________________ Fuel, Emissions, and Exhaust ® Fuel Filter-Water Separator Electronic Injection Pump The filter-water separator is located at the driver side of the en- The turbo diesel injection pump (Figure 3-5) is controlled by gine compartment firewall (Figure 3-4). It performs five func- the powertrain control module based on inputs from the elec- tions which are: tronic accelerator pedal and various engine sensors.
Page 141: Fuel Injectors
_____________________________________________ 3-4 Fuel, Emissions, and Exhaust ® Fuel Injectors Fuel Tanks, Lines, and Valves An identical fuel injector nozzle is used for each cylinder. The The main and auxiliary fuel tanks are made of high density nozzle is threaded into the cylinder head and positioned so the polyethylene.
Page 142 ____________________________________________ Fuel, Emissions, and Exhaust ® Electronic Fuel Injection Pump Operation PEDAL AND ARM The electronic fuel injection pump is operated by the power- train control module. The pump contains a fuel solenoid driver, an optical and fuel temperature sensor, a shut off solenoid, a stepper motor, and a fuel solenoid.
Page 143: Road Test
_____________________________________________ 3-6 Fuel, Emissions, and Exhaust ® POWERTRAIN CONTROL MODULE (PCM) Check exhaust system components for damage, loose joint connections, or grounding against body. The PCM controls operation of all of the engine and transmis- Inspect transmission linkage and wiring connections, sion outputs.
Page 144 ____________________________________________ Fuel, Emissions, and Exhaust ® Fuel System Diagnosis—Diesel Engine PROBLEM POTENTIAL CAUSE CORRECTION Hard Starting Driver/owner not following recommended Remind driver/owner of required procedure. Dem- start procedure. onstrate procedure if necessary. Fuel contaminated, low quality, or wrong Drain off sample at fuel filter drain plug. Flush fuel.
Page 145 _____________________________________________ 3-8 Fuel, Emissions, and Exhaust ® Fuel System Diagnosis—Diesel Engine PROBLEM POTENTIAL CAUSE CORRECTION No Start Condi- 1. Excessive amount of water or wax buildup in 1. Draw off sample at drain plug. Drain and ﬂush sys- tion (engine system.
Page 146 ____________________________________________ Fuel, Emissions, and Exhaust ® Fuel System Diagnosis—Diesel Engine PROBLEM POTENTIAL CAUSE CORRECTION Low Power, Contaminated or low-quality fuel. Drain, ﬂush, and reﬁll fuel system. Sluggish Accel- High fuel temperature. Normal condition in high ambient. eration Restriction in air intake system. Remove and clean ﬁlter, housing, weathercap, hose, air horn.
Page 147 ___________________________________________ 3-10 Fuel, Emissions, and Exhaust ® Fuel System Diagnosis—Diesel Engine PROBLEM POTENTIAL CAUSE CORRECTION Knock-Ping 1. Contaminated, incorrect, or low quality fuel. Drain, ﬂush, and reﬁll fuel system. Under Accelera- 2. Air leak in fuel delivery system. Inspect injector line fittings. Bleed injectors and tion.
Page 148 ___________________________________________ Fuel, Emissions, and Exhaust 3-11 ® SCAN TOOL DIAGNOSIS INJECTOR The scan tool is needed for operational testing of electronic components such as the PCM, electronic accelerator pedal po- tentiometer, and engine sensors. PART OF FITTING The scan tool is connected to the vehicle electrical system J–29079-125 AND LINE ADAPTER KIT...
Page 149: Engine Coolant Temperature
___________________________________________ 3-12 Fuel, Emissions, and Exhaust ® A drop of fluid should form and remain on nozzle tip for at least 10 seconds. d. Replace nozzle if fluid falls off tip in less than 10 seconds. 11. Test injector chatter as follows: Close test tool shutoff valve.
Page 150 ___________________________________________ Fuel, Emissions, and Exhaust 3-13 ® Low Temperature—High Resistance Test If the solenoid does not activate, perform wiring tests with a DVOM (Figure 3-12). 1. Connect scan tool and start engine. If the wiring tests OK, replace the solenoid. 2.
Page 151 ___________________________________________ 3-14 Fuel, Emissions, and Exhaust ® Installation PCM determine pump advance or retard requirements and fuel flow. The sensor is located at the top of the injection pump ad- 3. Install the O-ring seal above the threads at the bottom of jacent to the fuel shut-off solenoid.
Page 152 ___________________________________________ Fuel, Emissions, and Exhaust 3-15 ® Fuel Solenoid Driver Replacement Removal INDEX 1. Drain the engine coolant and remove the upper radiator NOTCH hose from the thermostat housing. 2. Remove the left intake manifold runner to gain access to the Fuel Solenoid Driver (on the left side of the injection pump).
Page 153 ___________________________________________ 3-16 Fuel, Emissions, and Exhaust ® Injection Timing Stepper Motor The stepper motor is used to advance or retard timing of the TORX electronic injection pump. The motor is controlled by the PCM SCREWS and is actuated by input signals primarily from the coolant, air, STEPPER MOTOR and fuel temperature sensors.
Page 154: Crankshaft Position Sensor
___________________________________________ Fuel, Emissions, and Exhaust 3-17 ® Crankshaft Position Sensor Sensor Test The crankshaft position sensor is a Hall-effect device that mon- Disconnect wires at fuel shut-off solenoid. itors crankshaft position and rpm. Four reference teeth 90° Connect voltmeter between PCM terminal BRA5 and apart, on the crankshaft timing sprocket cause the devise to ground and crank engine.
Page 155 ___________________________________________ 3-18 Fuel, Emissions, and Exhaust ® Boost Sensor Circuit Test Boost pressure readings are opposite what you would read for vacuum. For example, as throttle opening increases, sensor 1. Connect scan tool to diagnostic/data link connector. pressure readings will also increase. Vacuum readings on the 2.
Page 156: Air Cleaner Service
___________________________________________ Fuel, Emissions, and Exhaust 3-19 ® AIR CLEANER SERVICE Removal Installation Install tube, adapter, and ﬁtting on air cleaner assembly NOTE: To remove dust unloader only, perform steps 1 and 2. (Figure 3-23). 1. Remove air cleaner (Figure 3-23). Install dust unloader on air cleaner.
Page 157 ___________________________________________ 3-20 Fuel, Emissions, and Exhaust ® WEATHERCAP AIR INTAKE DUCT HOOD SEAL VENT LINE AIR CLEANER ASSEMBLY GASKET AIR HORN AIR INTAKE SUPPORT AIR INDUCTION HOSE DUST UNLOADER SEAL ELBOW AIR CLEANER ASSEMBLY VENT FITTING ADAPTER TUBE AIR CLEANER SHIELD Figure 3-23: Air Cleaner Assembly and Dust Unloader...
Page 158: Air Cleaner Filter Element Service
___________________________________________ Fuel, Emissions, and Exhaust 3-21 ® Air Cleaner Filter Element Service AIR HORN Removal Removal Loosen clamp and remove air induction hose from air horn 1. Remove ring clamp, cover, and gasket from air cleaner (Figure 3-25). (Figure 3-24). 2.
Page 159: Air Induction Hose Replacement
___________________________________________ 3-22 Fuel, Emissions, and Exhaust ® Air Induction Hose Replacement WEATHERCAP REPLACEMENT Removal Removal Remove clamp and weathercap from air intake duct 1. Loosen induction hose clamps. (Figure 3-27). 2. Remove hose from air horn and air cleaner (Figure 3-26). WEATHERCAP AIR HORN AIR INTAKE...
Page 160: Air Intake Vent Line Replacement
___________________________________________ Fuel, Emissions, and Exhaust 3-23 ® DRAINAGE BRACKET REPLACEMENT AIR INTAKE VENT LINE REPLACEMENT Removal Removal Remove air intake vent line from tee fitting and air cleaner fit- 1. Remove air cleaner assembly. ting (Figures 3-27 and 3-29) 2. Remove three screws and drainage bracket from body (Figure 3-29).
Page 161: Main Fuel Tank
___________________________________________ 3-24 Fuel, Emissions, and Exhaust ® MAIN FUEL TANK STRAP Removal FUEL TANK BRACKET SUPPORT STRAP 1. Drain tank with recommended equipment. 2. Remove bolts attaching fuel filler housing to body. UPPER STRAP Remove vapor canister shield and bracket. Then disconnect tank vent lines, and hoses at branch tee in fuel filler housing.
Page 162: Tank Cleaning
___________________________________________ Fuel, Emissions, and Exhaust 3-25 ® Fuel Level Transmitter/Pump/Vents/ Access Tank Cleaning Plate Replacement In cases where the tank was removed for correction of contam- ination, remove the transmitter, fuel pump, and access plate for The fuel level transmitter, vents, and access plate can all be maximum access.
Page 163 ___________________________________________ 3-26 Fuel, Emissions, and Exhaust ® Main Fuel Tank Installation AUXILIARY FUEL TANK Removal NOTE: If tank was replaced, or if transmitter, pump, fitting, or access plate was replaced, verify that components are properly Drain auxiliary fuel tank. Drain tank with air powered por- seated and secured.
Page 164 ___________________________________________ Fuel, Emissions, and Exhaust 3-27 ® FUEL LEVEL TRANSMITTER TANK ACCESS PLATE GASKET FUEL STRAINER ACCESS PLATE JUMPER GASKET HARNESS ROLLOVER VALVE AUXILIARY FUEL TANK O-RING (8) ACCESS PLATE RETAINER SKID PLATE FRAME MOUNTING BRACKETS Figure 3-35: Auxiliary Fuel Tank Components 5745159...
Page 165 ___________________________________________ 3-28 Fuel, Emissions, and Exhaust ® FUEL LEVEL TRANSMITTER AND TANK ACCESS Apply liquid teflon thread sealant to transmitter mounting screws. PLATE SERVICE Secure gasket and transmitter to access plate using same Removal method as indicated for access plate above. 1.
Page 166: Fuel Tank Vent Line Service
___________________________________________ Fuel, Emissions, and Exhaust 3-29 ® ELBOW FUEL TANK VENT LINE FUEL TANK VENT LINE FUEL LINES VENT LINE FILTER VENT LINE BODY BRACKET Figure 3-38: Fuel Tank Vent Filter Location BRACKETS MAIN OR AUXILIARY TANK FUEL LINE REPLACEMENT (ALL) Removal Figure 3-37: Fuel Tank Vent Line Locations Drain tank with portable, air powered equipment.
Page 167: Fuel Selector Valve
___________________________________________ 3-30 Fuel, Emissions, and Exhaust ® FUEL SELECTOR VALVE The selector valve is used on models equipped with an auxil- Selector Valve Replacement iary fuel tank (Figure 3-39). The valve is electrically operated The valve is accessible from under the vehicle. Disconnect the by a switch in the passenger compartment.
Page 168 ___________________________________________ Fuel, Emissions, and Exhaust 3-31 ® FUEL FILTER SERVICE Installation Install fuel ﬁlter on bracket and secure with washers and Fuel Filter Replacement bolts (Figure 3-40:). Connect sensor and fuel heater harnesses to body harness Removal connectors. 1. Loosen the hose clamps securing the CTIS compressor (if Connect drain hose to fuel filter.
Page 169 ___________________________________________ 3-32 Fuel, Emissions, and Exhaust ® Fuel Filter Drain Hose and Valve Replace- ment NOTE: To remove fuel filter drain valve only, perform steps 3 and 4. Removal 1. Disconnect fuel ﬁlter drain hose from fuel ﬁlter (Figure 3-42). 2.
Page 170 ___________________________________________ Fuel, Emissions, and Exhaust 3-33 ® FUEL LIFT PUMP SERVICE Fuel Tank-To-Filler Neck Hose Replacement Fuel Lift Pump Replacement Removal Removal Drain fuel tank. Remove filler tube housing bolts. 1. Disconnect fuel pump wiring harness (Figure 3-43). Disconnect filler tube vent hose. 2.
Page 171 ___________________________________________ 3-34 Fuel, Emissions, and Exhaust ® Diesel Injection Pump Fuel Hose or Tube Replacement Removal Installation 1. Remove supply hose. Install cap on rear injector nipple (Figure 3-46). 2. Remove return hose from injection pump and tube Install injector connecting hose. (Figure 3-45).
Page 172 ___________________________________________ Fuel, Emissions, and Exhaust 3-35 ® GLOW PLUG SERVICE Glow Plug Tip Removal (Damaged or Broken) 1. Remove fuel injector from necessary cylinder. INJECTOR PORT Using torsional damper bolt (Figure 3-47),rotate crankshaft to bring affected piston to TDC position. 3.
Page 173: Diesel Fuel Injection System
___________________________________________ 3-36 Fuel, Emissions, and Exhaust ® DIESEL FUEL INJECTION SYSTEM Installation Install clamps on lines if removed. Diesel Injection Line Bracket And Clamp Install bracket on valve cover studs (Figure 3-51). Tighten bracket nuts to 13-20 lb-ft (18-27 N•m). Removal 3.
Page 174 ___________________________________________ Fuel, Emissions, and Exhaust 3-37 ® Fuel Injector Replacement INJECTOR LINES INJECTOR Removal GASKET 1. If removing rear injector, remove console and engine cover. Remove fuel return hose and cap from injector (Figure 3-52). 2. Disconnect fuel return hoses from necessary injector (Figure 3-53).
Page 175: Fuel Injection Pump
___________________________________________ 3-38 Fuel, Emissions, and Exhaust ® Installation Service 1. Install clamps on injection lines (Figure 3-54). The turbo diesel electronic injection pump is not serviceable. Only the pump solenoids, sensors, gaskets, and drive gears are 2. Connect injection lines to pump (Figure 3-55). serviceable.
Page 176 ___________________________________________ Fuel, Emissions, and Exhaust 3-39 ® Reprogramming TDC Offset TDC offset must be reprogrammed whenever the PCM, front Correct learned TDC offset value should be between cover, timing gears, timing chain, crankshaft position sensor, minus 0.25 and minus 0.75. If value is not within specified or other components affecting timing are replaced.
Page 177: Sensor And Switch Service
___________________________________________ 3-40 Fuel, Emissions, and Exhaust ® ENGINE TEMPERATURE SENDER GLOW PLUG RELAY/CONTROLLER REPLACEMENT REPLACEMENT 1. Remove nut, lockwasher, lead, and sender from engine Disconnect battery ground cable. (Figure 3-58). Remove console and engine cover. 2. Apply teflon sealant to sender threads, and install sender, Disconnect power cable at relay/controller (Figure 3-59) lead, lockwasher, and nut on engine (Figure 3-58).
Page 178 ___________________________________________ Fuel, Emissions, and Exhaust 3-41 ® FUEL SYSTEM CONTAMINATION A quick check on fuel quality can be performed with tool J–38641–B. Organic Contamination NOTE: The fuel quality hydrometer provides a general indica- Diesel fuel systems are susceptible to fungi and other micro-or- tion of fuel quality and should not be considered to be scientif- ganism infestation when water is present.
Page 179: Muffler Replacement
___________________________________________ 3-42 Fuel, Emissions, and Exhaust ® MUFFLER REPLACEMENT Remove fasteners attaching mufﬂer and gasket to catalytic converter (Figure 3-60). 2. Remove fasteners attaching muffler to tailpipe. Remove fasteners attaching muffler to frame bracket and insulator. 4. Loosen tailpipe and transfer case exhaust pipe brackets. Remove old muffler and install new muffler and gasket.
Page 180 ___________________________________________ Fuel, Emissions, and Exhaust 3-43 ® HEATSHIELD HEATSHIELD INSULATOR CROSSOVER PIPE GASKET CATALYTIC CUSHIONED CONVERTER LOOP ASSEMBLY MUFFLER TRANSFER CASE AND EXHAUST PIPE BRACKETS AND U-BOLT TAILPIPE FRONT TAILPIPE BRACKET CUSHIONED LOOP ASSEMBLY CUSHIONED LOOP ASSEMBLY BRACKET Figure 3-61: Exhaust System 5745159 4-1-00...
Page 181: Crossover Pipe Replacement
___________________________________________ 3-44 Fuel, Emissions, and Exhaust ® CROSSOVER PIPE REPLACEMENT CATALYTIC CONVERTER REPLACEMENT Remove console and engine cover. 1. Loosen or remove necessary frame brackets and clamps that retain converter and pipe (Figures 3-61 and 3-62). Remove passenger side exhaust manifold rear heat shield. 2.
Page 182 ___________________________________________ Fuel, Emissions, and Exhaust 3-45 ® ESSENTIAL TOOLS J–29872-A J–29873 J–29075-AMG J–41089 J–29079-125 J–41516-A J–29698-A J–28552-A J–38641-B J–34151 Tool No. Description J–29075-AMG Fuel Injector Pressure Test Tool J–29872-A Injection Pump Adjusting Tool (used with ratchet handle) J–29873 Fuel Injector Socket (30mm) J–29698-A Injection Line (ﬂare nut) Wrench, 3/4 J–28552-A...
Page 183 ___________________________________________ 3-46 Fuel, Emissions, and Exhaust ® SPECIAL TOOLS J–26925 Tool No. Description J–26925 Mag-Tac Engine Tachometer Procure from Kent-Moore.
Page 184 ________________________________________________________________________________ ® Section 4 Cooling System TABLE OF CONTENTS Engine Cooling System Serpentine Belt Replacement ......4-16 Description .
Page 185 ____________________________________________________________ 4-2 Cooling System ® ENGINE TEMPERATURE SENDING UNIT THERMOSTAT WATER CROSSOVER OIL COOLER TRANSFER CASE OIL COOLER TRANSMISSION OIL RADIATOR COOLER BYPASS VALVE SURGE TANK HEATER Figure 4-2: Cooling System Routing When the thermostat detects the coolant is hot, the thermostat gauge on the instrument panel to let the driver know that the opens allowing coolant to be pumped to the radiator where it is system should be serviced as soon as possible.
Page 186 ___________________________________________________________ Cooling System ® quicker. At high temperatures, fluid viscosity decreases and NOTE : Off-road driving in extremely dusty conditions may more fluid circulates through the cooler maintaining an even result in debris entrapment between the radiator and oil cooler. operating temperature and a constant pressure in the cooler Trapped debris may increase coolant temperature.
Page 187 ____________________________________________________________ 4-4 Cooling System ® RADIATOR AND FAN SHROUD ASSEMBLY Cleaning and Inspection SERVICE NOTE: Clean all components, examine for wear or damage, and replace if necessary. Removal 1. Remove hood (Section 10). Remove debris embedded in radiator ﬁns using water and compressed air (Figure 4-5).
Page 188 ___________________________________________________________ Cooling System ® 5. Attach lower mount and radiator to frame bracket with 10. Connect upper and lower radiator hoses to radiator. washers, and locknut. Do not tighten (Figure 4-5). 11. Use bolts to attach power steering cooler to brackets. 6.
Page 189 ____________________________________________________________ 4-6 Cooling System ® ENGINE COOLING SYSTEM SERVICE Depressurizing/Draining WARNING: To avoid injury, do not remove surge tank ﬁller cap before depressurizing cooling system when engine temperature is above 190°F (88°C). 1. If engine is hot, place a thick cloth over surge tank ﬁller cap.
Page 190: Shroud Shield Assembly Replacement
___________________________________________________________ Cooling System ® SHROUD SHIELD ASSEMBLY REPLACEMENT RADIATOR Removal 1. Remove radiator and fan shroud. INSULATOR 2. Remove screws and shroud shield assembly from airlift bracket (Figure 4-9). SHROUD AIRLIFT BRACKET SHIELD ASSEMBLY REAR SUPPORT BRACKET Figure 4-10: Insulator and Rear Support Bracket Location SURGE TANK REPLACEMENT Removal...
Page 191 ____________________________________________________________ 4-8 Cooling System ® 3. Connect surge tank-to-lower radiator hose to surge tank. 4. Connect radiator vent hose to surge tank. SURGE TANK 5. Connect overflow hose to surge tank. 6. Fill and purge cooling system. VENT HOSE RADIATOR SURGE TANK BRACKET OVERFLOW...
Page 192 ___________________________________________________________ Cooling System ® UPPER RADIATOR HOSE REPLACEMENT LOWER RADIATOR HOSE REPLACEMENT Removal Removal 1. Drain cooling system as necessary. Drain cooling system. 2. Depressurize cooling system. Loosen clamps and remove lower radiator hose from radiator and lower tube assembly (Figure 4-16). 3.
Page 193 __________________________________________________________ 4-10 Cooling System ® RADIATOR LOWER TUBE ASSEMBLY REPLACEMENT Removal Installation 1. Drain cooling system. Secure lower tube assembly to frame bracket with bolts, washers, and locknuts. Tighten locknuts to 6 lb-ft (8 N•m) 2. Remove drain valve from lower tube assembly (Figure 4-17).
Page 194 _________________________________________________________ Cooling System 4-11 ® WATER PUMP INLET HOSE REPLACEMENT SURGE TANK OVERFLOW HOSE REPLACEMENT Removal Removal 1. Drain cooling system. Remove overﬂow hose from surge tank ﬁller neck 2. Loosen clamps and remove water pump inlet hose from (Figure 4-19). water pump and lower tube assembly (Figure 4-18).
Page 195: Low Coolant Sensor
__________________________________________________________ 4-12 Cooling System ® SURGE TANK-TO-LOWER RADIATOR TUBE LOW COOLANT SENSOR HOSE REPLACEMENT The coolant level sensor is a solid-state semi-conductor device. The sensor’s resistance varies as a function of its temperature. Removal As voltage/current flows through the sensor, sensor tempera- 1.
Page 196: Thermostat Replacement
_________________________________________________________ Cooling System 4-13 ® THERMOSTAT REPLACEMENT THERMOSTAT SEATS WATER AND COUNTER BORES CROSSOVER 1. Drain engine coolant below level of water crossover. 2. Remove bolts attaching thermostat cover to crossover housing. 3. Remove thermostat cover and gasket (Figure 4-22). 4.
Page 197 __________________________________________________________ 4-14 Cooling System ® Installation (18-27 N•m). Tighten large studs and large bolt marked B to 25-37 lb-ft (34-50 N•m) (Figure 4-26). 1. If new pump is being installed, transfer hose adapter ﬁt- Attach hoses to water pump. tings to new pump. Apply Loctite PST to ﬁtting threads beforehand.
Page 198 _________________________________________________________ Cooling System 4-15 ® BACKING PLATE COMPRESSOR A/C COMPRESSOR BOLT (4) COMPRESSOR CLUTCH CONNECTOR SEALER BEAD ENCIRCLE THIS BOLT HOLE WITH SEALER Figure 4-28: Backing Plate Sealer Application Figure 4-30: Compressor Clutch Bolt and WATER CROSSOVER SERVICE Connector Location Removal WATER CROSSOVER 1.
Page 199 __________________________________________________________ 4-16 Cooling System ® SERPENTINE BELT REPLACEMENT FAN AND CLUTCH ASSEMBLY SERVICE 1. Insert square lug of half-inch drive breaker bar in belt ten- Removal sioner. Then move tensioner counterclockwise to loosen Insert spanner J–41240-1 in holes in water pump pulley belt (Figure 4-32).
Page 200: Transmission/Transfer Case
The Hydra-matic, model 4L80-E is used for all engine applica- the control module and sensors for fluid temperature and out- tions in Hummer vehicles. The 4L80-E is a four-speed, auto- put shaft speed. Solenoids are used to actuate the shift valves matic transmission with fully electronic shift control.
Page 201 ______________________________________________ 5-2 Transmission/Transfer Case ® REACTION TORQUE PLANETARY CONVERTER OUTPUT PLANETARY OVERDRIVE OIL PUMP PLANETARY FOURTH CLUTCH PARK PAWL ROLLER REAR CLUTCH BAND FRONT INTERMEDIATE BAND CLUTCH OVERRUN OVERDRIVE DIRECT CLUTCH ROLLER FORWARD CLUTCH INTERMEDIATE CLUTCH CLUTCH SPRAG CLUTCH Figure 5-1: Transmission Drive and Apply Elements TRANSMISSION GEAR RANGES The 4L80-E gear ranges consist of: Park, Reverse, Neutral, terrain driving.
Page 202 _____________________________________________ Transmission/Transfer Case ® TRANSMISSION IDENTIFICATION ELECTRONIC SHIFT CONTROL COMPONENTS An I.D. plate is attached to the passenger side of each Hydra- Upshifts and downshifts in overdrive and manual D ranges are matic Transmission (Figure 5-2). The plate contains the model, electronically controlled.
Page 203 ______________________________________________ 5-4 Transmission/Transfer Case ® FLUID TEMPERATURE SENSOR INPUT SPEED SENSOR CONVERTER SHIFT CLUTCH PRESSURE PRESSURE SOLENOIDS SOLENOID CONTROL SWITCH SOLENOID ASSEMBLY Figure 5-3: Transmission Shift Control Components TRANSMISSION FLUID PRESSURE MANUAL VALVE POSITION SWITCH THREE PIN The pressure switch assembly is mounted on the valve body. It CONNECTOR contains five pressure switches in circuit with the PCM LO (1-2)
Page 204 _____________________________________________ Transmission/Transfer Case ® FLUID BODY O-RING CONTACT DIAPHRAGM CONTACT SWITCH GROUND ELEMENT CONTACT BODY O-RING FLUID CONTACT DIAPHRAGM CONTACT SWITCH GROUND ELEMENT CONTACT Figure 5-5: Pressure Switch Actuation Figure 5-6: Hydraulic/Electrical Circuitry for Pressure Switch Assembly (Third Gear Shown) 05745159...
Page 205 ______________________________________________ 5-6 Transmission/Transfer Case ® AUTOMATIC TRANSMISSION INPUT (SHAFT) TRANSMISSION FLUID TEMPERATURE SENSOR SPEED SENSOR AND OUTPUT (SHAFT) SPEED The fluid temperature sensor is mounted on the internal trans- SENSOR (VEHICLE SPEED SENSOR) mission harness. Failure of the sensor constitutes wiring har- ness replacement.
Page 206: Shift Solenoids
_____________________________________________ Transmission/Transfer Case ® SHIFT SOLENOIDS Two solenoids are used to control upshifts and downshifts in CONNECTOR COIL the forward gear ranges. Solenoid A controls the 1-2 shift valve while Solenoid B controls the 2-3 shift valve. Both sole- EXHAUST noids are mounted on the valve body and operated by the PORT PCM.
Page 207 ______________________________________________ 5-8 Transmission/Transfer Case ® TORQUE CONVERTER CLUTCH PULSE WIDTH Torque signal fluid from the solenoid, also affects the torque signal compensator valve in the accumulator, and the accumu- MODULATED SOLENOID lator valve in the valve body. The torque converter clutch (TCC) solenoid is located on the At low throttle openings, the PCM applies a maximum of 1.1 transmission valve body and is energized by the PCM.
Page 208: Engine Sensor Inputs
_____________________________________________ Transmission/Transfer Case ® ENGINE SENSOR INPUTS PRESSURE The electronic accelerator pedal, coolant temperature sensor, REGULATOR A/C switch, brake switch, and crankshaft position sensor, all VALVE affect transmission operation. The electronic accelerator pedal input signals inform the PCM of throttle position. This input affects pressure control solenoid operation and transmission line pressure.
Page 209 _____________________________________________ 5-10 Transmission/Transfer Case ® TURBINE CONVERTER COVER/ IMPELLER CONVERTER PUMP CLUTCH PRESSURE PLATE AND DAMPER STATOR SHAFT ROLLER (PART OF OIL CLUTCH PUMP COVER) TURBINE SHAFT STATOR Figure 5-14: Torque Converter Components...
Page 210 TRANSMISSION SERVICEABILITY Start engine, apply brakes, shift through all gear ranges and back to Park. Run engine at curb idle The Hydra-matic transmission used in Hummer vehicles is ser- speed. viced at two levels. Only external parts are serviced during the Remove dipstick and check fluid level.
Page 211 _____________________________________________ 5-12 Transmission/Transfer Case ® Road Test Road Test Analysis 1. If engine and transmission have cooled down, drive vehi- Shift problems such as harsh, or late shifts, indicate a problem cle 10-12 miles to return to normal operating temperature. with the wiring, a sensor, low fluid level, or a PCM fault.
Page 212 ____________________________________________ Transmission/Transfer Case 5-13 ® Functional Test Procedure Step Action Value(s) Perform the Transmission Fluid Checking Proce- Go to step 2 dure. Fill the reservoir to the suggested level. Is the ﬂuid level correct? Check for PCM trouble codes, both current and Go to the Diag- Go to step 3 history.
Page 213 _____________________________________________ 5-14 Transmission/Transfer Case ® Clutch Application Chart OVER- INTER- OVER- FOR- INTER- SHIFT SHIFT FOURTH DRIVE DIRECT FRONT MEDIATE REAR GEAR WARD MEDIATE ROLLER SOLE- SOLE- CLUTCH ROLLER BAND BAND SPRAG BAND CLUTCH CLUTCH CLUTCH CLUTCH NOID A NOID B CLUTCH CLUTCH Holding...
Page 214: Line Pressure Test
Pressure Control Solenoid Test Fluid Capacity 1. Connect scan tool to diagnostic/data link connector. Fluid capacity of the 4L80-E used in Hummer vehicles is: 2. Connect pressure test gauge to transmission. • Transmission refill capacity (after filter change) is ap- proximately 7.7 qts.
Page 215 _____________________________________________ 5-16 Transmission/Transfer Case ® Fluid Level and Condition Transmission fluid level and condition are important to proper operation. An incorrect fluid level can lead to shift problems, fluid breakdown, and accelerated wear. Check fluid level and condition during the preliminary inspec- FRONT LIFT HANDLE tion procedure.
Page 216 ____________________________________________ Transmission/Transfer Case 5-17 ® Transmission Fluid Checking Procedure Step Action Value(s) Check the ﬂuid color. Go to step 2 Go to step 11 Is the ﬂuid color red? Is the ﬂuid level satisfactory? Go to step 21 Go to step 3 Check the ﬂuid.
Page 217 Figure 5-20: Tech 1 Scan Tool Transmission Warning Lamps All Hummer vehicles are equipped with a malfunction indica- tor light (check engine) and a check throttle light. The purpose of the lights is to alert the driver when a transmission/engine, or electronic accelerator pedal circuit fault has occurred.
Page 218 ____________________________________________ Transmission/Transfer Case 5-19 ® Trouble Code Identification Description DTC Type Default Action P0218 Transmission Fluid Overtemperature The PCM freezes shift adapts. DTC P0218 is stored in PCM history. P0560 Sysem Voltage Malfunction The PCM inhibits TCC engagement. The PCM freezes shift adapts. The PCM turns off the PC Sol.
Page 219 _____________________________________________ 5-20 Transmission/Transfer Case ® Trouble Code Identification Description DTC Type Default Action P0741 Torque Converter Clutch System 1. The PCM illuminates the MIL. Stuck Off 2. The PCM inhibits TCC engagement. 3. The PCM inhibits fourth gear engagement. 4. The PCM commands increased line pressure. 5.
Page 220 ____________________________________________ Transmission/Transfer Case 5-21 ® Trouble Code Identification Description DTC Type Default Action P1860 Torque Converter Clutch Pulse Width The PCM illuminates teh MIL. Modulation Solenoid Circuit Electri- The PCM inhibits TCC engagement. The PCM inhibits fourth gear engagement. The PCM freezes shift adapts. DTC P1860 is stored in PCM history P1870 Transmission Component Slipping...
Page 221 _____________________________________________ 5-22 Transmission/Transfer Case ® Transmission Wiring Diagrams HOT AT HOT IN RUN HOT IN RUN ALL TIMES AND START AND START FUSE 2D FUSE 3A FUSE 4B 20 AMP 20 AMP 5 AMP INTERIOR EXTERIOR INTERIOR C10-J C1-10 STATUS CENTER LAMP LAMP...
Page 222 ____________________________________________ Transmission/Transfer Case 5-23 ® FUSE 2D FUSE 3A FUSE 4D FUSE 6B 20 AMP 20 AMP 15 AMP 5 AMP INTERIOR EXTERIOR INTERIOR INTERIOR BRAKE TCC/ LAMP CRUISE TO BRAKE LAMP C28-D13 C28-C13 C28-C12 C28-C11 C29-B10 C29-B9 BATTERY IGNITION BRAKE LIGHT TCC / CRUISE POSITIVE...
Page 223 _____________________________________________ 5-24 Transmission/Transfer Case ® POWERTRAIN ACCELERATIOR CONTROL PEDAL POSITION MODULE SENSOR (PCM) 722 PP C29-A12 GROUND 721 LB C27-C5 APP 2 SIGNAL 719 BR C29-B1 GROUND 718 DB C29-B2 APP 1 SIGNAL 725 GY C27-D6 GROUND 724 DG C27-D4 APP 3 SIGNAL 723 YL...
Page 224 ____________________________________________ Transmission/Transfer Case 5-25 ® HOT IN RUN AND START FUSE 2A EXTERIOR C33-F C34-E TRANSMISSION FLUID TORQUE TEMPERATURE CONVERTER PRESSURE SENSOR CLUTCH 1-2 SHIFT CONTROL (TFT) SOLENOID SOLENOID SOLENOID (TCC) (1-2) (PCS) 2-3 SHIFT SOLENOID (2-3) C32-F C32-E C32-D C32-C C32-J C32-H...
Page 225 _____________________________________________ 5-26 Transmission/Transfer Case ® HOT IN RUN AND START SPEEDO W / TRIP FUSE EXTERIOR POWERTRAIN CONTROL A/T OUTPUT BUFFERED MODULE SPEED SENSOR C3-P9 (PCM) SIGNAL (VSS) SIGNAL C29-A3 C29-A6 VEHICLE SPEED SENSOR (VSS) TWISTED PAIR C1-18 570 BK GROUND IGNITION VEHICLE SPEED...
Page 226 ____________________________________________ Transmission/Transfer Case 5-27 ® Automatic Transmission Fluid Auto Trans Input Shaft Pressure Manual Valve Speed Sensor Position Switch A/T ISS Switch (TFP) Switch Switch Switch Switch C32-H C32-S C32-K Tw i s t e d C32-A P a i r C27-D1 C27-D11 C29-B6...
Page 227 _____________________________________________ 5-28 Transmission/Transfer Case ® Connector Legend 76 WAY BULKHEAD LOCATION: LEFT SIDE FIREWALL PIN 1 PIN 12 PIN 13 PIN 26 PIN 27 PIN 38 PIN39 PIN 50 PIN 51 PIN 64 PIN 65 PIN 76 C1 MALE 9-S12-048 CAV 12 CAV 1 CAV 26...
Page 228 ____________________________________________ Transmission/Transfer Case 5-29 ® COLOR CIRCUIT DESCRIPTION Ignition relay feed Rear window defrost feed APP 3 5volt reference APP 3 signal + From dimmer module APP 1 signal Speedometer signal ABS module diagnostic line APP 1 5-volt reference TT4 lamp activation APP 2 5-volt reference IGN+ CTIS warning circuits CTIS rear inﬂate solenoid activation...
Page 229 _____________________________________________ 5-30 Transmission/Transfer Case ® COLOR CIRCUIT DESCRIPTION Water-in-fuel lamp activation Underhood lamp power Left front turn signal PCM class 2 communication line to DLC Tachometer signal Low washer ﬂuid level lamp activation Headlight switch feed ABS lamp activation APP 1 ground Low coolant lamp activation Low air warning lamp activation Brake ﬂuid level sensor feed...
Page 230 ____________________________________________ Transmission/Transfer Case 5-31 ® 56 WAY INSTRUMENT PANEL LOCATION: BEHIND INSTRUMENT PANEL PIN H6 PIN A1 C3 MALE 9-S12-050 CAV A1 CAV H6 C3 FEMALE 9-S12-049 COLOR DESCRIPTION Headlight switch feed Dome lamp switch feed Dome lamps feed Rear wiper relay activation (not used 99) Headlamp switch feed Headlamp feed to dimmer module CTIS switch ignition feed...
Page 231 _____________________________________________ 5-32 Transmission/Transfer Case ® COLOR DESCRIPTION Right turn indicator lamp activation TT4 indicator lamp activation Brake indicator lamp activation ABS indicator lamp activation Low washer ﬂuid activation Rear Wiper feed (not used 99) High Beam indicator lamp activation Left turn indicator lamp activation Check engine lamp activation Drain Filter lamp activation Power mirror switch battery feed...
Page 232 ____________________________________________ Transmission/Transfer Case 5-33 ® COLOR DESCRIPTION Ignition feed to guages Windshield wiper washer pump activation Intermittent wiper relay activation Rear cargo lamp activation Fuel guage signal Engine temperature guage signal Speedometer signal Ground 05745159...
Page 233 _____________________________________________ 5-34 Transmission/Transfer Case ® 8 WAY STATUS CENTER-LH LOCATION: INSTRUMENT PANEL 9-S12-018 9-S12-017 C10 FEMALE C10 MALE COLOR DESCRIPTION Headlamp high beam Left turn lamp Check engine lamp Drain ﬁlter lamp ABS lamp Seat belt lamp CTIS pump lamp Check throttle lamp Ignition feed Ground...
Page 234 ____________________________________________ Transmission/Transfer Case 5-35 ® 32WAY PCM-BROWN LOCATION: CENTER CONSOLE, PCM 9-S12-042 C27 MALE COLOR DESCRIPTION Crankshaft position sensor ground – A/C request+ Intake air temp sensor signal APP sensor (2) signal Glow plug enable + Pressure Control Solenoid (Hi) Fuel temperature signal Transmission ﬂuid temp signal Engine coolant temp signal...
Page 235 _____________________________________________ 5-36 Transmission/Transfer Case ® COLOR DESCRIPTION Optical sensor ground – Cruise control resume/accelerate Transmission input speed signal (hi) APP (1) 5 volt ref. Boost sensor/crankshaft position sensor 5 volt ref. Optical sensor 5 volt reference...
Page 236 ____________________________________________ Transmission/Transfer Case 5-37 ® 32 WAY PCM-BLUE LOCATION: CENTER CONSOLE, PCM 9-S12-042 C28 MALE COLOR DESCRIPTION APP (2) 5 volt ref. Fuel inject signal 1-2 shift solenoid control Torque converter clutch soleniod control 2-3 shift solenoid control A/C clutch control ? Class 2 communications (DLC) Ignition / axle switch jumper Ignition...
Page 237 _____________________________________________ 5-38 Transmission/Transfer Case ® COLOR DESCRIPTION Check throttle lamp control Battery Waste gate solenoid control...
Page 238 ____________________________________________ Transmission/Transfer Case 5-39 ® 24 WAY PCM-BROWN LOCATION: CENTER CONSOLE, PCM C29 MALE 9-S12-028 COLOR DESCRIPTION Closure ground High resolution sensor signal Transmission output speed sensor/VSS Cam sensor signal Crankshaft position sensor signal Vehicle speed sensor Injection timing stepper motor (HI) Injection timing stepper motor (LO) Injection timing stepper motor (LO) Injection timing stepper motor (HI)
Page 239 _____________________________________________ 5-40 Transmission/Transfer Case ® 10 WAY TRANSMISSION-GREY LOCATION: A BEAM, LEFT NEAR LIFT PUMP 9-S12-023 9-S12-024 C32 MALE C32 FEMALE COLOR CIRCUIT DESCRIPTION Transmission Input Speed Sensor low Transmission Input Speed Sensor high 1-2 shift solenoid control 2-3 shift solenoid control Torque Converter Clutch solenoid activation Pressure Control Solenoid high Pressure Control Solenoid low...
Page 240 ____________________________________________ Transmission/Transfer Case 5-41 ® 10 WAY TRANSMISSION-BLACK LOCATION: A BEAM, LEFT NEAR LIFT PUMP 9-S12-023 9-S12-024 C33 MALE C33 FEMALE COLOR CIRCUIT DESCRIPTION Vehicle Speed Sensor high Vehicle Speed Sensor low Transfer case lock switch light activation Transmission ignition feed Transmission Fluid Temperature signal Transmission Fluid Temperature sensor ground Transfer case range switch signal...
Page 241 _____________________________________________ 5-42 Transmission/Transfer Case ® 20 WAY TRANSMISSION PASSTHROUGH LOCATION: TRANSMISSION, LEFT 9-S12-022 C34 FEMALE COLOR CIRCUIT DESCRIPTION 1-2 Shift Solenoid activation 2-3 Shift Solenoid activation Pressure Control Solenoid high Pressure Control Solenoid low Transmission ignition feed Transmission Fluid Temperature signal Transmission Fluid Temperature sensor ground Transmission ﬂuid pressure manual vavle position switch range “A”...
Page 242 ____________________________________________ Transmission/Transfer Case 5-43 ® NOTE: Some corrections indicated in the table below may not be allowed on vehicles covered under the provisions of the war- ranty policy. The proper correction may be transmission replacement. Contact the AMG warranty department for direction in such cases.
Page 243 _____________________________________________ 5-44 Transmission/Transfer Case ® TRANSMISSION DIAGNOSIS GUIDE (Cont’d) Problem Potential Cause Correction Vehicle Creeps Manual valve mispositioned or stuck. 1. Remove valve body and repair as needed. In Neutral Forward clutch fault. 2. Replace transmission. Vehicle Moves Manual linkage loose, damaged, misadjusted, 1.
Page 244 ____________________________________________ Transmission/Transfer Case 5-45 ® TRANSMISSION DIAGNOSIS GUIDE (Cont’d) Problem Potential Cause Correction 6. Overdrive roller clutch failure. Replace transmission. 7. Valve body fault: Remove and free-up binding valves. Replace switch assembly if failed. Replace trans- • manual valve stuck, damaged mission if valve body bores are damaged.
Page 245 _____________________________________________ 5-46 Transmission/Transfer Case ® TRANSMISSION DIAGNOSIS GUIDE (Cont’d) Problem Potential Cause Correction Intermediate clutch air bleed cup plug leaking 3. Replace transmission. or missing. Overrun clutch fault. 4. Replace transmission. Forward clutch fault. 5. Replace transmission. Intermediate clutch fault. 6.
Page 246 ____________________________________________ Transmission/Transfer Case 5-47 ® TRANSMISSION DIAGNOSIS GUIDE (Cont’d) Problem Potential Cause Correction No Torque 1. Worn or damaged intermediate sprag clutch. Replace transmission. (Drive) In Sec- No Overrun 1. Rear band or servo fault. Replace transmission. Braking In: 2. Main or output shaft damage. Replace transmission.
Page 247 _____________________________________________ 5-48 Transmission/Transfer Case ® TRANSMISSION DIAGNOSIS GUIDE (Cont’d) Problem Potential Cause Correction Converter Incorrect sensor input signal to PCM caused 1. Test operation of all sensors with scan tool. by inoperative sensor. Replace failed sensors as needed. Clutch Apply PCM problem.
Page 248 ____________________________________________ Transmission/Transfer Case 5-49 ® DTC P0218 Transmission Fluid Over temperature Circuit Description Test Description The numbers below refer to the step numbers on the diagnostic The flow of transmission fluid starts in the transmission pan. It is then drawn through the filter and transmission case into the table.
Page 249 _____________________________________________ 5-50 Transmission/Transfer Case ® DTC P0218 Transmission Fluid Overtemperature Step Action Value(s) Was the Powertrain On-Board Diagnostic (OBD) Go to step 2 Go to Power- System Check performed? train OBD Sys- tem Check Install the scan tool. Go to step 3 Go to transmis- WIth the engine off, turn the ignition switch to the sion ﬂuid check-...
Page 250 ____________________________________________ Transmission/Transfer Case 5-51 ® DTC P0560 System Voltage Fault HOT AT HOT IN RUN HOT IN RUN ALL TIMES AND START AND START FUSE 2D FUSE 3A FUSE 4B 20 AMP 20 AMP 5 AMP INTERIOR EXTERIOR INTERIOR C10-J C1-10 STATUS CENTER...
Page 251 _____________________________________________ 5-52 Transmission/Transfer Case ® DTC P0560 System Voltage Fault Step Action Value Connect scan tool. Turn the ignition switch to “on” position. Important: Before clearing DTC(s), use the scan tool to record “Failure Records” for reference, as data will be lost when the “Clear Info”...
Page 252 ____________________________________________ Transmission/Transfer Case 5-53 ® DTC P0711 Transmission Fluid Temperature Sensor Circuit Range/Performance HOT IN RUN AND START FUSE 2A EXTERIOR C33-F C34-E TRANSMISSION FLUID TORQUE TEMPERATURE CONVERTER PRESSURE SENSOR CLUTCH 1-2 SHIFT CONTROL (TFT) SOLENOID SOLENOID SOLENOID (TCC) (1-2) (PCS) 2-3 SHIFT SOLENOID...
Page 253 _____________________________________________ 5-54 Transmission/Transfer Case ® Conditions For Setting The DTC Test Description • No DTCs P1117 or P1118. • The numbers below refer to the step numbers on the di- agnostic chart. • No OSS sensor DTC P0502. 2. This step tests for proper A/T fluid level and condition. •...
Page 254 ____________________________________________ Transmission/Transfer Case 5-55 ® DTC P0711 Transmission Fluid Temperature Sensor Circuit Range/Performance Step Action Value Was the Powertrain ON-Board Diagnostic (OBD) System Go to Powertrain OBD — Check performed? Go to Step 2 System Check Perform the A/T Fluid Checking Procedure. Go to Transmission Did you perform the ﬂuid checking procedure? —...
Page 255 _____________________________________________ 5-56 Transmission/Transfer Case ® DTC P0711 Transmission Fluid Temperature Sensor Circuit Range/Performance (Cont’d) Step Action Value In order to verify your repair, perform the following proce- dure: 1. Select DTC. 2. Select Clear Info. 3. Operate the vehicle under the following conditions: •...
Page 256 ____________________________________________ Transmission/Transfer Case 5-57 ® DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit - Low Input (High Temperature Indicated) HOT IN RUN AND START FUSE 2A EXTERIOR C33-F C34-E TRANSMISSION FLUID TORQUE TEMPERATURE CONVERTER PRESSURE SENSOR CLUTCH 1-2 SHIFT CONTROL (TFT) SOLENOID SOLENOID...
Page 257 _____________________________________________ 5-58 Transmission/Transfer Case ® Diagnostic Aids • With a transmission fluid overtemperature DTC P1812 also set, check the transmission cooling system. • Check harness routing for a potential short to ground in circuit. Scan tool TFT display should rise steadily to about 100°...
Page 258 ____________________________________________ Transmission/Transfer Case 5-59 ® DTC P0712 Fluid Temperature Circuit Low/High Step Action Value Perform transmission ﬂuid checking procedure. Go to Step — Was the ﬂuid checking Procedure performed? — 1. Install the scan tool. Turn the ignition switch to “on” position. Important: Before clearing DTC(s), use the scan tool to record “Freeze Frame”...
Page 259 _____________________________________________ 5-60 Transmission/Transfer Case ® DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit - High Input (Low Tem- perature Indicated) HOT IN RUN AND START FUSE 2A EXTERIOR C33-F C34-E TRANSMISSION FLUID TORQUE TEMPERATURE CONVERTER PRESSURE SENSOR CLUTCH 1-2 SHIFT CONTROL (TFT) SOLENOID...
Page 260 ____________________________________________ Transmission/Transfer Case 5-61 ® Diagnostic Aids • Check harness for a faulty connection or an open in cir- cuit. • Inspect wiring for poor electrical connections at the PCM and at the transmission 20-way connector. Look for possible bent, backed out, deformed or damaged ter- minals.
Page 261 _____________________________________________ 5-62 Transmission/Transfer Case ® DTC P0713 Fluid Temperature Low Step Action Value Perform the transmission ﬂuid checking procedure. — Was the ﬂuid checking Procedure performed? Go to Step 2 — Install the scan tool. With the engine “off,” turn the ignition switch “on.”...
Page 262 ____________________________________________ Transmission/Transfer Case 5-63 ® DTC P0713 Fluid Temperature Low (Cont’d) Step Action Value Replace PCM. Is the replacement complete? Go to Step 12 After the repair is complete, use the scan tool to select “DTC,” then “Clear Info” function. Select “Speciﬁc DTC”...
Page 263 _____________________________________________ 5-64 Transmission/Transfer Case ® DTC P0716 Input Speed Sensor Circuit - Range/Performance Automatic Transmission Fluid Auto Trans Input Shaft Pressure Manual Valve Speed Sensor Position Switch A/T ISS Switch (TFP) Switch Switch Switch Switch C32-S C32-H C32-K Tw i s t e d P a i r C32-A C27-D1...
Page 264 ____________________________________________ Transmission/Transfer Case 5-65 ® DTC P0716 Input Speed Sensor Range/Performance Step Action Value Connect scan tool. NOTE: Important: Before clearing DTC(s) use the scan tool to record “Freeze Frame” and “Failure Records” for reference, as data will be lost when the —...
Page 265 _____________________________________________ 5-66 Transmission/Transfer Case ® DTC P0717 Input Speed Sensor Circuit - No Signal Automatic Transmission Fluid Auto Trans Input Shaft Pressure Manual Valve Speed Sensor Position Switch Switch A/T ISS (TFP) Switch Switch Switch Switch C32-S C32-H C32-K Tw i s t e d P a i r C32-A C27-D1...
Page 266 ____________________________________________ Transmission/Transfer Case 5-67 ® DTC P0719 Brake Switch Circuit - Low Input, Stuck “ON” FUSE 2D FUSE 3A FUSE 4D FUSE 6B 20 AMP 20 AMP 15 AMP 5 AMP INTERIOR EXTERIOR INTERIOR INTERIOR BRAKE TCC/ LAMP CRUISE TO BRAKE LAMP C28-D13 C28-C13...
Page 267 _____________________________________________ 5-68 Transmission/Transfer Case ® Diagnostic Aids • Inspect the wiring for poor electrical connections at the PCM and brake switch. Look for damaged terminals, check for weak terminal tension, inspect for broken wire. • When diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change.
Page 268 ____________________________________________ Transmission/Transfer Case 5-69 ® DTC P0722 Output Speed Sensor Low Input HOT IN RUN AND START SPEEDO FUSE EXTERIOR POWERTRAIN CONTROL A/T OUTPUT BUFFERED MODULE SPEED SENSOR C3-P9 (PCM) SIGNAL (VSS) SIGNAL C29-A3 C29-A6 VEHICLE SPEED SENSOR (VSS) TWISTED PAIR C1-18 570 BK...
Page 269 _____________________________________________ 5-70 Transmission/Transfer Case ® Conditions for Clearing the DTC • When diagnosing for an intermittent short or open, mas- sage the wiring harness while watching the test equipment 1. The PCM turns OFF the MIL after three consecutive igni- for a change.
Page 270 ____________________________________________ Transmission/Transfer Case 5-71 ® DTC P0722 Output Speed Sensor Low Input (Cont’d) Step Action Value Turn the ignition OFF. Greater than 0.5 volts at Disconnect the OSS Sensor connector from the above 10 mph. OSS Sensor. Connect a J– 39200 DVOM on AC Voltage scale between terminals A and B at the OSS Sensor.
Page 271 _____________________________________________ 5-72 Transmission/Transfer Case ® DTC P0722 Output Speed Sensor Low Input (Cont’d) Step Action Value With the connector off of the VSS Buffer Module and 4.8-5.2 volts the key to the ON position, measure the voltage between terminal 13 of the VSS Buffer Harness Connector and a good ground.
Page 272 ____________________________________________ Transmission/Transfer Case 5-73 ® DTC P0723 Output Speed Sensor Intermittent HOT IN RUN AND START SPEEDO FUSE EXTERIOR POWERTRAIN CONTROL A/T OUTPUT BUFFERED MODULE SPEED SENSOR C3-P9 (PCM) SIGNAL (VSS) SIGNAL C29-A3 C29-A6 VEHICLE SPEED SENSOR (VSS) TWISTED PAIR C1-18 570 BK GROUND...
Page 273 _____________________________________________ 5-74 Transmission/Transfer Case ® Conditions for Clearing the DTC • It may be necessary to drive the vehicle. • When diagnosing for an intermittent short or open, mas- 1. The PCM tuns OFF the MIL after three consecutive igni- sage the wiring harness while watching the test equipment tion cycles without a failure reported.
Page 274 ____________________________________________ Transmission/Transfer Case 5-75 ® DTC P0723 Output Speed Sensor Intermittent (Cont’d) Step Action Value Turn the ignition OFF. Disconnect the OSS Sensor connector from the OSS Sensor. Connect a J– 39200 DVOM (covered in Electrical Section 12) on AC Voltage scale between terminals A and B at the OSS Sensor.
Page 275 _____________________________________________ 5-76 Transmission/Transfer Case ® DTC P0723 Output Speed Sensor Intermittent (Cont’d) Step Action Value With the engine OFF, turn the ignition to the RUN position. 4.8-5.2 volts Using the J– 39200 DVOM, measure the voltage at the VSS Buffer Harness connector terminal 13. Is the voltage steady and within the speciﬁed voltage? Go to Step 13 Go to Step 14...
Page 276 ____________________________________________ Transmission/Transfer Case 5-77 ® DTC P0723 Output Speed Sensor Intermittent (Cont’d) Step Action Value In order to verify your repair, perform the fol- lowing procedure: Select DTC. Select Clear Info. Operate the vehicle under the following conditions: — • Drive the vehicle in D3. •...
Page 277 _____________________________________________ 5-78 Transmission/Transfer Case ® DTC P0724 Brake Switch Circuit High Input HOT AT HOT IN RUN HOT IN RUN ALL TIMES AND START AND START HVAC CONTROL MODULE FUSE 2C REQUEST 10 AMP SIGNAL INTERIOR FUSE 4D FUSE 6B 15 AMP 5 AMP C6-J8...
Page 278 ____________________________________________ Transmission/Transfer Case 5-79 ® DTC P0724 Brake Switch Circuit High Input Step Action Value Install scan tool. — Turn ignition switch “on.” NOTE: Important: Before clearing DTC(s), use the scan tool to record “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. Record the DTC “Failure Records.”...
Page 279 _____________________________________________ 5-80 Transmission/Transfer Case ® DTC P0730 Incorrect Gear Ratio Interm. Fourth Overrun Direct Front Interm Rear Range Gear 1-2 Sol 2-3 Sol Roller Sprag Roller Clutch Clutch Clutch Clutch Band Clutch Band Clutch Clutch Clutch – – – – –...
Page 280 ____________________________________________ Transmission/Transfer Case 5-81 ® DTC P0730 Incorrect Gear Ratio Step Action Value Was the Powertrain On-Board Diagnostic (OBD) Sys- Go to Power- tem Check performed? – train OBD Go to Step 2 System Check Perform the Transmission Fluid Checking Procedure. Go to Trans- Refer to Transmission Fluid Checking Procedure.
Page 281 _____________________________________________ 5-82 Transmission/Transfer Case ® DTC P0730 Incorrect Gear Ratio (Cont’d) Step Action Value Is the system line pressure low only in the speciﬁc gear – Go to System which indicated an incorrect gear ratio? Diagnosis Table; Low Line Pressure Go to Step 9 Inspect for ﬂuid pressure loss in the following areas: –...
Page 282 ____________________________________________ Transmission/Transfer Case 5-83 ® DTC P0741 Torque Converter Clutch Solenoid Stuck OFF HOT IN RUN AND START FUSE 2A EXTERIOR C33-F C34-E TRANSMISSION FLUID TORQUE TEMPERATURE CONVERTER PRESSURE SENSOR CLUTCH 1-2 SHIFT CONTROL (TFT) SOLENOID SOLENOID SOLENOID (TCC) (1-2) (PCS) 2-3 SHIFT SOLENOID...
Page 283 _____________________________________________ 5-84 Transmission/Transfer Case ® Circuit Description Diagnostic Aids The PCM energizes the converter clutch solenoid by creating a • Inspect the wiring for poor electrical at the PCM and the ground path on CKT 924. When grounded (energized) by the transmission 20-way connector.
Page 284 ____________________________________________ Transmission/Transfer Case 5-85 ® DTC P0742 Torque Converter Clutch Stuck On HOT IN RUN AND START FUSE 2A EXTERIOR C33-F C34-E TRANSMISSION FLUID TORQUE TEMPERATURE CONVERTER PRESSURE SENSOR CLUTCH 1-2 SHIFT CONTROL (TFT) SOLENOID SOLENOID SOLENOID (TCC) (1-2) (PCS) 2-3 SHIFT SOLENOID (2-3)
Page 285 _____________________________________________ 5-86 Transmission/Transfer Case ® Circuit Description Diagnostic Aids The PCM energizes the converter clutch solenoid by creating a • If the converter clutch is seized with the parking brake ground path on circuit 924. When grounded (energized) by the applied and any gear range selected, the clutch fluid PCM, the solenoid stops converter signal oil from exhausting.
Page 286 ____________________________________________ Transmission/Transfer Case 5-87 ® DTC P0742 Torque Converter Clutch Stuck On Step Action Value Connect scan tool. Turn the ignition switch to on. Record the DTC “Freeze Frame” and Failure Records.” 0.6 - 5.0 volts Using the scan tool, verify the “TP Sensor” opera- tion.
Page 287 _____________________________________________ 5-88 Transmission/Transfer Case ® DTC P0748 Pressure Control Solenoid (PCS) - Electrical HOT IN RUN AND START FUSE 2A EXTERIOR C33-F C34-E TRANSMISSION FLUID TORQUE TEMPERATURE CONVERTER PRESSURE SENSOR CLUTCH 1-2 SHIFT CONTROL (TFT) SOLENOID SOLENOID SOLENOID (TCC) (1-2) (PCS) 2-3 SHIFT SOLENOID...
Page 288 ____________________________________________ Transmission/Transfer Case 5-89 ® Diagnostic Aids • Inspect the wiring for poor electrical connections at the PCM and at the transmission 20-way connector. Look for possible bent, backed out, deformed or damaged ter- minals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring.
Page 289 _____________________________________________ 5-90 Transmission/Transfer Case ® DTC P0748 Pressure Control Solenoid - Electrical Step Action Value Connect scan tool. Turn the ignition switch to on. NOTE: Important: Before clearing DTC(s), use the scan tool to record “Failure Records” for reference, as data will be lost when the “Clear Info”...
Page 290 ____________________________________________ Transmission/Transfer Case 5-91 ® DTC P0751 1-2 Shift Solenoid Valve Performance HOT IN RUN AND START FUSE 2A EXTERIOR C33-F C34-E TRANSMISSION FLUID TORQUE TEMPERATURE CONVERTER PRESSURE SENSOR CLUTCH 1-2 SHIFT CONTROL (TFT) SOLENOID SOLENOID SOLENOID (TCC) (1-2) (PCS) 2-3 SHIFT SOLENOID (2-3)
Page 291 _____________________________________________ 5-92 Transmission/Transfer Case ® Stuck Off: (after two occurrences) Diagnostic Aids • Verify that the transmission meets the specifications in • Ist gear is commanded and the ratio is equal to 2nd gear the 4L80-E shift speed chart. for greater than 1.7 seconds. •...
Page 292 ____________________________________________ Transmission/Transfer Case 5-93 ® DTC P0753 1-2 Shift Solenoid Valve Electrical HOT IN RUN AND START FUSE 2A EXTERIOR C33-F C34-E TRANSMISSION FLUID TORQUE TEMPERATURE CONVERTER PRESSURE SENSOR CLUTCH 1-2 SHIFT CONTROL (TFT) SOLENOID SOLENOID SOLENOID (TCC) (1-2) (PCS) 2-3 SHIFT SOLENOID (2-3)
Page 293 _____________________________________________ 5-94 Transmission/Transfer Case ® Diagnostic Aids • Inspect the wiring for poor electrical connections at the 4L80-E CHART PCM and at the transmission 20-way connector. Look 1-2 Shift 2-3 Shift for possible bent, backed out, deformed or damaged ter- Gear Solenoid Solenoid...
Page 294 ____________________________________________ Transmission/Transfer Case 5-95 ® DTC P0753 1-2 Shift Solenoid Valve Electrical (Cont’d) Step Action Value Turn the ignition “off” long enough to power down — Go to step 6. Go to step 5. PCM. Disconnect the transmission 20-way connector (additional DTCs will set).
Page 295 _____________________________________________ 5-96 Transmission/Transfer Case ® DTC P0753 1-2 Shift Solenoid Valve Electrical (Cont’d) Step Action Value 250K Ω Disconnect the internal wiring harness from 1-2 Go to step 13. Go to step 14. shift solenoid. Using multimeter measure the resistance from solenoid terminals to ground.
Page 296 ____________________________________________ Transmission/Transfer Case 5-97 ® DTC P0756 2-3 Shift Solenoid Valve Performance HOT IN RUN AND START FUSE 2A EXTERIOR C33-F C34-E TRANSMISSION FLUID TORQUE TEMPERATURE CONVERTER PRESSURE SENSOR CLUTCH 1-2 SHIFT CONTROL (TFT) SOLENOID SOLENOID SOLENOID (TCC) (1-2) (PCS) 2-3 SHIFT SOLENOID (2-3)
Page 297 _____________________________________________ 5-98 Transmission/Transfer Case ® Stuck On: • Commanded Gear equals 1st and ratio equals 3rd for 4L80-E CHART greater than 2 seconds (Actual gear equals 4th). 1-2 Shift 2-3 Shift Gear • Commanded Gear equals 2nd and ratio equals 3rd for Solenoid Solenoid greater than 2 seconds.
Page 298 ____________________________________________ Transmission/Transfer Case 5-99 ® DTC P0756 2-3 Shift Solenoid Valve Performance Step Action Value Connect scan tool. Turn the ignition switch on. Record “Freeze Frame” and “Failure Records.” Go to Pres- — Start engine, apply brake pedal and shift into D1, D2, D3, sure Switch D4, N, R, and P.
Page 299 ___________________________________________ 5-100 Transmission/Transfer Case ® DTC P0758, 2-3 Shift Solenoid Electrical HOT IN RUN AND START FUSE 2A EXTERIOR C33-F C34-E TRANSMISSION FLUID TORQUE TEMPERATURE CONVERTER PRESSURE SENSOR CLUTCH 1-2 SHIFT CONTROL (TFT) SOLENOID SOLENOID SOLENOID (TCC) (1-2) (PCS) 2-3 SHIFT SOLENOID (2-3) C32-F...
Page 300 ___________________________________________ Transmission/Transfer Case 5-101 ® Diagnostic Aids • Inspect the wiring for poor electrical connections at the 4L80-E CHART PCM and at the transmission 20-way connector. Look 1-2 Shift 2-3 Shift for possible bent, backed out, deformed or damaged ter- Gear Solenoid Solenoid...
Page 301 ___________________________________________ 5-102 Transmission/Transfer Case ® DTC P0758 2-3 Shift Solenoid B Electrical (Cont’d) Step Action Value Turn ignition “Off”. Go to step 6. Go to step 5. Disconnect transmission 20-way connector (addi- tional DTCs will set). Connect 05743837 Jumper Harness to engine har- ness connector.
Page 302 ___________________________________________ Transmission/Transfer Case 5-103 ® DTC P0758 2-3 Shift Solenoid B Electrical (Cont’d) Step Action Value Replace the 2-3 shift solenoid valve. — Go to step 15 — Is replacement complete? Preform the following procedure in order to verify the —...
Page 303 ___________________________________________ 5-104 Transmission/Transfer Case ® DTC P1810 Pressure Switch Assembly (PSA) Fault Automatic Transmission Fluid Auto Trans Input Shaft Pressure Manual Valve Speed Sensor Position Switch A/T ISS Switch (TFP) Switch Switch Switch Switch C32-S C32-H C32-K Tw i s t e d C32-A P a i r C27-D1...
Page 304 ___________________________________________ Transmission/Transfer Case 5-105 ® Condition 3: check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insula- • No DTCs P0121, P0122, P0123, P0220, P0221, P0222, tion. P0223, P0225, P0226, P0227 or P0228. •...
Page 305 ___________________________________________ 5-106 Transmission/Transfer Case ® DTC P1810 Pressure Switch Circuit Fault Step Action Value Perform following check: • Transmission linkage (from select lever to the manual valve) is properly adjusted. — • Fluid check. Were checks performed? Go to Step 2 —...
Page 306 ___________________________________________ Transmission/Transfer Case 5-107 ® DTC P1810 Pressure Switch Circuit Fault (Cont’d) Step Action Value After the repair is complete, use the scan tool to select “DTC,” then “Clear in fold function. Select “Speciﬁc DTC” and enter DTC “P1810.” Operate the vehicle under the following condi- tions: —...
Page 307 ___________________________________________ 5-108 Transmission/Transfer Case ® DTC P1811 Maximum Adapt and Long Shift HOT IN RUN AND START FUSE 2A EXTERIOR C33-F C34-E TRANSMISSION FLUID TORQUE TEMPERATURE CONVERTER PRESSURE SENSOR CLUTCH 1-2 SHIFT CONTROL (TFT) SOLENOID SOLENOID SOLENOID (TCC) (1-2) (PCS) 2-3 SHIFT SOLENOID (2-3)
Page 308 ___________________________________________ Transmission/Transfer Case 5-109 ® Conditions For Clearing DTC • The DTC can be cleared using the scan tool. The DTC will be cleared from history when the vehicle has achieved 40 warm-up cycles without reported failure. • PCM will cancel DTC default actions when the fault no longer exists and ignition is cycled “Off”...
Page 309 ___________________________________________ 5-110 Transmission/Transfer Case ® DTC P1811 Maximum Adapt and Long Shift Step Action Value Was the Powertrain ON-Board Diagnostic (OBD) Go to OBD System Check performed? — Go to Powertrain Step 2 System Check. Have you performed the transmission ﬂuid checking procedure? Go to Transmis- —...
Page 310 ___________________________________________ Transmission/Transfer Case 5-111 ® DTC P1811 Maximum Adapt and Long Shift (Cont’d) Step Action Value Did the 2-3 shift time exceed the speciﬁed value? Go to 1.25 seconds Step 13 Go to Step 11 Did the 1-2 shift time exceed the speciﬁed value? Go to 1.25 seconds Step 14...
Page 311 ___________________________________________ 5-112 Transmission/Transfer Case ® DTC P1860 Torque Converter Clutch Pulse Width Modulation Solenoid Electrical HOT IN RUN AND START FUSE 2A EXTERIOR C33-F C34-E TRANSMISSION FLUID TORQUE TEMPERATURE CONVERTER PRESSURE SENSOR CLUTCH 1-2 SHIFT CONTROL (TFT) SOLENOID SOLENOID SOLENOID (TCC) (1-2) (PCS)
Page 312 Section 5 Transmission/Trans er Case ___________________________________________ Transmission/Transfer Case 5-113 ® Conditions For Clearing DTC 1. The PCM turns OFF the MIL after three consecutive igni- tion cycles without a failure reported. 2. A scan tool can clear the DTC from the PCM history. The PCM clears the DTC from the PCM history if the vehicle completes 40 warm-up cycles without a failure reported.
Page 313 ___________________________________________ 5-114 Transmission/Transfer Case ® DTC P1860 Torque Converter Clutch Pulse Width Modulation Solenoid Electrical Step Action Value Was the Powertrain On-Board Diagnostic (OBD) Sys- Go to Power- tem Check performed? — train OBD Go to Step 2 System Check Install the scan tool (Tech 1).
Page 314 ___________________________________________ Transmission/Transfer Case 5-115 ® DTC P1860 Torque Converter Clutch Pulse Width Modulation Solenoid Electrical (Cont’d) Step Action Value Replace the PCM. Refer to PCM Replacement/Pro- gramming , Section 6. — Is the replacement complete? Go to Step 17 — Disconnect the internal wiring harness at the TCC PWM Sol.
Page 315 ___________________________________________ 5-116 Transmission/Transfer Case ® DTC P1870 Transmission Component Slipping Interm. Fourth Overrun Roller Direct Front Sprag Interm. Roller Rear Range Gear 1-2 Sol 2-3 Sol Clutch Clutch Clutch Clutch Clutch Band Clutch Clutch Clutch Band Ð Ð Ð Ð Ð...
Page 316 ___________________________________________ Transmission/Transfer Case 5-117 ® DTC P1870 Transmission Component Slip Step Action Value Was the Powertrain On-Board Diagnostic (OBD) Sys- — Go to Power- tem Check performed? train OBD Go to Step 2 System Check Perform the Transmission Fluid Checking Procedure. —...
Page 317 ___________________________________________ 5-118 Transmission/Transfer Case ® DTC P1870 Transmission Component Slip (Cont’d) Step Action Value Repeat the procedure in step 5. Drive the vehicle under the following conditions: • The transmission is in D4. 140-500 RPM • The TCC is engaged. •...
Page 318 ___________________________________________ Transmission/Transfer Case 5-119 ® DTC P1871 Undeﬁned Gear Ratio AUTOMATIC TRANSMISSION TRANFER CASE AUTO TRANS FLUID PRESURE MANUAL VALVE POSITION SWITCH VEHICLE INPUT SHAFT (TFP) SPEED SPEED SENSOR SENSOR A/T ISS SWITCH SWITCH SWITCH SWITCH SWITCH T W I S T E D T W I S T E D PA I R PA I R...
Page 319 ___________________________________________ 5-120 Transmission/Transfer Case ® DTC P1871 Undefined Gear Ratio Step Action Value Was the powertrain On-Board Diagnostic (OBD) Sys- Go to Power- tem Check Performed? — train OBD Go To step 2 system Check Perform the transmission ﬂuid checking procedure. Go to Trans- Refer to Fluid Level and Condition.
Page 320 ___________________________________________ Transmission/Transfer Case 5-121 ® DTC P1871 Undefined Gear Ratio (Cont’d) Step Action Value In order to verify your repair, perform the following procedure: Select DTC. Select Clear Info. Operate the vehicle under the following condi- tions: • Key ON, the engine is running. •...
Page 321 ___________________________________________ 5-122 Transmission/Transfer Case ® DTC P1875 Four-Wheel Drive Low Switch Fault FUSE 2D FUSE 3A FUSE 4D FUSE 6B 20 AMP 20 AMP 15 AMP 5 AMP INTERIOR EXTERIOR INTERIOR INTERIOR BRAKE TCC/ LAMP CRUISE C33-J TO BRAKE LAMP C28-D13 C28-C13 C28-C12 C28-C11...
Page 322 ___________________________________________ Transmission/Transfer Case 5-123 ® Action Taken When The DTC Sets Diagnostic Aids • Assume “Low” state when stuck “off' and “High” state • Inspect the wiring for poor electrical connections at the when stuck ”on”. PCM and at the transmission 20-way connector. Look for possible bent, backed out, deformed or damaged ter- •...
Page 323 ___________________________________________ 5-124 Transmission/Transfer Case ® DTC P1875 4WD Low Switch Fault Step Action Value Connect scan tool. NOTE: Important: Before clearing DTC(s) use the scan tool to record “Freeze Frame” and Failure Records for reference, as data will be lost when the “Clear Info” function is used.
Page 324 ___________________________________________ Transmission/Transfer Case 5-125 ® Electrical/Garage Shift Test assembly. The solenoid valve energizes or de-energizes by making or breaking an electrical circuit through a combination Perform this test before a road test in order to make sure that of switches and sensors. electronic control inputs are connected and operating.
Page 325 ___________________________________________ 5-126 Transmission/Transfer Case ® Torque Converter Evaluation and Diagnosis If the shudder occurs while the TCC is applying, the problem can be within the transmission or the torque converter. Some- Replace the torque converter under any of the following condi- thing is causing one of the following conditions to occur: tions: •...
Page 326 ___________________________________________ Transmission/Transfer Case 5-127 ® TFP Valve Position Switch Resistance Check Step Action Value(s) 50 k Ω Install the J 39775 Jumper harness on the Go to step 3 Go to step 2 transmission side of the 20 way transmission pass-through connector.
Page 327 ___________________________________________ 5-128 Transmission/Transfer Case ® TFP Valve Position Switch Resistance Check (Cont’d) Step Action Value(s) 200 Ω 1. Place the gear selector in Low (D1). Go to step 10 Go to step 14 Measure the resistance from terminal N to the transmission case.
Page 328 ___________________________________________ Transmission/Transfer Case 5-129 ® Automatic Transmission Wiring Harness Check Step Action Value(s) 1. Install the J 39775 jumper on the transmis- 19-24Ω @ 20° Go to step 3 Go to step 2 sion 20 way connector. C (68°F) Using a DVOM and a J 35616 Test Adapter 24-31Ω...
Page 329 ___________________________________________ 5-130 Transmission/Transfer Case ® Automatic Transmission Wiring Harness Check (Cont’d) Step Action Value(s) Measure the resistance between terminals L and 3333-3689Ω @ Go to step 10 Go to step 12 M (Transmission Fluid Temperature Sensor) 20° C (68°F) Is the resistance within the values indicated? 24-31Ω...
Page 330 ___________________________________________ Transmission/Transfer Case 5-131 ® Transmission Cooler Flushing Procedure the trigger down. The discharge will foam vigorously when the solution is introduced into the water stream. Equipment Needed Flush the oil cooler and pipes with water and solution for two minutes. During this flush, attach the air supply to the •...
Page 331 ___________________________________________ 5-132 Transmission/Transfer Case ® 4. Remove the discharge hose, reconnect the cooler feed and 10. Insert filter pipe in case with twisting motion. Align filter return pipes to the transmission and refill the unit to the with valve body and work into place (Figure 5-30). proper level.
Page 332 FILL TUBE SEAL Figure 5-31: Bypass Valve Connections Figure 5-33: Fill Tube Attachment A bypass valve is used in all Hummer vehicles (Figure 5-32). The valve limits pressure buildup in the oil cooler and Install fill tube seal in transmission.
Page 333: Vent Line Service
___________________________________________ 5-134 Transmission/Transfer Case ® VENT LINE SERVICE Vent lines or fittings can be replaced individually. It is not nec- essary to replace all of the lines if only one section is damaged. The transmission, transfer case, front and rear hubs, and winch In cases where plastic vent line is supplied in bulk quantity, the are all connected to a common vent line system (Figure 5-34).
Page 334 ___________________________________________ Transmission/Transfer Case 5-135 ® CONVERTER HOUSING UPPER COVER CONVERTER HOUSING LOWER COVER REPLACEMENT REPLACEMENT 1. Remove converter housing upper cover from transmission Remove crossover pipe. ﬂange (Figure 5-35). Remove converter housing upper cover. 2. Remove gasket from cover. Remove lower bolts and remove cover from transmission 3.
Page 335: Valve Body Switch And Solenoid Service
___________________________________________ 5-136 Transmission/Transfer Case ® VALVE BODY SWITCH AND SOLENOID CAUTION: The valve body check-balls are not secured and are loose. Keep the valve body level and the spacer plate in position SERVICE during removal. This will avoid losing or mispositioning the The following electrical components can be replaced once the check-balls.
Page 336 ___________________________________________ Transmission/Transfer Case 5-137 ® CAUTION: The valve body bolts must be tightened to speci- fied torque and in the indicated pattern. Overtightening or ran- dom tightening will distort the valve body resulting in valve 2-3 SHIFT bind, cross leakage, and shift problems. SOLENOID B Connect wire harness to solenoids and switch.
Page 337 ___________________________________________ 5-138 Transmission/Transfer Case ® RETAINER PLUG STUD PAWL SEAL SHAFT PARK PAWL RETURN DETENT SPRING SHAFT ACTUATOR BRACKET SHAFT BOLT (2) DETENT DETENT Figure 5-41: Park Lock Components...
Page 338 ___________________________________________ Transmission/Transfer Case 5-139 ® TORQUE CONVERTER/FLEXPLATE/ TRANSMISSION REMOVAL CONVERTER SEAL REPLACEMENT Remove console and engine cover. 1. Remove transmission as described in this section. Remove bolts attaching transmission fill tube to heat shield and intake manifold (Figure 5-44). Then remove fill 2.
Page 339 ___________________________________________ 5-140 Transmission/Transfer Case ® OPERATING BRACKET WAVY LEVER TRANSFER WASHER CASE SHIFT ROD VEHICLE SPEED SENSOR LOCK INDICATOR SWITCH FLAT WASHERS Figure 5-45: Shift Rod Attachment Figure 5-47: Vehicle Speed Sensor and Switch Harness Connections SHIFT ROD RANGE TRUNNION INDICATOR SWITCH Figure 5-48: Range Indicator Connection Figure 5-46: Transmission Shift Rod and Trunnion...
Page 340 ___________________________________________ Transmission/Transfer Case 5-141 ® TRANSMISSION TRANSMISSION WIRING ADAPTER HARNESS HARNESS CLIPS FRAME INPUT BRACKET SPEED SENSOR TRANSMISSION MOUNT Figure 5-50: Speed Sensor Connections 10. Remove transmission harness from retaining clips. 11. Disconnect front propeller shaft and remove rear propeller CROSSMEMBER shaft.
Page 341 ___________________________________________ 5-142 Transmission/Transfer Case ® 10. Install rear crossmember and secure transmission mount to adapter. Tighten adapter-to-mount bolts to 65 lb-ft (88 N•m) torque. Tighten crossmember-to-frame bracket bolts to 90 lb-ft (122 N•m) torque. 11. Connect oil cooler lines to transmission and transfer case. Be sure lines are properly secured in clamps and brackets.
Page 342 ___________________________________________ Transmission/Transfer Case 5-143 ® SHIFT CONTROL ASSEMBLY REMOVAL Disconnect body harness wires from park/neutral position switch wires. NOTE: Wavy washers eliminate any potential transfer case shift linkage rattle (Figure 5-54). If a rattle is present on a vehi- cle not equipped with a wavy washer, install one as shown. Re- SHIFT CONTROL ASSEMBLY fer to parts manual for wavy washer part number.
Page 343 ___________________________________________ 5-144 Transmission/Transfer Case ® SHIFT CONTROL ASSEMBLY SERVICE The only control assembly parts that can be replaced sepa- rately, include the following (Figure 5-57): NOTE: Shifter Boot Cover (procedure in this section) must be • shift indicators removed for access to Shifter Control Boot. •...
Page 344 ___________________________________________ Transmission/Transfer Case 5-145 ® PARK/NEUTRAL POSITION OR BACKUP LAMP Remove tie strap and disconnect switch leads. SWITCH REPLACEMENT 10. Disconnect backup or position switch wires at body harness. 1. Remove driver side inner kick panel. 11. Install switch on shift control housing and secure with 2.
Page 345: Shifter Boot Cover Replacement
___________________________________________ 5-146 Transmission/Transfer Case ® SHIFTER BOOT COVER REPLACEMENT BEZEL A “shifter boot cover” protects the shifter boot and linkage. The shifter boot cover is made of a silicone coated fiberglass, heat resistant material. This material provides the additional benefits of reduced noise and heat intrusion from under the ve- hicle into the passenger compartment.
Page 346 ___________________________________________ Transmission/Transfer Case 5-147 ® Installation Seat shift control assembly in tunnel opening and secure with assembly attaching bolts. Tighten bolts to 6 lb-ft (8 1. Work shifter boot cover lip into tunnel opening and align N•m) torque. edges carefully to match opening. Install two shift control housing boot protectors.
Page 347: Shift Linkage Adjustment
___________________________________________ 5-148 Transmission/Transfer Case ® SHIFT LINKAGE ADJUSTMENT 1. Move shift lever to manual low (1) range. 2. Disconnect transmission shift rod from arm in shift control housing. 3. Verify that transmission shift lever (Figure 5-63) is in REAR manual low (1) range. If not, disconnect lever trunnion MOUNT and adjust trunnion in, or out as needed.
Page 348 The transfer case extension, bearing retainer, rear case, and front case are all aluminum castings. The front and rear output Hummer vehicles are equipped with the New Process Gear, drive sprockets are interconnected by a drive chain model 242 transfer case. If you have questions about the trans- (Figure 5-66).
Page 349: Recommended Lubricant
® TRANSFER CASE OIL COOLER TRANSFER CASE IDENTIFICATION The NP 242 used in Hummer vehicles is equipped with an in- An identification tag is attached to the rear case of each NP 242 ternal oil cooler (Figure 5-67). transfer case (Figure 5-68). The tag provides the model num- ber, assembly number, serial number, and low range ratio.
Page 350: Operating Ranges
___________________________________________ Transmission/Transfer Case 5-151 ® OPERATING RANGES TRANSFER CASE SHIFTING The three operating ranges are for specific use on or off road. The transfer case shift lever is adjacent to the transmission shift Usage recommendations are: lever. A straight-line shift pattern is employed (Figure 5-69). The transfer case can be shifted from High (H) to High Lock High Lock (HL) (HL) and back, at any legal speed without putting the transmis-...
Page 351 ___________________________________________ 5-152 Transmission/Transfer Case ® TRANSFER CASE DIAGNOSIS PROBLEM POTENTIAL CAUSE CORRECTION Transfer Case Vehicle speed too great to permit shifting. Reduce speed to 15 mph if shifting from H to HL Hard to Shift and back. Stop vehicle completely if shifting into low range.
Page 352: Vent Line Replacement
___________________________________________ Transmission/Transfer Case 5-153 ® TRANSFER CASE SHIFT ROD SERVICE Adjustment Apply parking brakes and shift transmission into neutral. Removal Shift transfer case into high lock (HL) position. 1. Unfasten snaps and pull velcro strips apart to open shifter Disconnect shift rod and trunnion at control housing shift boot cover.
Page 353: Guide Cable Replacement
___________________________________________ 5-154 Transmission/Transfer Case ® SPEED SENSOR AND/OR SWITCH GUIDE CABLE REPLACEMENT REPLACEMENT Remove bolts, nuts, and washers attaching cable bracket to mufﬂer bracket (Figure 5-75). 1. Disconnect harness connector from vehicle speed sensor, lock indicator switch, and/or range indicator switch Remove bolts, nuts, and washers securing guide cable.
Page 354 ___________________________________________ Transmission/Transfer Case 5-155 ® FRONT OUTPUT SHAFT SEAL REPLACEMENT 1. Mark front propeller shaft and transfer case yoke for align- ment reference. 2. Disconnect front propeller shaft at yoke. Retain U-bolts and nuts (Figure 5-76). 3. Remove yoke nut (Figure 5-77). 4.
Page 355 ___________________________________________ 5-156 Transmission/Transfer Case ® TRANSFER CASE REMOVAL TRANSMISSION ADAPTER 1. Remove drain plug and drain oil from transfer case. Rein- stall drain plug afterward. 2. Disconnect propeller shafts from transfer case. TRANSFER CASE 3. Disconnect wiring harness connectors from vehicle speed sensors range switch, and lock switch.
Page 356 ___________________________________________ Transmission/Transfer Case 5-157 ® TRANSFER CASE DISASSEMBLY AND OVERHAUL REAR CASE 1. Remove vehicle speed sensor and both indicator switches. REAR RETAINER 2. Remove front output shaft yoke (Figure 5-82). Remove yoke nut with suitable size socket and impact wrench. Then remove seal washer and yoke.
Page 357 ___________________________________________ 5-158 Transmission/Transfer Case ® REAR CASE REAR RETAINER PUMP SCREWDRIVER Figure 5-86: Rear Retainer Removal 7. Remove speedometer tone wheel and snap rings Figure 5-88: Rear Case Removal (Figure 5-87). Remove oil pump, pickup tube, hose, and screen 8. Remove rear case attaching bolts and remove rear case (Figure 5-89).
Page 358 ___________________________________________ Transmission/Transfer Case 5-159 ® OIL PUMP DRIVE CHAIN DRIVE SPROCKET INLET PORT O-RING Figure 5-90: Oil Pump O-ring Location 11. Remove drive sprocket snap ring (Figure 5-91). 12. Remove drive sprocket (Figure 5-92). 13. Remove drive chain. Figure 5-92: Drive Sprocket Removal 14.
Page 359 ___________________________________________ 5-160 Transmission/Transfer Case ® SECTOR SHAFT RANGE LEVER SHIFT RAIL WASHER MODE FORK ASSEMBLY Figure 5-94: Range Lever Mounting 16. Remove detent plug, spring, and plunger (Figure 5-95). 17. Remove oil cooler attaching nuts and washers. Then remove cooler, support bracket and O-rings (Figure 5-95). 18.
Page 360 ___________________________________________ Transmission/Transfer Case 5-161 ® 20. Remove mode fork sleeve from mainshaft (Figure 5-98). Note position of sleeve for installation reference. Do not disassemble fork assembly. Only the fork pads are serviceable. 21. Remove snap ring that secures intermediate clutch shaft on mainshaft (Figure 5-99).
Page 361 ___________________________________________ 5-162 Transmission/Transfer Case ® 23. Remove differential snap ring (Figure 5-101). 24. Remove differential from mainshaft (Figure 5-102). 25. Remove mainshaft needle roller bearings and spacers (Figure 5-103). NEEDLE ROLLER BEARINGS BEARING SPACERS MAINSHAFT Figure 5-103: Mainshaft Bearing and Spacer Removal 26.
Page 362 ___________________________________________ Transmission/Transfer Case 5-163 ® 32. Disassemble input gear and low range planetary as follows: Remove retaining ring that secures input gear in low range planetary (Figure 5-108). Remove lock ring and front thrust washer (Figure 5-109). Remove input gear and rear thrust washer from low range planetary (Figure 5-109).
Page 363 ___________________________________________ 5-164 Transmission/Transfer Case ® REAR THRUST WASHER CASE BOLTS FRONT THRUST WASHER LOW RANGE PLANETARY Figure 5-111: Differential Case Bolt Removal INPUT GEAR FRONT CASE LOCK RING Figure 5-109: Input/Low Range Planetary Gear Disassembly Sequence 33. Remove and disassemble differential as follows: Scribe or paint mark front and rear cases for assembly reference (Figure 5-110).
Page 364 ___________________________________________ Transmission/Transfer Case 5-165 ® TRANSFER CASE CLEANING AND MAINSHAFT GEAR INSPECTION Clean the transfer case components thoroughly with standard parts cleaning solvent. Remove all traces of sealer from the case and retainer sealing surfaces. SPROCKET GEAR Clean the oil pickup screen with solvent and dry it with com- pressed air.
Page 365: Oil Pump
___________________________________________ 5-166 Transmission/Transfer Case ® FRONT OUTPUT SHAFT BEARING AND SEAL REPLACEMENT ANNULUS GEAR Remove snap ring securing shaft front bearing in front FRONT CASE case (Figure 5-117). Tap old bearing out rear of front case with plastic or raw hide mallet.
Page 366 ___________________________________________ Transmission/Transfer Case 5-167 ® SLIDE HAMMER TOOL J–2619-01 HANDLE J–8092 TOOL J–33833 TOOL J–26369 REAR CASE FRONT OUTPUT SHAFT REAR BEARING Figure 5-118: Front Output Shaft Front Bearing Installation Figure 5-120: Front Output Shaft Rear Bearing Removal TOOL J–38869 TOOL HANDLE J–8092...
Page 367: Input Gear Bearing Replacement
___________________________________________ 5-168 Transmission/Transfer Case ® INPUT GEAR BEARING REPLACEMENT MAINSHAFT PILOT BEARING REPLACEMENT 1. Remove old bearing from interior of front case as shown. Remove pilot bearing from input gear with slide hammer Use tool handle J–8092 and tool J–29170 (Figure 5-122). J–2619-01, and puller tool J–29369-1 (Figure 5-124).
Page 368 ___________________________________________ Transmission/Transfer Case 5-169 ® EXTENSION HOUSING BUSHING AND SEAL REPLACEMENT J–33843 OR 1. Remove old seal with pry tool. SUITABLE SIZE SEAL INSTALLER 2. Drive out old bushing with tool handle J–8092 and tool J– 33839 (Figure 5-126). 3. Position new bushing on tool J–33839 and tap bushing into place until flush with bushing bore.
Page 369 ___________________________________________ 5-170 Transmission/Transfer Case ® TRANSFER CASE ASSEMBLY 1. Assemble input gear and low range planetary: INPUT GEAR Lubricate gear, planetary, and thrust washers with Dexron III. LOW RANGE PLANETARY b. Install rear thrust washer in planetary. Be sure washer tabs are aligned in planetary notches as shown (Figure 5-129) NOTE: The thrust washers are the same size and are inter-...
Page 370 ___________________________________________ Transmission/Transfer Case 5-171 ® INPUT GEAR FRONT SNAP RING SHIFT BEARING CASE SECTOR Figure 5-133: Shift Sector Installation INPUT GEAR SHAFT Figure 5-135: Input Gear Snap Ring Installation INPUT GEAR/ PLANETARY ASSEMBLY TOOL J–33831 FRONT RETAINER INPUT GEAR BEARING Figure 5-134: Input Gear/Low range Planetary Installation 8.
Page 371 ___________________________________________ 5-172 Transmission/Transfer Case ® Check condition of tone wheel on mainshaft. Replace wheel if teeth are chipped, cracked, or broken. FRONT RETAINER 10. Coat needle bearing surface of mainshaft with petroleum jelly. Then install first spacer, 53 needle bearings, and remaining spacer.
Page 372 ___________________________________________ Transmission/Transfer Case 5-173 ® THRUST WASHERS (6) LONG PINION (3) SHORT PINION (3) THRUST NEEDLE ROLLER WASHERS (6) BEARINGS (HOLD IN PLACE WITH PETROLEUM BEARING JELLY) SPACERS SPROCKET GEAR MAINSHAFT Figure 5-143: Mainshaft Bearing Roller Installation GEAR FRONT CASE Figure 5-141: Differential Pinion and Sprocket Gear Installation DIFFERENTIAL...
Page 373 ___________________________________________ 5-174 Transmission/Transfer Case ® DIFFERENTIAL SNAP RING CLUTCH SHAFT THRUST RING CLUTCH SHAFT SNAP RING INTERMEDIATE CLUTCH SHAFT Figure 5-145: Differential Snap Ring Installation Figure 5-147: Intermediate Clutch Shaft Thrust Ring and Snap Ring Installation INTERMEDIATE 18. Install shift rail. Install rail through mode fork, range fork, CLUTCH SHAFT MAINSHAFT and into case bore and install lock pin (Figure 5-153).
Page 374 ___________________________________________ Transmission/Transfer Case 5-175 ® MANIFOLD TRANSFER CASE OIL COOLER DIFFERENTIAL MODE FORK COOLER SUPPORT ASSEMBLY BRACKET MAINSHAFT COOLER SEALING WASHERS MODE SLEEVE Figure 5-149: Mode Fork and Sleeve Installation 19. Install detent plunger, spring, and plug. Replace O-ring on plug before hand and tighten plug to 12-18 lb-ft (16-24 N•m) (Figure 5-154).
Page 375 ___________________________________________ 5-176 Transmission/Transfer Case ® 24. Assemble driven sprocket and front output shaft. Use new snap ring if old one is worn or distorted (Figure 5-155). 25. Install front output shaft and driven sprocket. Then install drive chain (Figure 5-156). MAINSHAFT AND 26.
Page 376 ___________________________________________ Transmission/Transfer Case 5-177 ® 30. Position pump assembly in rear case. Be sure pickup screen is seated in case notch as shown (Figure 5-160). SNAP RING DRIVEN SPROCKET DRIVE DRIVE SPROCKET SPROCKET SNAP RING FRONT OUTPUT SHAFT Figure 5-157: Securing Drive Sprocket to Mainshaft Figure 5-155: Front Output Shaft and Sprocket 31.
Page 377 ___________________________________________ 5-178 Transmission/Transfer Case ® OIL PUMP REAR CASE TOOL J–33835 OIL PUMP HOUSING PICKUP TUBE OIL PICKUP CASE SCREEN NOTCH Figure 5-160: Oil Pump Assembly Installation Figure 5-158: Oil Pump Seal Installation OIL PUMP FRONT CHIP CASE MAGNET POCKET OIL PICKUP TUBE Figure 5-161: Chip Magnet Installation CONNECTOR...
Page 378 ___________________________________________ Transmission/Transfer Case 5-179 ® TOOL DOWEL HANDLE TOOL J–8092 PUMP J–33832 REAR CASE BEARING Figure 5-164: Installing Mainshaft Bearing In Rear Retainer MAINSHAFT SNAP BEARING RING Figure 5-162: Rear Case Installation REAR RETAINER SNAP RING TONE WHEEL Figure 5-165: Rear Retainer and Mainshaft Bearing SNAP RING MAINSHAFT Snap Ring Installation...
Page 379 ___________________________________________ 5-180 Transmission/Transfer Case ® YOKE FRONT OUTPUT SHAFT FRONT OUTPUT SEAL YOKE WASHER Figure 5-167: Front Yoke Installation 43. Install drain plug in rear case. Tighten plug to 15-25 lb-ft (20-33 N•m). 44. Apply Loctite PST to threads of indicator switches and speed sensor.
Page 380 ___________________________________________ Transmission/Transfer Case 5-181 ® TRANSFER CASE TORQUE SPECIFICATIONS Case bolts (all) ......20-25 lb-ft (27-34 N•m) Detent plug .
Page 381 ___________________________________________ 5-182 Transmission/Transfer Case ® ESSENTIAL TOOLS J–8614-01 J–35944-AMG J–35944-500 J–8092 J–33043-2 J–35944-22 J–25025-B J–33835 J–33831 J–42497 J–21867 J–39775 Tool No. Description J–35944-AMG Transmission Oil Cooler Flush Kit J–35944-500 Cooler Line Adapters J–35944-22 Oil Cooler Flushing Fluid J–8614-01 Yoke Holding Tool J–8092 Universal Driver Handle J–25025-B...
Page 382 ___________________________________________ Transmission/Transfer Case 5-183 ® SPECIAL TOOLS J–2619-01 J–29369 J–33839 J–33829 J–29170 J–33833 J–33832 Tool No. Description J–2619-01 Slide Hammer and Adapter J–29369 Bushing/Bearing Remover Kit J–33839 Rear Output Bushing Remover (use with J–8092) J–33829 Pilot Bearing Installer (use with J–8092) J–33833 Output Shaft Main Bearing Installer (use with J–8092) J–33832...
Page 383 ___________________________________________ 5-184 Transmission/Transfer Case ® THIS PAGE INTENTIONALLY BLANK.
Page 384: Wheels And Tires
________________________________________________________________________________ ® Section 6 Wheels and Tires/Central Tire Inﬂation System (CTIS) TABLE OF CONTENTS Central Tire Inflation System Rear Tube Connection Shield ..... . 6-53 Air Intake Line and Assembly.
Page 385: Removal And Disassembly
_________________ 6-2 Wheels and Tires/Central Tire Inflation System (CTIS) ® 2. Remove support and lower corner of vehicle. 3. Two-piece wheel lugnut torque is 110 lb-ft (149 N•m). Use tightening sequence shown (Figure 6-3). TIGHTENING SEQUENCE HOSE SHIELD GEARED HUB SPINDLE WHEEL AND TIRE ASSEMBLY...
Page 386 ________________ Wheels and Tires/Central Tire Inflation System (CTIS) ® Remove the brass fitting from the center of the geared Remove wheel half nut covers. hub spindle on the wheel(s) to be worked on. When tire is fully deflated, use a circular pattern and d.
Page 387 _________________ 6-4 Wheels and Tires/Central Tire Inflation System (CTIS) ® 13. Remove O-ring from insert. Discard O-ring. 14. Remove O-ring seal from inner rim half. Discard O-ring seal. 15. Remove tire from inner rim half. WARNING: Balance weights contain lead. Wash hands RUNFLAT after handling.
Page 388 ________________ Wheels and Tires/Central Tire Inflation System (CTIS) ® 8. Inspect outside of tire for sidewall damage. Replace tire if damaged. 9. Inspect tread for puncture damage. If damage is too extensive for patch repair, replace tire. CORE HOUSING WARNING: O-ring sealing surfaces must be kept clean VALVE and free from rust and dirt.
Page 389 _________________ 6-6 Wheels and Tires/Central Tire Inflation System (CTIS) ® Assembly WARNING: Never use wheel assemblies with wheel half studs that are damaged, loose, or have stripped WARNING: Never use tubes in the two-piece take- threads. Damaged studs can cause improper assembly apart wheel assemblies.
Page 390 ________________ Wheels and Tires/Central Tire Inflation System (CTIS) ® Insert runflat compressor side first as far as possible into RUNFLAT tire. RUNFLAT Lay tire flat on side. Slowly loosen compressor. Runflat COMPRESSOR should position itself inside tire. If not, repeat steps 4 through 6 and/or use a tire spoon to assist in installation.
Page 391 _________________ 6-8 Wheels and Tires/Central Tire Inflation System (CTIS) ® NOTE: Before installing tire on inner rim half, inspect tire CAUTION: Ensure the runflat is properly aligned with the sidewalls for a “paint dot.” Paint dots are often used to indicate valve stem in the wheel.
Page 392 ________________ Wheels and Tires/Central Tire Inflation System (CTIS) ® CAUTION: Tighten locknuts gradually to avoid bending and/ THICKNESS or breaking studs, or damage to wheel components. GAUGE NOTE: If vehicle is equipped with central tire inflation sys- tem, position shield mounting bracket on outer rim. STUD 15.
Page 393 _______________ 6-10 Wheels and Tires/Central Tire Inflation System (CTIS) ® WHEEL HALF STUD REPLACEMENT CORE HOUSING Removal EDGE Remove wheel from vehicle. INSERT Place wheel in tire inflation cage. WARNING: Ensure the tire is totally deﬂated before removing wheel locknuts. Failure to follow proper safety precautions may result in serious injury or death.
Page 394 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-11 ® 2. Inspect inner rim for cracked, broken, rusted, pitted, bent, or loose studs, and studs with damaged, mutilated, or deformed threads. Replace defective parts (Figure 6-19). STUD S06-103.1 Figure 6-20: Wheel Half LockNut Tightening Se- quence Check wheel assembly for gaps at each stud.
Page 395 _______________ 6-12 Wheels and Tires/Central Tire Inflation System (CTIS) ® RUNFLAT COMPRESSOR BELT REPLACEMENT TIRE, ONE-PIECE ALUMINUM WHEEL (OPTION), AND TWO-PIECE RUNFLAT SER- Installation VICE CAUTION: It is not recommended mixing one-piece wheel and runflat assemblies and two-piece take-apart wheel and runflat assemblies on the same vehicle.
Page 396 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-13 ® Inspection and Cleaning RETAINING SCREW Cleaning WASHER RUNFLAT Remove any existing lubricant that has been applied to the LOCKING CLIP inside of the tire, using tire bufﬁng solution. Clean all wheel, runflat and tire parts using tire buffing SQUARE solution.
Page 397 _______________ 6-14 Wheels and Tires/Central Tire Inflation System (CTIS) ® Assembly moved. Failure to do so could result in damage to wheel/tire assembly. NOTE: If tires are to be replaced allow new tires to reach Apply one tube (approximately 11 ounces) of runﬂat gel room temperature (above 60°) before mounting.
Page 398 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-15 ® RETAINING SCREW LOCKING CLIP 21 MM 00-S06-013 Figure 6-25: Runflat Assembly 2. Position wheel on tire machine with outside facing up. NOTE: The distance between the two runflat end gaps must Lubricate tire beads and mount inside tire bead on wheel.
Page 399 _______________ 6-16 Wheels and Tires/Central Tire Inflation System (CTIS) ® sure using a clip-on air chuck. Do not exceed 50 psi (345 kPa) cold inﬂation pressure. Failure to follow these instructions may result in serious injury or death. 12. Before installing valve core, inflate tire to seat beads. Use of tire bead seater may be required.
Page 400 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-17 ® Inspecting Tire Tread Wear loped tread wear patterns (Figure 6-27). Tire wear inspection should be performed for all vibration complaints. Resolve tire Tire tread wear is a good indicator of tire balance and suspen- wear problems before continuing with diagnosis.
Page 401 _______________ 6-18 Wheels and Tires/Central Tire Inflation System (CTIS) ® WHEEL AND TIRE BALANCING NOTE: Most electronic off-vehicle balancers are more accu- rate than on-vehicle spin balancers. They are easy to use and General give a dynamic (two-plane) balance. On-vehicle balancing is not recommended.
Page 402 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-19 ® 3. Locate and mark wheel and tire assembly light spot on the WEIGHT CLIP WEIGHT tire (Figure 6-31). (CLIP-ON TYPE) WHEEL AND 4. Record weight and position readings. TIRE ASSEMBLY LIGHT SPOT LIGHT SPOT WHEEL...
Page 403 _______________ 6-20 Wheels and Tires/Central Tire Inflation System (CTIS) ® TROUBLESHOOTING A NON-BALANCING WHEEL AND TIRE ASSEMBLY OUTBOARD INBOARD SIDE NOTE: If a wheel and tire assembly cannot be balanced, or SIDE balance cannot be maintained, any of the following conditions may be causing the problem: •...
Page 404 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-21 ® Wheel And Tire Assembly Runout Inspection GEARED HUB NOTE: Before measuring the runout of a tire and wheel as- sembly, drive the vehicle long enough to warm up the tires. SPINDLE Then do the following: 1.
Page 405 _______________ 6-22 Wheels and Tires/Central Tire Inflation System (CTIS) ® WHEEL ALIGNMENT Check upper ball joints: With the vehicle on the ground (being careful not to damage the boot), place the tip of a Check alignment on a rack with the front tires in the straight- prybar between the steering knuckle and the ball joint boot ahead position and inflated to manufacturer’s recommended (Figure 6-39).
Page 406 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-23 ® (Figure 6-40). Maximum play should not exceed 1/8" PRYBAR CONTACT POINT (3.5 mm). Replace ball joint if end play exceeds the limit. Check steering center link, idler arm and tie rod ends for wear or damage (Figure 6-41).
Page 407 _______________ 6-24 Wheels and Tires/Central Tire Inflation System (CTIS) ® STABILIZER PITMAN HALFSHAFT IDLER TIE ROD END ADJUSTING SLEEVE TIE ROD GEARED CENTER LINK TIE ROD SPRING SCALE Figure 6-41: Suspension Component Identification...
Page 408 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-25 ® CHECKING WHEEL ALIGNMENT Measure and record caster, camber, toe-in, and toe-out. Refer to alignment specifications (Figure 6-42). 1. Move vehicle onto alignment rack and position front tires If alignment angles are within specified limits, move on alignment rack turntables.
Page 409 (Figure 6-43). A positive caster an- Verify correct caster angle at both front wheels. Be sure gle is required on all Hummer vehicles. side-to-side caster variation does not exceed 0.5 degree. Preferred caster angle is +2.5 to +3.5 degrees. Maximum al- Leave vehicle on rack for camber and toe adjustments.
Page 410 (Figure 6-43). Adjust camber angle by rotating the front eccentric of the Preferred camber for all Hummer vehicles is zero to +0.5 de- upper control arm bracket (Figure 6-43). gree at the front and +0.25 to +0.75 degrees at the rear. Maxi- •...
Page 411 _______________ 6-28 Wheels and Tires/Central Tire Inflation System (CTIS) ® Rear Wheel Toe Adjustment Verify correct camber angle at both front wheels. Be sure side-to-side variation does not exceed 0.5 degree. 1. Position both rear wheels on alignment rack turntables. Leave vehicle on rack for toe settings and steering stop 2.
Page 412: Steering Stop Adjustment
______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-29 ® STEERING STOP ADJUSTMENT NOTE: Alignment equipment currently used in the auto- 36° LINE A motive field should be used for steering stop adjustment LEFT FRONT TIRE procedure. This procedure should be followed if align- 34°...
Page 413: Central Tire Inflation System
CENTRAL TIRE INFLATION SYSTEM RADIAL TIRE The optional Central Tire Inflation System (CTIS) is unique to the HUMMER. The CTIS allows the driver to increase or de- crease tire pressure based on terrain and climate conditions. 1-PIECE The system can also be used to direct air to a tire that has a...
Page 414 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-31 ® CTIS TROUBLESHOOTING The following pages contain troubleshooting information for QUICK- locating and correcting mechanical, pneumatic, and electrical DISCONNECT problems that may develop with the CTIS. VALVE VALVE ASSEMBLY SPINDLE Electrical Troubleshooting Symptoms are listed for system malfunctions, and procedures and corrections are diagramed to assist service technicians.
Page 415 _______________ 6-32 Wheels and Tires/Central Tire Inflation System (CTIS) ® CTIS AIR LEAK TROUBLESHOOTING 10. Check the air pressure in each tire and compare it to the information taken earlier. Note any air pressure loss and This section contains troubleshooting information for locating concentrate on that tire position.
Page 416 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-33 ® Troubleshooting Chart 1 – Geared Hubs, Seals and Fittings Inspect the steering arm cover, connector, and tube for damage. Replace the con- Use a soap and water solution or a Damage is found nector or tube.
Page 417 _______________ 6-34 Wheels and Tires/Central Tire Inflation System (CTIS) ® Troubleshooting Chart 2 – Deflate Valve Area Inspect the deﬂate valve and con- Air is escaping from the Replace nections for damage (Figure 6-65). dust excluder or the seams deflate valve. Use a soap and water solution to on the Deflate Valve check for leaks.
Page 418 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-35 ® Troubleshooting Chart 5– Tire and Quick-Disconnect Valve Inspect the quick-disconnect valve, Quick-disconnect compo- Replace quick-disconnect valve nut, tube, nut nent is frayed, stripped, component. and sleeve assembly, insert, and el- cracked, or broken.
Page 419: Compressor Service
_______________ 6-36 Wheels and Tires/Central Tire Inflation System (CTIS) ® COMPRESSOR SERVICE Cleaning and Inspection Clean and inspect compressor, leads, fittings, and mounting WARNING: CTIS components are subject to high air hardware. Check for cracks, frayed wire, stripped threads, and pressure.
Page 420 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-37 ® CTIS INSTRUMENT CLUSTER Disassembly WARNING: CTIS components are subject to high air pressure. Always relieve air pressure before loosening Remove inﬂate/deﬂate switch and tire selector switch. or removing air system components by disconnecting Remove air pressure gauge.
Page 421: Inflate/Deflate And Tire Selector Switches
_______________ 6-38 Wheels and Tires/Central Tire Inflation System (CTIS) ® INFLATE/DEFLATE AND TIRE SELECTOR Cleaning and Inspection SWITCHES Clean and inspect inflate/deflate and tire selector switches for damage. Replace defective parts. Removal Installation 1. Remove CTIS instrument cluster panel. 2. Disconnect connector from inflate/deflate switch and tire Install inﬂate/deﬂate and tire selector switches in housing selector switch (Figures 6-54 and 6-55).
Page 422 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-39 ® COMPRESSOR/LOW PRESSURE INDICATOR Cleaning and Inspection LIGHTS Clean and inspect indicator lamps for damage. Replace defec- tive parts. Removal Installation 1. Remove lower closeout panel and swing steering column down. Install lamps in sockets and turn one quarter turn 2.
Page 423: Air Pressure Gauge
_______________ 6-40 Wheels and Tires/Central Tire Inflation System (CTIS) ® AIR PRESSURE GAUGE Cleaning and Inspection Clean and inspect air pressure gauge and lamp. Check for WARNING: CTIS components are subject to high air cracks and stripped threads. Replace defective parts. pressure.
Page 424 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-41 ® AIR PRESSURE GAUGE LAMP REPLACEMENT Installation Install lamps in sockets and turn one quarter turn Removal (Figure 6-56). 1. Remove lower closeout panel and swing steering column Install instrument panel. down.
Page 425 _______________ 6-42 Wheels and Tires/Central Tire Inflation System (CTIS) ® CTIS LOW PRESSURE ALARM REPLACEMENT Installation Install low pressure alarm on the interior fuse box. Removal 2. Install the fuse box access panel in the left closeout panel. 1. Remove the interior fuse box access panel in the left close- out panel under the instrument panel.
Page 426 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-43 ® CTIS INTERIOR HARNESS Cleaning and Inspection Clean and inspect CTIS harness and connectors. Check for de- NOTE: Prior to removal, tag all leads for installation. fects such as frayed wires and cracks. Repair or replace defec- Removal tive parts.
Page 427 _______________ 6-44 Wheels and Tires/Central Tire Inflation System (CTIS) ® AIR PRESSURE SWITCH REPLACEMENT Removal Disconnect harness leads from air pressure switch. WARNING: CTIS components are subject to high air Remove air pressure switch from manifold. pressure. Always relieve air pressure before loosening or removing air system components by disconnecting CAUTION: Do not allow sealant into air system.
Page 428 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-45 ® AIR PRESSURE INDICATOR LINES CAUTION: Do not allow sealant into air system. Sealant will damage CTIS components. REPLACEMENT NOTE: Apply sealant to threads prior to installation. WARNING: CTIS components are subject to high air pressure.
Page 429 _______________ 6-46 Wheels and Tires/Central Tire Inflation System (CTIS) ® CTIS COMPRESSOR FUSE REPLACEMENT CTIS COMPRESSOR RELAY REPLACEMENT Removal Removal 1. Raise and secure hood. Raise and secure hood. 2. Remove the left side cowell cover and the fuse box cover. Remove left cowl cover and fuse box cover.
Page 430 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-47 ® DEFLATE VALVE ASSEMBLY REPLACEMENT Cleaning and Inspection Clean and inspect deflate valve and bracket. Check for cracks WARNING: CTIS components are subject to high air and stripped threads. Replace if defective. pressure.
Page 431 _______________ 6-48 Wheels and Tires/Central Tire Inflation System (CTIS) ® DUST EXCLUDER REPLACEMENT Installation CAUTION: Do not allow sealant into air system. Sealant will WARNING: CTIS components are subject to high air damage CTIS components. pressure. Always relieve air pressure before loosening or removing air system components by disconnecting NOTE: Apply sealant to threads prior to installation.
Page 432 Work line out from under vehicle rather than through engine compartment. The HUMMER CTIS uses rubber hoses, nylon tubing, and re- Tape ends of new hose to prevent dirt entry. inforced (braided) lines. Damaged portions of any air line type Work line up to pump/valve assembly from underneath.
Page 433: Front Cti Line Replacement
_______________ 6-50 Wheels and Tires/Central Tire Inflation System (CTIS) ® FRONT CTI LINE REPLACEMENT REAR CTI LINE REPLACEMENT 1. Disconnect line at front hub (Figure 6-69). Disconnect line at rear wheel and at T-ﬁtting (Figure 6-71). 2. Loosen clamp on bracket attached to lower control arm, Remove line from clamp on lower control arm and from then move air line out of bracket (Figure 6-70).
Page 434: Tube Shield Replacement
______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-51 ® AIR INTAKE LINE REPLACEMENT Cleaning and Inspection Clean and inspect air intake hose, elbow, coupling assembly Removal and seal. Check for leaks, cracks, and stripped threads. 1. Raise and secure hood. CAUTION: Do not allow sealant into air system.
Page 435 _______________ 6-52 Wheels and Tires/Central Tire Inflation System (CTIS) ® QUICK-DISCONNECT VALVE AND TUBE CAUTION: Do not force apart quick-disconnect valve. The quick-disconnect valve is a one-piece component. Damage to REPLACEMENT quick-disconnect valve will result if forced apart. WARNING: CTIS components are subject to high air Remove quick-disconnect valve from spindle.
Page 436 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-53 ® REAR TUBE CONNECTION SHIELD GEARED HUB REPLACEMENT (CTIS) REPLACEMENT WARNING: CTIS components are subject to high air NOTE: The replacement of the left and right rear tube connec- pressure. Always relieve air pressure before loosening tion shields is basically the same.
Page 437 _______________ 6-54 Wheels and Tires/Central Tire Inflation System (CTIS) ® SPINDLE EXTENSION AND SEAL AUXILIARY AIR HOSE REPLACEMENT REPLACEMENT Removal Removal Raise and secure hood. 1. Remove rear tube connection shield. WARNING: The CTIS air system contains air under 2. Remove four bolts, washers, and steering arm cover from high pressure.
Page 438 ______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-55 ® Installation Connect tires to CTIS by pushing in quick-disconnect valve body until valve tee section locks (clicks) into place. NOTE: Ensure that any new fittings have pipe sealant pre-ap- Perform this procedure on remaining three wheels plied to threads.
Page 439 _______________ 6-56 Wheels and Tires/Central Tire Inflation System (CTIS) ® SPECIAL TOOLS 05710216 05710215 Tool No. Description 05710216 Internal tubeless tire repair kit 05710215 External tubeless tire repair kit...
Page 440: Brake System
________________________________________________________________________________ ® Section 7 Brake System TABLE OF CONTENTS Anti-lock Brake System (ABS) and Automatic Traction Control, Hydro-Boost System Diagnosis..... . 7-7 TorqTrac 4™...
Page 441: Component Inspection
______________________________________________________________ 7-2 Brake System ® BRAKE SYSTEM DIAGNOSIS Pedal Falls Away A brake pedal that falls away under steady foot pressure is gen- Road Testing erally the result of a system leak. The leak point could be at a brakeline, fitting, hose, or caliper. Internal leakage in the mas- 1.
Page 442 _____________________________________________________________ Brake System ® Some common causes of brake drag are: switch direction in favor of the brake unit that is functioning normally. • seized or sticking caliper piston When diagnosing a change in pull condition, remember that • caliper binding on bushings or pin slides pull will return to the original direction if the dragging brake •...
Page 443: Brake Noise
Pedal Goes to Floor covered with grease or oil due to leaking axle seals. CAUTION: The HUMMER is equipped with DOT 3 brake fluid. Do not mix with other brake fluids . Failure to use the proper brake fluid will damage the brake system.
Page 444: Steering System
_____________________________________________________________ Brake System ® 1. Remove master cylinder cover and visually check reser- Check brake pads for proper installation, contamination, voirs for low ﬂuid level or contamination. or distortion. Check brake pads for excessive wear. Minimum brake lining thickness is 1/8 in. (3.2 mm). If fluid is contaminated, flush system with clean brake Replace brake pads as axle sets (front or rear) if any pad fluid.
Page 445 ______________________________________________________________ 7-6 Brake System ® Brake Chatter Erratic Braking Action On some new vehicles, roughness or a chatter sound from the 1. Check for correct tire pressure. brakes may be noticed during low speed brake application. The Check brake pads for binding as a result of corrosion or dirt. noise is a result of the lining edges of an unburnished brake pad Check brake pads for excessive wear.
Page 446: Hydro-Boost System Diagnosis
_____________________________________________________________ Brake System ® HYDRO-BOOST SYSTEM DIAGNOSIS PROBLEM POSSIBLE CAUSE CORRECTION Slow Brake Pedal 1. Damaged/broken return spring. Replace spring. Return 2. Excessive seal friction in booster. Replace the hydro-boost. 3. Faulty spool action. Flush the steering system while pumping the Brakes Apply When brake pedal.
Page 447: Booster Functional Test
______________________________________________________________ 7-8 Brake System ® Booster Functional Test WARNING: If the reservoir has run very low or dry, bleed the master cylinder before bleeding the remainder With the engine off, apply the brake pedal several times until of the brake system to keep from introducing additional the accumulator is completely depleted.
Page 448 _____________________________________________________________ Brake System ® PRESSURE TANK BLEEDER ADAPTER BLEEDER SCREW PROTECTIVE CALIPER MASTER CYLINDER VALVE ASSEMBLY HOSE Figure 7-5: Manually Bleeding Brake System When pedal reaches floor, tighten bleeder screw and have assistant slowly release brake pedal. Repeat steps 3 and 4 until fluid flows clear and free of air PRESSURE TANK bubbles.
Page 449 _____________________________________________________________ 7-10 Brake System ® FRONT SERVICE BRAKE CALIPER REPLACE- Inspect dust boot for tears or deterioration (Figure 7-6). MENT Inspect rotor for heat cracks, spotting, discoloration, pitting, or scoring. Resurface rotors if discolored, pitted, NOTE: The following procedure applies to the front brake or scored.
Page 450 ____________________________________________________________ Brake System 7-11 ® Installation MASTER CYLINDER REPLACEMENT Install a washer and coupling to caliper (Figure 7-6). Removal WARNING: Ensure brake pads are installed with lin- CAUTION: Cover or plug all open connections immediately ings facing rotor. Failure to do this will cause poor per- after disconnecting to prevent contamination formance and damage to equipment and may result in NOTE: Have drainage container ready to catch brake fluid.
Page 451 _____________________________________________________________ 7-12 Brake System ® MASTER CYLINDER BLEEDING RESERVOIR NOTE: Master cylinder must be filled and kept at least half full during bleeding operation (Figure 7-9). MASTER CYLINDER 1. Depress brake pedal slowly and hold. Loosen front brake FLANGE line to purge air from the front section of the reservoir. 2.
Page 452: Hydro-Boost Replacement
1. Install gasket and hydro-boost on cowl with four washers, lockwashers, and nuts. Do not tighten nuts. (Figure 7-10). CAUTION: The HUMMER is equipped with DOT 3 brake fluid. Do not mix with other brake fluids. Failure to use the 2.
Page 453: Brake Line Replacement
_____________________________________________________________ 7-14 Brake System ® BRAKE LINE REPLACEMENT Intermediate Brake Line Replacement Metal brake lines should be inspected for leaks or deterioration NOTE: The procedure is the same for the right and left inter- every time the vehicle is being serviced. mediate brake lines.
Page 454 ____________________________________________________________ Brake System 7-15 ® METAL BRAKE LINES LINE MOUNTIG CLIP FROM ABS/TT4 MODULATOR UNION CALIPER Figure 7-13: Rear Brake Component Location 05745159...
Page 455 _____________________________________________________________ 7-16 Brake System ® LINE MOUNTING CLIP CALIPER METAL LINES TO REAR CALIPERS METAL BRAKE LINES MODULATOR MASTER CYLINDER HYDROBOOST Figure 7-14: Front Brake Component Location...
Page 456 ____________________________________________________________ Brake System 7-17 ® SERVICE BRAKE PEDAL REPLACEMENT SERVICE BRAKE ROTOR REPLACEMENT Removal Removal Disconnect the stoplight switch (Figure 7-15). Remove service brake caliper. Remove pushnut and disconnect stoplight switch rod (if so Remove six capscrews, lockwashers, halfshaft, and rotor equipped) from brake pedal assembly.
Page 457 _____________________________________________________________ 7-18 Brake System ® REAR DUAL SERVICE/PARKING BRAKE PAD TAPPED REPLACEMENT HOLE ADAPTER ADAPTER SLIDE ROTOR Removal 1. Put transmission in PARK, chock wheels, and release parking brake. 2. Remove cotter pin, washer, and clevis pin securing BRAKE PAD parking brake cable to lever.
Page 458 ____________________________________________________________ Brake System 7-19 ® BUSHING CALIPER CABLE BRACKET CALIPER CLIP CALIPER CABLE BRACKET CALIPER CABLE BRACKET STOP LEVER CALIPER PISTON FACE DUST BOOT Figure 7-20: Rear Dual Brake Caliper PARKING BRAKE Installation CABLE WARNING: Ensure brake pads are installed with lin- CLEVIS PIN ings facing rotor.
Page 459: Rear Dual Service/Parking Brake
_____________________________________________________________ 7-20 Brake System ® REAR DUAL SERVICE/PARKING BRAKE Cleaning and Inspection CALIPER REPLACEMENT NOTE: Clean all components, examine for wear or damage, and replace if necessary. Apply a light coat of brake compo- Removal nent lubricant on adapter slides. 1.
Page 460 ____________________________________________________________ Brake System 7-21 ® CALIPER CABLE BRACKET CLIP CALIPER LEVER CABLE BRACKET STOP LEVER PARKING BRAKE CABLE PARKING CLEVIS BRAKE CLEVIS Figure 7-23: Rear Dual Service/Parking Brake Caliper Cable Bracket CALIPER CABLE BRACKET CALIPER BLEEDER VALVE CALIPER PISTON FACE DUST BOOT Figure 7-24: Rear Caliper and Bleeder Valve 05745159...
Page 461 _____________________________________________________________ 7-22 Brake System ® Installation Open bleeder valve and depress piston into caliper while rotating piston in a clockwise direction, and at the same time apply pressure until piston is seated in piston bore ADAPTER (Figure 7-24). NOTE: Perform step 2 only if caliper guide pins were re- placed.
Page 462 ____________________________________________________________ Brake System 7-23 ® RIGHT PARKING BRAKE CABLE REPLACEMENT Removal Installation 1. Put transmission in PARK, chock wheels, and release NOTE: Perform step 1 if clamp bracket was removed, if not, parking brake. proceed to step 2. 2. Remove cotter pin, washer, clevis pin, and brake clevis Rotate bracket inward on support bracket and secure with from lever.
Page 463: Left Parking Brake Cable Replacement
_____________________________________________________________ 7-24 Brake System ® LEFT PARKING BRAKE CABLE REPLACEMENT Removal Installation 1. Put transmission in PARK, chock wheels, and release NOTE: Perform step 1 if clamp bracket was removed. If not, parking brake. proceed to step 2. 2. Remove cotter pin, washer, clevis pin, and brake clevis Rotate bracket inward on support bracket and secure with from lever.
Page 464 ____________________________________________________________ Brake System 7-25 ® PARKING BRAKE ROD REPLACEMENT CALIPER CABLE BRACKET Removal 1. Put transmission in PARK, chock wheels, and release parking brake. 2. Remove cotter pin, washer, clevis pin, and brake clevis from lever. Discard cotter pin (Figure 7-28). 3.
Page 465: Body
_____________________________________________________________ 7-26 Brake System ® Adjustment NOTE: Perform step 7 on both sides of vehicle. 1. Put transmission in PARK, chock wheels, and release Parking brake rod is properly adjusted if lever is in contact parking brake. with caliper cable bracket stop (Figure 7-31). 2.
Page 466 ____________________________________________________________ Brake System 7-27 ® Installation PARKING BRAKE LEVER 1. Install boot on body. Install upper boot on parking brake WIRING HARNESS CLAMP hand lever. Install parking brake hand lever on body and secure with two washers, bolts, washers, and locknuts. Secure parking brake hand lever on body with bolt, nut and lockwasher assembly, wiring harness clamp, and nut and lockwasher assembly.
Page 467 Assembly HOSE INLET CAUTION: The HUMMER is equipped with DOT 3 fluid. Do not mix with other brake fluids . Failure to use the proper brake fluid will damage brake system. Lubricate caliper bore and seal with DOT 3 brake ﬂuid (Figure 7-35).
Page 468 ____________________________________________________________ Brake System 7-29 ® REAR CALIPER OVERHAUL 13. Remove and discard actuator shaft dust seal. Discard seal. 14. Remove and discard centering pin plug O-ring. Rear Caliper Disassembly (Figure 7-37) 15. Remove and discard centering pin O-ring. 1. Mount caliper in vise so parking brake lever and spring are 16.
Page 469 _____________________________________________________________ 7-30 Brake System ® 6. Install thrust screw as follows: a. Align slot in thrust screw with centering pin. b. Insert thrust screw in caliper and seat it on centering pin and on ball bearings. c. Compress thrust screw retaining ring with fingers and install it in caliper bore below piston seal groove.
Page 470 ____________________________________________________________ Brake System 7-31 ® LEVER RETAINER AND BOOT THRUST SCREW CENTERING PIN O-RING SPACER BLEEDER SCREW CAP PLUG BLEEDER SCREW LEVER RETURN SPRING PARKING BRAKE O-RING LEVER ACTUATOR ACTUATOR SHAFT SHAFT DUST SEAL O-RING CABLE HOUSING CALIPER BEARING RACE ACTUATOR SHAFT THRUST BEARING...
Page 471: Brake Rotor
_____________________________________________________________ 7-32 Brake System ® BRAKE ROTOR tachments should always be used when refinishing braking sur- faces. These attachments eliminate tool chatter to allow for a Cleaning and Inspection better surface finish. Make sure these adaptors are clean and free of nicks. The optional swirl pattern finish will provide the NOTE: Clean all components, examine for wear or damage, best initial braking effectiveness.
Page 472: Parking Brake Lever Adjustment
Slowly let up on service brake pedal. Parking brake should hold vehicle stationary. PARKING BRAKE LEVER CAUTION: The HUMMER is equipped with DOT 3 brake fluid. Do not mix with other brake fluids . Failure to use the PARKING BRAKE ROD proper brake fluid will damage brake system.
Page 473: System Description
_____________________________________________________________ 7-34 Brake System ® ANTI-LOCK BRAKE SYSTEM (ABS) AND AUTO- Anti-lock braking operates by continually sensing the speed of each wheel. Wheel speed information is transmitted to an Elec- ™ MATIC TRACTION CONTROL, TORQTRAC 4 tronic Control Unit (ECU) which evaluates the information to ™...
Page 474: Fault Code List
____________________________________________________________ Brake System 7-35 ® 3. The start phase consists of the ABS warning light flashing The first part of the code number (Figure 7-46:): A pause in the following sequence (Figure 7-45): of 2.5 seconds precedes a series of short flashes. Count the flashes until the next long pause occurs.
Page 475 _____________________________________________________________ 7-36 Brake System ® Fault Code List - Ignition key “OFF” to test system (except where noted) Test Pin Fault Code Problem Area Values Check/Repair Locations Shuttle valve 25 and 27 Brake pedal at If wiring and connections OK, replace modulator. rest 3k Ω...
Page 476 ____________________________________________________________ Brake System 7-37 ® Fault Code List Ignition key “OFF” to test system (except where noted) Test Pin Fault Code Problem Area Values Check/Repair Locations 3.0-5.0 W Open circuit 24 and 27 Check electrical resistance of affected valve wir- between ECU ing to ground at the ECU connector and at the and left front...
Page 477 _____________________________________________________________ 7-38 Brake System ® Fault Code List Ignition key “OFF” to test system (except where noted) Test Pin Fault Code Problem Area Values Check/Repair Locations 5.0-7.5 W Short circuit to 23 and 27 Check electrical resistance of affected valve wir- ground between ing to ground at ECU connector and at modulator ECU and left...
Page 478 ____________________________________________________________ Brake System 7-39 ® Fault Code List Ignition key “OFF” to test system (except where noted) Test Pin Fault Code Problem Area Values Check/Repair Locations 500-2000 W 4-13 Left rear wheel 18 and 35 Check electrical resistance of affected sensor and speed sensor wiring at ECU connector and at harness plugs.
Page 479 _____________________________________________________________ 7-40 Brake System ® Fault Code List Ignition key “OFF” to test system (except where noted) Test Pin Fault Code Problem Area Values Check/Repair Locations Short circuit to 5 and 27 0 volts Check voltages at wiring harness including con- 3.0-5.0 W battery between nectors.
Page 480 ____________________________________________________________ Brake System 7-41 ® Fault Code List Ignition key “OFF” to test system (except where noted) Test Pin Fault Code Problem Area Values Check/Repair Locations 5-15 Right rear 16 and 33 Greater than 0.9 Check for damaged tone wheel, incorrect sensor wheel speed volts AC at one adjustment, excessive tone wheel runnout...
Page 481 _____________________________________________________________ 7-42 Brake System ® Fault Code List Ignition key “OFF” to test system (except where noted) Test Pin Fault Code Problem Area Values Check/Repair Locations 5.0-7.5 W Short circuit 21 and 4, 5, 6, Check electrical resistance of affected valves and between two 7, 22, 23, 24 wiring at ECU connector and at modulator assem-...
Page 482 ____________________________________________________________ Brake System 7-43 ® RIGHT LEFT RIGHT FRONT REAR REAR WHEEL WHEEL WHEEL WHEEL SPEED SPEED SPEED SPEED SENSOR SENSOR SENSOR SENSOR C2-11 C2-10 C2-19 C2-20 C2-32 C2-31 C2-23 C2-22 MOTOR MONITOR PUMP MOTOR MODULATOR 9-S07-001 Figure 7-47: ABS/TT4 Main System Diagram. 05745159...
Page 483 _____________________________________________________________ 7-44 Brake System ® C1-19 C1-34 DIAGNOSTIC FUSE C1-21 5 AMP Exterior Fuse C1-52 C3-D3 C9-C WARNING RELAY TO IGNITION SWITCH C3-E2 ATC INFORMATION LAMP STATUS C10-E CENTER VALVE RELAY TO GUAGES FUSE 575 OR ABS WARNING FUSE IC LAMP 25 AMP Exterior...
Page 484 ____________________________________________________________ Brake System 7-45 ® C7 FEMALE ONLY D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16 D17 D18 D19 D20 D21 D22 D23 D24 D25 D26 D27 D28 D29 D30 D31 D32 D33 D34 D35 9-S12-043 Figure 7-49: 35 Pin ECU Connector Female Half COLOR...
Page 485 _____________________________________________________________ 7-46 Brake System ® COLOR DESCRIPTION Shuttle valve switch signal ABS warning lamp activation Ground Pump motor monitor Reference ground Left front wheel speed sensor high Right rear wheel speed sensor high Right front wheel speed sensor high Left rear wheel speed sensor high C11 FEMALE ONLY CAV 5 CAV 1...
Page 486 ____________________________________________________________ Brake System 7-47 ® C2 MALE PIN 34 PIN 42 PIN 28 PIN 33 PIN 22 PIN 27 PIN 16 PIN 21 PIN 10 PIN 15 PIN 1 PIN 9 9-S12-015 Figure 7-51: 42 Pin Underbody Connector Male Half C2 FEMALE CAV 42 CAV 34...
Page 487: Abs Modulator Replacement
_____________________________________________________________ 7-48 Brake System ® ABS MODULATOR REPLACEMENT 8. Remove the four bolts, washers and lock washers securing the modulator bracket to the air lift bracket (Figure 7-54). Removal WARNING: Batteries must be disconnected when the brake hydraulic system is being serviced and bled. If the ABS motor pump runs when air is in the hydraulic sys- tem, air can get trapped behind the valves in the modu- lator causing a spongy brake pedal.
Page 488: Speed Sensor Replacement
____________________________________________________________ Brake System 7-49 ® 11. Disengage the modulator alignment pin from the mounting bracket and remove the modulator from the mounting bracket. 12. Remove the brake line adapters, noting the position for reinstallation Installation 1. Install the brake line adapters in the same position as in the original modulator.
Page 489: Abs Ecu Replacement
_____________________________________________________________ 7-50 Brake System ® Installation ABS ECU REPLACEMENT Turn ignition switch “OFF”. NOTE: Left side speed sensor leads route across above the Remove the ECU enclosure hold-down bracket and lift the halfshaft cv-joint. Care must be taken to ensure the lead does top half of the ECU enclosure up and out of the pocket in not come in contact with the cv-joint.
Page 490 ____________________________________________________________ Brake System 7-51 ® ESSENTIAL TOOLS 8-S07-001 9-S07-016 J–35592 J–42553 00-S07-001 J-44237 00-S07-002 J-42883 Tool No. Description J–42553 Disc Brake Piston Retraction Tool J–35592 ABS Pinout Box J–44237 ABS Blink Code Jumper J–44238 Master Cylinder Bleed Adapter (not shown) J–42883 Wheel Speed Sensor Test Cable J–29532...
Page 491 _____________________________________________________________ 7-52 Brake System ® THIS PAGE INTENTIONALLY BLANK.
Page 492 A recirculating ball-type steering gear is used for all applica- tions. The gear is also supplied by Delphi Saginaw Steering Systems. A steering fluid cooler is used on all Hummer models. The ver- tical mount cooler is located at the driver side of the fan shroud.
Page 493 ___________________________________________________________ 8-2 Steering System ® Power Steering Fluid STEERING ARM Recommended fluid for the power steering system is Dexron III. Power Steering Component Service Most of the power steering pump components are not service- able. The seals and the flow control valve, however, can be serviced.
Page 494: Center Link Replacement
___________________________________________________________ Steering System ® CENTER LINK REPLACEMENT Installation Secure the center link to the pitman arm and the idler arm Removal with two slotted nuts and tighten to 80 lb-ft (108 N•m). Raise and support the front of the vehicle. Install a cotter pin in each slotted nut.
Page 495: Tie Rod End Replacement
___________________________________________________________ 8-4 Steering System ® TIE ROD END REPLACEMENT 3. Before final tightening of the sleeve clamp hardware, center both tie rod end studs in their sockets (Figure 8-5). Removal CAUTION: If the stud and socket are not properly aligned, a 1.
Page 496 ___________________________________________________________ Steering System ® TIE ROD REPLACEMENT Assembly Apply anti-seize compound to the threads in the adjusting Removal sleeve. 1. Raise and support the front of the vehicle. Thread two tie rod ends into the adjusting sleeve, turning 2. Remove the cotter pins and slotted nuts from the center them the same number of revolutions that were required link end and the geared hub end of the tie rod (Figure 8-6).
Page 497: Idler Arm Replacement
___________________________________________________________ 8-6 Steering System ® IDLER ARM REPLACEMENT STEERING WHEEL REPLACEMENT Removal NOTE: Ensure front wheels are in a straight ahead position. 1. Raise and support the front of the vehicle. Removal 2. Remove the cotter pin and the slotted nut securing the 1.
Page 498 ___________________________________________________________ Steering System ® STEERING COLUMN REPLACEMENT 10. Remove two locknuts, washers, pivot bolts, and steering column from mounting bracket. Removal Installation NOTE: Before removing steering wheel, turn steering column Hang steering column from mounting bracket with two to gain access to intermediate shaft mounting hardware. pivot bolts, washers, and locknuts.
Page 499 ___________________________________________________________ 8-8 Steering System ® STEERING COLUMN MULTI-SWITCH LOCK AND SWITCH HOUSING ASSEMBLY REPLACEMENT REPLACEMENT Removal NOTE: This procedure covers the directional signal, horn, high beam, and hazard light switches. 1. Disconnect battery ground cable. 2. Follow steps 2, 3, 5 and 6 of Steering Column Removal Replacement .
Page 500: Steering Column Repair
___________________________________________________________ Steering System ® STEERING COLUMN REPAIR Remove the retainer ring, shaft, and bearing from the tube and bracket assembly. Lock and Switch Housing Assembly Assembly Disassembly Install the shaft, bearing, and retainer ring into tube and bracket assembly (Figure 8-15). NOTE: The key must stay in the ignition switch at all times.
Page 501 __________________________________________________________ 8-10 Steering System ® Steering Column and Shaft STEERING WHEEL HUB COVER AND STEERING COLUMN SHROUD REPLACEMENT Disassembly Removal Remove two screws and the multi-switch assembly from the lock and switch housing (Figure 8-12). 1. Remove three screws holding front half of steering wheel hub cover to the rear half.
Page 502: Ignition Interlock Cable Replacement
_________________________________________________________ Steering System 8-11 ® IGNITION SWITCH LOCK CYLINDER IGNITION INTERLOCK CABLE REPLACEMENT REPLACEMENT Removal Removal Remove ﬁve screws and lower shroud from steering col- umn (Figure 8-17). 1. Disconnect battery ground cable. 2. Remove close-out panel. 31 lb-ft (42 N•m) 3.
Page 503: Steering Gear Replacement
__________________________________________________________ 8-12 Steering System ® Test IGNITION SWITCH LOCK AND SWITCH 1. With transmission lever in P, turn ignition key to run. HOUSING ASSEMBLY CONNECTOR 2. Activate brake switch and move transmission lever to N. 3. Without turning ignition key off, move transmission shift lever to P.
Page 504 _________________________________________________________ Steering System 8-13 ® Removal 2. Turn steering wheel left and right several times to bleed off power steering fluid. Remove close-out panel. 3. Remove bolt on intermediate shaft yoke at steering gear Remove three nuts, six washers, and three screws from and disconnect intermediate shaft from steering gear.
Page 505 __________________________________________________________ 8-14 Steering System ® INTERMEDIATE STEERING SHAFT DUST BOOT Installation REPLACEMENT 1. Secure spacer and dust boot to cowl panel with four screws, eight washers, and four locknuts. Tighten locknuts Removal to 60 lb-ft (81 N•m) (Figure 8-23). Remove close-out panel. 2.
Page 506 _________________________________________________________ Steering System 8-15 ® POWER STEERING PUMP AND PULLEY Check condition of O-ring seal and connect high pressure line to back of pump. REPLACEMENT Removal CAUTION: In step 7, do not attempt to drive the pulley onto the pump shaft with a hammer. The pulley and pump ring will 1.
Page 507 __________________________________________________________ 8-16 Steering System ® POWER STEERING HYDRAULIC SYSTEM PRESSURE HOSE PRESSURE AND RETURN HOSE REPLACEMENT O-RING SEALS NOTE: Removal and installation procedures are basically the same for all hydraulic system pressure and return hoses. This procedure covers the power steering pump to hydro-boost re- STEERING turn hose and the steering gear to hydro-boost pressure hose.
Page 508 _________________________________________________________ Steering System 8-17 ® POWER STEERING COOLER AND COOLER Installation HOSE REPLACEMENT Secure power steering oil cooler to fan shroud with two bolts, reinforcement plate, four washers, and two nuts Removal (Figure 8-28). 1. Disconnect two hoses from cooler (Figure 8-28). Reinstall cooling fan.
Page 509: Power Steering Gear Service
__________________________________________________________ 8-18 Steering System ® POWER STEERING GEAR SERVICE The Saginaw recirculating ball, power steering gear (Figure 8-29), is a fully serviceable component. The gear can be adjusted, or overhauled as needed. Overhaul requires that the gear be removed from the vehicle as repair can only be per- formed on the bench.
Page 510 _________________________________________________________ Steering System 8-19 ® POWER STEERING SYSTEM DIAGNOSIS CHARTS The diagnosis charts are guidelines to potential system faults. While the charts outline common faults, they may not cover all The charts list potential faults in order of probability (most possible problem causes.
Page 511 __________________________________________________________ 8-20 Steering System ® Table 2 Power Steering Diagnosis Chart - part 2 Problem Possible Cause Correction “Hiss” Noise Noisy relief valve in the pump. There is some noise in all power steering systems. One of the most common is a hissing sound most evident at standstill parking.
Page 512 _________________________________________________________ Steering System 8-21 ® Table 3 Power Steering Diagnosis Chart - part 3 Problem Possible Cause Correction Low Oil Pressure Due to 1. Check for kinks in hose. Remove the kinks or replace the hose. Restriction in the Hose 2.
Page 513 __________________________________________________________ 8-22 Steering System ® PURGING AIR FROM THE POWER STEERING POWER STEERING SYSTEM PRESSURE TEST SYSTEM Power steering system performance can be checked with ana- lyzer set J– 25323 and hose fitting adapters J– 33141. The ana- Air must be bled from the system before pressure testing and lyzer checks flow in gallons per minute (gpm) and min/max anytime the hoses are disconnected or the pump and/or gear is pressure in psi.
Page 514 _________________________________________________________ Steering System 8-23 ® POWER STEERING GEAR DISASSEMBLY AND 13. Turn steering wheel lightly against each stop and record maximum pressure. OVERHAUL If pressure at each stop is about the same as recorded Cleanliness is extremely important to a successful gear over- in step 10, and flow drops to 0.5 gpm (1.85 L/min.), haul.
Page 515 __________________________________________________________ 8-24 Steering System ® Gear Housing End Plug Removal Rotate end plug retaining ring until one end is under small PLUG O-RING access hole in housing (Figure 8-32). RETAINING RING PUNCH GEAR SCREWDRIVER HOUSING Figure 8-33: End Plug and Seal Removal Adjuster Plug Removal and Disassembly 1.
Page 516 _________________________________________________________ Steering System 8-25 ® STUB STUB SHAFT SHAFT SNAP DUST SEAL BEARING RING O-RING THRUST SEAL BEARING SPANNER TOOL J–7624 SPACER STUB SHAFT OIL SEAL ADJUSTER PLUG INNER OUTER RACE RACE RETAINER Figure 8-37: Adjuster Plug Components ADJUSTER PLUG Remove stub shaft seal retainer.
Page 517 __________________________________________________________ 8-26 Steering System ® Rack Piston Removal and Disassembly 1. Rotate stub shaft counterclockwise until rack piston is ARBOR TOOL J–21552 even with seal groove in open end of housing. Do not allow the rack piston to extend out of the housing. It only needs to be about 1/4 inch from the end.
Page 518 _________________________________________________________ Steering System 8-27 ® Valve Body-Stub Shaft-Wormshaft Removal VALVE SPOOL and Disassembly 1. Grasp splined end of stub shaft and carefully rotate valve body/stub shaft assembly out of gear housing. O-RING If wormshaft remained engaged in stub shaft cap, disengage and remove wormshaft at this time.
Page 519 __________________________________________________________ 8-28 Steering System ® Pitman Shaft Bearing and Seal Removal POWER STEERING GEAR CLEANING AND INSPECTION 1. Remove seal retaining ring with internal-type snap ring Discard all the old O-rings, seals, and seal rings. Do not reuse pliers. these parts. 2.
Page 520 _________________________________________________________ Steering System 8-29 ® ADJUSTER RACK PISTON BACKUP O-RING SIDE COVER END PLUG GASKET O-RING ADJUSTER SCREW PITMAN WORMSHAFT SHAFT THRUST BEARING HOSE RACK PISTON SEATS SEAL RING END PLUG GUIDE WORMSHAFT CLAMP END PLUG RETAINING RING RACES BALL GUIDES BEARING PITMAN SHAFT...
Page 521 __________________________________________________________ 8-30 Steering System ® POWER STEERING GEAR ASSEMBLY AND Pitman Shaft Bearing and Seal Installation ADJUSTMENT 1. Lubricate bearing and seals with power steering ﬂuid, or petroleum jelly. Gear Housing Hose Seat Replacement Install bearing in gear housing with handle J–8092 and The hose seats in the gear housing (Figure 8-49), can be re- installer J–6278 or J–21551 (Figure 8-50).
Page 522 _________________________________________________________ Steering System 8-31 ® Install wormshaft in rack piston. Wormshaft flange should be seated against piston as shown (Figure 8-53). LOAD BEARING BALLS INTO THIS BALL GUIDE PORT INSTALLER WORMSHAFT TOOL FLANGE J–6219 RACK PISTON GEAR Figure 8-53: Rack Piston Loading Port HOUSING For Bearing Balls Figure 8-51: Pitman Shaft Seal Installation...
Page 523 __________________________________________________________ 8-32 Steering System ® TEFLON COATED BALL SEAL RING GUIDE (OVER O-RING) HALVES BEARING BALLS PETROLEUM JELLY Figure 8-54: Assembling Remaining Bearing Balls Figure 8-55: Valve Body Seal Ring Installation and Ball Guides 4. Install new O-ring on valve spool. 7.
Page 524 _________________________________________________________ Steering System 8-33 ® 6. Install stub shaft in valve body as follows: a. Insert stub shaft into valve body. b. Leave approximately 1/4 inch (6 mm) space between stub shaft cap and valve body for access to pin (Figure 8-57).
Page 525 __________________________________________________________ 8-34 Steering System ® Adjuster Plug Assembly THRUST 1. Position new stub shaft bearing on installer tool J–6221. BEARING Position bearing so ID number is toward installer tool. This will minimize any chance of damaging the bearing during installation. 2.
Page 526 _________________________________________________________ Steering System 8-35 ® Gear Housing Assembly SNAP STUB SHAFT Lubricate wormshaft, stub shaft-valve body, rack piston, RING DUST SEAL and adjuster plug with power steering ﬂuid. ADJUSTER PLUG Install wormshaft and stub shaft/valve body assembly in INNER gear housing. Be sure wormshaft thrust bearings are not RACE OUTER displaced during installation.
Page 527 __________________________________________________________ 8-36 Steering System ® Wormshaft Bearing Preload Torque Adjustment 1. Mount gear in vise equipped with protective vise jaws. RING GAP Position gear so adjuster plug is accessible and wormshaft is horizontal. PUNCH 2. If adjuster plug locknut is installed, loosen nut with punch ACCESS HOLE and hammer and remove it from adjuster plug.
Page 528 _________________________________________________________ Steering System 8-37 ® FIRST MARK SPANNER WRENCH HOLE IN ADJUSTER PLUG FIRST INDEX MARK HOUSING) SPANNER WRENCH SECOND J–7624 MARK Figure 8-66: Placing First Index Mark On Housing Figure 8-68: Backing Off Adjuster Plug To Second Index Mark 6.
Page 529 __________________________________________________________ 8-38 Steering System ® Pitman Shaft Overcenter Preload Torque 5. Measure wormshaft bearing preload as follows: Adjustment • Position suitable size 12 point socket and inch pound torque wrench J–7754-C on stub shaft (Figure 8-71). Loosen locknut on pitman shaft adjuster screw. •...
Page 530 _________________________________________________________ Steering System 8-39 ® POWER STEERING PUMP REPAIR Disassembly NOTE: Fitting assembly is spring loaded. Remove care- (Figures 8-72 through 8-77) fully to avoid losing parts. 1. Suction ﬂuid from reservoir and disconnect ﬂuid reservoir hose from pump. Remove fitting assembly and O-ring seal. Discard O-ring 2.
Page 531 __________________________________________________________ 8-40 Steering System ® RETAINING RING PRESSURE PLATE SPRING O-RING SEAL END PLATE O-RING PUMP BODY SEALS Figure 8-75: End Plate Removal CAUTION: If end of driveshaft in steering pump housing MAGNET is corroded, clean with an abrasive crocus cloth before removing shaft.
Page 532 _________________________________________________________ Steering System 8-41 ® Cleaning and Inspection Inspect studs for damage. (Figure 8-78) Inspect fitting for damage. NOTE: Clean all components, examine for wear or dam- Inspect housing for damage. age, and replace if necessary. Inspect remaining components for damage. Replace power steering pump if any component is damaged.
Page 533 __________________________________________________________ 8-42 Steering System ® Assembly (Figures 8-72 through 8-83) NOTE: For general assembly instructions refer to Sec- CAUTION: To avoid damage to equipment, install pump tion 2. ring with arrow pointing up. Install O-ring seal in bottom groove of pump body 8.
Page 534 _________________________________________________________ Steering System 8-43 ® 12. Install O-ring seal in center groove in pump body 17. Install O-ring seal on pump body (Figure 8-82). (Figure 8-80). 18. Install housing on pump body. 13. Install pressure plate spring in pump body. 14.
Page 535: Steering Specifications
__________________________________________________________ 8-44 Steering System ® POWER STEERING SYSTEM FLUSHING STEERING SPECIFICATIONS The power steering system can be flushed but only when the Recommended fluid is Dextron III. fluid does not contain metal particles, foreign material, or de- Steering Gear Adjustment Preload Torques bris from a gear or pump failure.
Page 536 _________________________________________________________ Steering System 8-45 ® ESSENTIAL TOOLS – 24319-B – 25033-C – 33141 – 8092 – 25034-C – 25323 – 42548 Tool Description J–24319-B Steering Linkage and Tie-Rod Puller J–25033-C Pump Pulley Installer J–33141 Adapter Fittings (used with J–25323) J–25034-C Pump Pulley Remover J–25323 Power Steering System Analyzer...
Page 537 __________________________________________________________ 8-46 Steering System ® SPECIAL TOOLS – 4245 – 6219 – 6221 – 8092 or J – 7079 – 6278 or J – 21551 – 7624 – 21552 – 7754-C Tool Description J–6219 Pitman Shaft Seal Installer J–6221 Stub Shaft Bearing and Seal Remover/Installer J–6278 (or J–21551) Pitman Shaft Bearing Remover/Installer J–7624...
Page 538 ________________________________________________________________________________ ® Section 9 Axles, Suspension, and Frame TABLE OF CONTENTS Airlift Brackets ....... . . 9-48, 9-49 Transmission Mount Crossmember .
Page 539: Stabilizer Bar Replacement
9-2 Axles, Suspension, and Frame ® SUSPENSION SYSTEM DESCRIPTION FRAME The HUMMER suspension system consists of a heavy-duty BRACKET coil spring, a heavy-duty hydraulic shock absorber, and an up- per and lower control arm at each wheel. This suspension sys- tem provides for a smoother ride and allows for more positive control of the vehicle.
Page 540 __________________________________________ Axles, Suspension, and Frame ® RADIUS ROD REPLACEMENT UPPER BALL JOINT WEAR CHECK PROCEDURE Removal NOTE: If the vehicle was previously lifted off the ground for other service, center the steering wheel, roll the vehicle for- 1. Remove wheel. ward and back to settle the suspension and relieve the tension 2.
Page 541: Upper Ball Joint Replacement
___________________________________________ 9-4 Axles, Suspension, and Frame ® UPPER BALL JOINT REPLACEMENT LOWER BALL JOINT WEAR CHECK Support lower control arm with a jack or stand to unload Removal lower ball joint. 1. Remove wheel. Place prybar between lower arm at ball joint and geared 2.
Page 542 __________________________________________ Axles, Suspension, and Frame ® LOWER BALL JOINT REPLACEMENT UPPER CONTROL ARM REPLACEMENT Removal NOTE: The procedure for removing and installing the front and rear upper control arms is basically the same. This proce- 1. Remove wheel. dure covers the left front upper control arm. 2.
Page 543 ___________________________________________ 9-6 Axles, Suspension, and Frame ® Installation 3. Install upper ball joint on geared hub with slotted nut. Using crowfoot and adapter, tighten slotted nut to 65 lb-ft 1. Install upper control arm on brackets with two washers, (88 N•m). Install cotter pin in slotted nut. eccentrics, bolts, and locknuts.
Page 544 __________________________________________ Axles, Suspension, and Frame ® CONTROL ARM BUSHING REPLACEMENT LOWER CONTROL ARM REPLACEMENT Removal NOTE: The procedure for removing and installing the front and rear lower control arms is basically the same. This proce- NOTE: Control arm bushings must be replaced as a set dure covers the left front lower control arm.
Page 545: Geared Hub Replacement
___________________________________________ 9-8 Axles, Suspension, and Frame ® Installation GEARED HUB REPLACEMENT WARNING: Lower control arm must be supported dur- NOTE: Replacement procedures are basically the same for front and rear geared hubs. This procedure covers the front ing removal and installation. Failure to support lower geared hub.
Page 546 __________________________________________ Axles, Suspension, and Frame ® Installation WARNING: To avoid injury and damage to equip- NOTE: Make sure mounting hole and bolt are cleared of old Loctite. ment, support geared hub during removal and installa- tion. Apply thread-locking compound to halfshaft retaining bolt and secure halfshaft to geared hub with lockwasher and 1.
Page 547 _________________________________________ 9-10 Axles, Suspension, and Frame ® 13. Remove fill plug and washer from geared hub (Figure 9-18). GEARED HUB TIE ROD END FILL PLUG SLOTTED NUT GEARED HUB Figure 9-16: Tie Rod End Into Geared Hub VENT LINE Figure 9-18: Geared Hub Fill Plug 14.
Page 548 ________________________________________ Axles, Suspension, and Frame 9-11 ® GEARED HUB SIDE COVER REPLACEMENT GEARED HUB INPUT SEAL REPLACEMENT Removal NOTE: Geared hub side cover replacement procedures are basically the same for front and rear covers. This procedure Remove wheel. covers the front side cover. Remove access plug and washer from geared hub (Figure 9-15).
Page 549 _________________________________________ 9-12 Axles, Suspension, and Frame ® NOTE: Be sure that bolt and bolt hole are cleaned of old Loctite. DRIVER HANDLE J–8092 6. Apply thread-locking compound to halfshaft retaining bolt and secure halfshaft to geared hub with lockwasher and halfshaft retaining bolt.
Page 550 ________________________________________ Axles, Suspension, and Frame 9-13 ® CLAMPNUT STEERING ARM COVER SOCKET GEARED HUB CLAMPNUT LOCK SCREW KEYED WASHER CLAMPNUT INNER BEARING DRIVE BEARING GEAR SPACER DIAL INDICATOR J–8001 Figure 9-24: Dial Indicator Positioning 5. Remove four bolts, washers, and steering arm cover from geared hub (Figure 9-25).
Page 551 _________________________________________ 9-14 Axles, Suspension, and Frame ® Inspection NOTE: Clean all components, examine for wear or damage, DRIVE GEAR RETAINER and replace if necessary. Drive and driven gears must be re- placed as matched set (Figure 9-28). 1. Inspect splines and gear teeth on drive gear and driven gear for damage.
Page 552 ________________________________________ Axles, Suspension, and Frame 9-15 ® Assembly Install retaining washer in shallow end of drive gear (Figure 9-31). 1. Place the new output seal on the installer J–44906, with the seamed side of the stainless steel perimeter facing toward the geared hub and drive the seal in until the DRIVE GEAR RETAINER installer bottoms out on the geared hub surface.
Page 553 _________________________________________ 9-16 Axles, Suspension, and Frame ® incorrect, add or subtract shim gaskets and recheck end 13. Apply a thin coat of grease to boss (protruding side) of play. clampnut and install clampnut on spindle. 8. Install driven gear and bearing spacer in geared hub NOTE: If an excessive amount of torque (18-26 lb-in.
Page 554 ________________________________________ Axles, Suspension, and Frame 9-17 ® 23. Clean sealing surfaces on geared hub and side cover. Apply anaerobic sealer to side cover and install on geared hub (Figure 9-34). GEARED HUB GEARED HUB SIDE COVER Figure 9-34: Geared Hub Side Cover Removal NOTE: Make sure bolts and holes are free of old Loctite.
Page 555 _________________________________________ 9-18 Axles, Suspension, and Frame ® Remove spindle, bearing spacer, inner bearing, and outer screw with a new one or remove all previously applied bearing spacer from geared hub. Loctite from threads of old screw and apply fresh Loctite 272 to old screw threads prior to reinstallation.
Page 556 ________________________________________ Axles, Suspension, and Frame 9-19 ® 16. Apply thread-locking compound to bolt threads and install steering arm cover on geared hub with four washers and bolts. Tighten bolts to 65 lb-ft (88 N•m). GEARED HUB 17. Remove fill plug and washer from geared hub (Figure 9-40).
Page 557 _________________________________________ 9-20 Axles, Suspension, and Frame ® CLAMPNUT LOCK SCREW GEARED HUB GEARED CLAMPNUT SOCKET SBAS-07M CLAMPNUT KEYED WASHER Figure 9-42: Clampnut Installation STEERING ARM COVER 11. Loosen and retighten clampnut to 25 lb-ft (34 N•m). Figure 9-43: Steering Arm Cover Installation NOTE: Ensure clampnut does not move while clampnut lock NOTE: Thoroughly clean old Loctite before applying fresh screw is being tightened.
Page 558: Halfshaft Boot Replacement
________________________________________ Axles, Suspension, and Frame 9-21 ® GEARED HUB SPINDLE STUD REPLACEMENT WARNING: Always wear eye protection when replac- ing spindle studs. Severe eye injury may result if metal GEARED chips contact eyes. HALFSHAFT RETAINING Removal BOLT 1. Remove wheel. 2.
Page 559 _________________________________________ 9-22 Axles, Suspension, and Frame ® Installation Install inner boot on shaft. Push boot past groove on shaft. Install the snap ring and retaining clip into grooves on 1. Position outer boot and two clamps on shaft near outer shaft (Figure 9-48).
Page 560 ________________________________________ Axles, Suspension, and Frame 9-23 ® AXLE VENT LINE REPLACEMENT 11. Position joint inner housing over bearing assembly. NOTE: Ensure all ball bearings are in the tracks of the inner NOTE: Axle vent line replacement procedures are basically joint. the same.
Page 561 _________________________________________ 9-24 Axles, Suspension, and Frame ® GEARED HUB VENT LINE REPLACEMENT Secure vent line to control arm with clamp and bolt (Figure 9-52). NOTE: All geared hub vent line replacement procedures are NOTE: Position clamp at a 45 degree angle toward the wheel basically the same.
Page 562 ________________________________________ Axles, Suspension, and Frame 9-25 ® AXLE ASSEMBLY COVER SERVICE AXLE OUTPUT SHAFT SEAL REPLACEMENT Removal Removal 1. Remove drainplug from axle assembly and drain axle Remove brake caliper and yoke from caliper adapter (dis- assembly (Figure 9-53). connect park brake cable from rear calipers) and support caliper to the side being careful not to kink brake line.
Page 563: Pinion Seal Replacement
_________________________________________ 9-26 Axles, Suspension, and Frame ® PINION SEAL REPLACEMENT AXLE ASSEMBLY REPLACEMENT Removal NOTE: Removal and installation procedures for pinion seals are basically the same for front and rear axle assemblies. This NOTE: Removal and installation procedures are basically the procedure covers the rear axle assembly pinion seal.
Page 564 ________________________________________ Axles, Suspension, and Frame 9-27 ® WARNING: Axle assembly must be supported during removal and installation. Failure to do this may cause AXLE ASSEMBLY personal injury or damage to equipment. 7. Support axle assembly. 8. Remove four bolts and washers securing axle assembly to side mounting brackets.
Page 565 _________________________________________ 9-28 Axles, Suspension, and Frame ® AXLE ASSEMBLY REPAIR SIDE Disassembly MOUNTING BRACKET MOUNTING Remove axle assembly. BRACKET Loosen locknut on output shaft assembly (Figure 9-60). AXLE ASSEMBLY SEAL WASHER VENT LINE LOCKNUT LOCKNUT TAPPED OUTPUT SHAFT ASSEMBLY OUTPUT HOLES FLANGE Figure 9-60: Output Shaft Assembly Removal...
Page 566 ________________________________________ Axles, Suspension, and Frame 9-29 ® 10. Spread housing 0.010 in. (0.25 mm) and remove dial indicator. DIFFERENTIAL 11. Remove differential assembly, two bearing cups, and COVER shims from housing (Figure 9-64). Tag bearing shims and bearing cups for assembly. DIFFERENTIAL BEARING ASSEMBLY...
Page 567 _________________________________________ 9-30 Axles, Suspension, and Frame ® FRONT PINION YOKE PINION NUT PINION HOUSING BEARING COVER PINION SEAL PINION GEAR COLLAPSIBLE SPACER Figure 9-66: Axle Housing 15. Remove pinion nut and pinion yoke from pinion gear. 16. Drive pinion gear out of front pinion bearing. DRIVER HANDLE 17.
Page 568 ________________________________________ Axles, Suspension, and Frame 9-31 ® PINION GEAR REAR PINION BEARING Figure 9-73: Ring Gear Figure 9-70: Pinion Bearing Removal 21. Remove two differential side bearings from differential assembly (Figure 9-69). 22. Remove rear pinion bearing from pinion gear (Figure 9-70). Figure 9-74: Pinion Gear 23.
Page 569: Axle Assembly
_________________________________________ 9-32 Axles, Suspension, and Frame ® NOTE: If the old pinion is marked -3 and the new pinion is marked +2, the procedure would be as follows: Refer to Old Pinion Marking column at left side of table and locate -3 in this DIFFERENTIAL ASSEMBLY column.
Page 570 ________________________________________ Axles, Suspension, and Frame 9-33 ® Table 4 Pinion Variance Table - Inches (millimeters) NEW PINION MARKING PINION MARKING +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 (0.20) (+0.18) (+0.15) (+0.13) (+0.10) (+0.08) (+0.05) (+0.03) +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001...
Page 571 _________________________________________ 9-34 Axles, Suspension, and Frame ® 10. Install two bearing caps and four bolts in housing and 13. After the zero setting is obtained, rotate the gauge shaft finger tighten bolts. until the dial indicator plunger does not touch the gauge block.
Page 572 ________________________________________ Axles, Suspension, and Frame 9-35 ® 23. Rotate housing 180 degrees. Lubricate outside diameter of PINION GEAR PINION DEPTH pinion rear bearing cup with gear oil (Figure 9-90). VARIANCE NUMBER NOTE: If pinion shim is beveled, be sure beveled side faces bottom of bearing cup bore.
Page 573 _________________________________________ 9-36 Axles, Suspension, and Frame ® PINION NUT HOUSING PINION YOKE COLLAPSIBLE PINION REAR SPACER BEARING PINION GEAR Figure 9-91: Rear Pinion Bearing Location NOTE: Side bearing shims are available in thickness from CAUTION: Collapsible spacer controls pinion bearing pre- 0.077-0.117 in.
Page 574 ________________________________________ Axles, Suspension, and Frame 9-37 ® 33. Install differential assembly, bearing cups, and shims in 38. Tighten four bolts to 55-70 lb-ft (75-95 N•m). housing. 39. Rotate differential assembly and check runout. Runout 34. Install two bearing caps and four bolts in housing. Snug should not exceed 0.002 in.
Page 575 _________________________________________ 9-38 Axles, Suspension, and Frame ® RING GEAR TOOTH RING GEAR DIAL INDICATOR J–8001 HOUSING PINION YOKE Figure 9-97: Checking Ring Gear Backlash NOTE: Backlash must be checked at four equally spaced 56. Remove four bolts, bearing caps, bearing cup, shims, and points on ring gear and must not vary more than 0.002 in.
Page 576 ________________________________________ Axles, Suspension, and Frame 9-39 ® 59. Preload differential side bearings by increasing shim 66. Using axle shaft and seal installer J–33142, install output thickness at each side of differential assembly by 0.004 in. shaft assemblies into axle assembly (Figure 9-101). (0.10 mm) for a total bearing preload of 0.008 in.
Page 577 _________________________________________ 9-40 Axles, Suspension, and Frame ® FRONT PROPELLER SHAFT AND Remove bolts attaching center bearing to engine mount (Figure 9-106). U-JOINT SERVICE Front Shaft Removal 1. Remove U-joint clamp bolts and straps. Then disconnect shaft yoke (Figure 9-104). FRONT AXLE YOKE ENGINE MOUNT...
Page 578 ________________________________________ Axles, Suspension, and Frame 9-41 ® REAR PROPELLER SHAFT SERVICE 7. Clean part with solvent. 8. Inspect shaft, slip yokes and U-joints for wear or damage. Removal 9. Replace worn U-joints. Refer to procedure in this section. Remove U-bolts, attaching rear shaft to rear axle yoke 10.
Page 579 _________________________________________ 9-42 Axles, Suspension, and Frame ® U-JOINT REPLACEMENT SUSPENSION HEIGHT MEASUREMENT 1. Remove propeller shaft. NOTE: Before checking suspension height, check the follow- 2. Remove grease fitting from cross (Figure 9-111). ing items: 3. Remove two bearing cups from cross (rear shaft only). Broken spring coil or shock absorber.
Page 580 Install coil spring over shock absorber and onto lower con- trol arm ensuring end of coil spring ﬁts in spring pocket of NOTE: Various load capacity springs are used in the Hummer lower control arm (Figure 9-113). based on powertrain and option packages. Refer to the parts...
Page 581 _________________________________________ 9-44 Axles, Suspension, and Frame ® SHOCK ABSORBER REPLACEMENT Installation NOTE: It may be necessary to spread spring seat to allow in- NOTE: The procedure for removing and installing all shock stallation of shock absorber. absorbers is the same, except rear lower shock pins must be in- stalled with head of pin facing rearward.
Page 582 ________________________________________ Axles, Suspension, and Frame 9-45 ® FRONT BUMPER AND TOWING BRACKETS FRONT BUMPER AND TOWING BRACKETS REPLACEMENT (VEHICLES WITHOUT WINCH) REPLACEMENT (VEHICLES WITH WINCH) Removal Removal 1. Remove brushguard, if equipped. WARNING: Winch must be supported prior to per- 2.
Page 583: Front Bumper Mounting Bracket
_________________________________________ 9-46 Axles, Suspension, and Frame ® FRONT BUMPER MOUNTING BRACKET RADIATOR FRONT MOUNT BRACKET REPLACEMENT REPLACEMENT Removal Removal Remove locknut, washer, bolt, washer, and spacer securing NOTE: Mark location of bolts for installation. radiator to front mount bracket (Figure 9-118). 1.
Page 584: Lifting Shackle Replacement
________________________________________ Axles, Suspension, and Frame 9-47 ® LIFTING SHACKLE REPLACEMENT FRAME EXTENSION REPLACEMENT Removal Removal Remove cotter pin, slotted nut, bolt, spring washer, and shackle Remove front bumper. from tiedown bracket. Discard cotter pin (Figure 9-119). Remove hood and hinge (Section 10). Remove two locknuts, washers, bolts, and washers Installation securing front suspension brace to frame extension...
Page 585 _________________________________________ 9-48 Axles, Suspension, and Frame ® LEFT AIRLIFT BRACKET AND FRONT UPPER Installation CONTROL ARM BRACKETS REPLACEMENT Install airlift bracket, shim(s) and two control arm brackets on frame rail with eight washers, bolts, washers, and lock- Removal nuts. Tighten locknuts to 90 lb-ft (122 N•m) (Figure 9-121). 1.
Page 586 ________________________________________ Axles, Suspension, and Frame 9-49 ® RIGHT AIRLIFT BRACKET AND FRONT UPPER Installation CONTROL ARM BRACKETS REPLACEMENT Install airlift bracket, shim(s), two control arm brackets, and cooler line bracket on frame rail with ten washers, Removal bolts, washers, and locknuts. Tighten locknuts to 90 lb-ft 1.
Page 587: Front Suspension Brace Replacement
_________________________________________ 9-50 Axles, Suspension, and Frame ® FRONT SUSPENSION BRACE REPLACEMENT FRONT SUSPENSION BRACE REPLACEMENT (VEHICLES WITHOUT WINCH) (VEHICLES WITH WINCH) Removal Removal WARNING: To avoid personal injury or equipment WARNING: To avoid personal injury or equipment damage, support lower control arm during removal and damage, support lower control arm during removal and installation.
Page 588 ________________________________________ Axles, Suspension, and Frame 9-51 ® SPLASH SHIELD SUPPORT BRACKET REPLACEMENT Removal 1. Remove locknut, washer, bolt, and washer securing splash shield to bracket (Figure 9-125). NOTE: Note direction of bolts for installation. 2. Remove two locknuts, washers, bolts, washers, and bracket from frame rail.
Page 589: Rear Bumper Replacement
_________________________________________ 9-52 Axles, Suspension, and Frame ® REAR BUMPER REPLACEMENT Installation Install rear bumper on two mounting brackets and secure Removal with eight washers and bolts. Do not tighten bolts 1. Remove swing-away spare tire carrier, if equipped (Sec- (Figure 9-126). tion 6).
Page 590 ________________________________________ Axles, Suspension, and Frame 9-53 ® SPRING SEAT REPLACEMENT REAR BUMPER OUTER MOUNTING BRACKET AND TIEDOWN BRACKET REPLACEMENT NOTE: Replacement of the four spring seats is basically the Removal same. This procedure covers the right front spring seat. Remove rear body mount (Section 10). Removal Remove two locknuts, washers, bolts, and washers 1.
Page 591 _________________________________________ 9-54 Axles, Suspension, and Frame ® LEFT ENGINE MOUNT BRACKET REPLACEMENT Installation Install engine mount bracket on frame rail with four wash- Removal ers, bolts, washers, and locknuts. Tighten locknuts to 90 1. Remove two bolts securing brake line and oil line clamps lb-ft (122 N•m) (Figure 9-129).
Page 592: Right Engine Mount Bracket
________________________________________ Axles, Suspension, and Frame 9-55 ® RIGHT ENGINE MOUNT BRACKET RIGHT FRONT BODY MOUNT BRACKET REPLACEMENT REPLACEMENT Removal Removal 1. Remove right engine mount and insulator (Section 2). Remove right front body mount. 2. Remove two locknuts, washers, bolts, and washers Remove three locknuts, washers, bolts, washers, and right securing support bracket to engine mount bracket front body mount bracket from frame rail (Figure 9-132).
Page 593: Transmission Crossmember Support
_________________________________________ 9-56 Axles, Suspension, and Frame ® TRANSMISSION MOUNT CROSSMEMBER TRANSMISSION CROSSMEMBER SUPPORT REPLACEMENT BRACKET REPLACEMENT Removal Removal Remove transmission mount crossmember. CAUTION: To prevent equipment damage during removal and Remove two locknuts and washers securing transmission installation of transmission mount crossmember, transmission crossmember support bracket to frame rail (Figure 9-134).
Page 594: Right Intermediate Body Mount Bracket
________________________________________ Axles, Suspension, and Frame 9-57 ® RIGHT INTERMEDIATE BODY MOUNT BRACKET LEFT INTERMEDIATE BODY MOUNT BRACKET REPLACEMENT REPLACEMENT Removal Removal 1. Remove right intermediate body mount (Section 10). Remove left intermediate body mount (Section 10). 2. Remove three bolts, washers, and body mount bracket Remove tailpipe hanger (Section 11).
Page 595: Rear-Rear Tiedown Bracket
_________________________________________ 9-58 Axles, Suspension, and Frame ® REAR-REAR TIEDOWN BRACKET REPLACEMENT BRACKET Removal VENT Remove two locknuts, washers, bolts, washers, and tie-down LINE bracket from frame rail (Figure 9-137). Installation Install tiedown bracket on frame rail with two washers, bolts, washers, and locknuts.
Page 596: Rear-Front Tiedown Bracket
________________________________________ Axles, Suspension, and Frame 9-59 ® REAR-FRONT TIEDOWN BRACKET AXLE SUPPORT BRACKET AND SIDE REPLACEMENT MOUNTING BRACKET REPLACEMENT Removal Removal 1. Remove wheel (Section 6). Remove brake caliper and rotor. 2. Remove four locknuts, washers, bolts, washers, and Remove locknut, seal washer, and output flange from tiedown bracket from frame rail (Figure 9-140).
Page 597: Front Suspension Front Crossmember
_________________________________________ 9-60 Axles, Suspension, and Frame ® FRONT SUSPENSION FRONT CROSSMEMBER REPLACEMENT SUPPORT BRACKET Removal 1. Remove front lower control arms. Remove lower radiator hose. Remove horn. Remove radiator front mounting bracket. Remove two nuts, washers, bolts, and washers securing front crossmember to support bracket (Figure 9-142).
Page 598: Front Suspension Rear Crossmember
________________________________________ Axles, Suspension, and Frame 9-61 ® Installation FRONT SUSPENSION REAR CROSSMEMBER REPLACEMENT 1. Position left and right crossmember mounting brackets on crossmember (Figure 9-145). Removal 2. Install crossmember and mounting brackets on frame rails Remove radiator (Section 4). with four washers, bolts, washers, and locknuts. Do not Remove right front upper control arm.
Page 599: Rear Suspension Front Crossmember
_________________________________________ 9-62 Axles, Suspension, and Frame ® Secure vent line to rear crossmember and two vent line brackets with three clamps and bolts. VENT LINE BRACKET LEFT FRAME RAIL 10. Secure steering gear to left frame rail with three washers, CROSSMEMBER lockwashers, and bolts.
Page 600 ________________________________________ Axles, Suspension, and Frame 9-63 ® Installation WARNING: To avoid personal injury, support cross- member during removal. Install two crossmember mounting brackets on front cross- member with six washers, bolts, washers, and locknuts. 8. Loosen six locknuts securing front crossmember to Tighten locknuts to 90 lb-ft (122 N•m) (Figure 9-150).
Page 601 _________________________________________ 9-64 Axles, Suspension, and Frame ® FRAME INSPECTION INSPECTION The visual inspection is the first and most critical step in form- General Information ing a decision of whether to repair or replace a damaged frame component (Figure 9-151). Factors to consider when making a The frame rails are constructed by arc-welding two “C”...
Page 602 ________________________________________ Axles, Suspension, and Frame 9-65 ® VERTICAL (SIDE VIEW) MEASUREMENT Measure and record frame rail height at corresponding points on opposite frame rail. 1. Select a hard and level surface area 1-1/2 times the size of Compare measurements from both frame rails.
Page 603 _________________________________________ 9-66 Axles, Suspension, and Frame ® NOTE: Strings used for this horizontal bow measurement will distance from the right and left points to the center string remain in place until the next measurement (Frame Skew) is should be within 1/4-inch (6 mm) of being equal. If completed.
Page 604 ________________________________________ Axles, Suspension, and Frame 9-67 ® METHOD 2 FRAME REPAIRS 1. Position a string across a plumb bob point on each of the Cracks frame rail strings (Figure 9-155). 2. Place a square with one leg coincident with a frame rail NOTE: All frame welding should be heli-arc type.
Page 605 _________________________________________ 9-68 Axles, Suspension, and Frame ® HELI-ARC WELD CRACK V-NOTCH CRACK STOP DRILL WITH 1/8-INCH (3MM) DRILL GRIND WELD FLAT IF ADDING A REINFORCEMENT 6-S09-007 Figure 9-156: Crack Repair Bends 1. Do not attempt to repair a bend when: •...
Page 606 ________________________________________ Axles, Suspension, and Frame 9-69 ® Straightening 1. When performing straightening repairs with the frame on Vertical bends, except at end sections, require removal of the vehicle: frame rail from vehicle. • Use spreader plates or wood blocking to distribute chain Application of bulk heating to frame components is not force to avoid damage to frame box section.
Page 607 _________________________________________ 9-70 Axles, Suspension, and Frame ® WINCH (OPTION) PRIOR TO VIN 186477 Remove nut, lockwasher, capscrew, and clamp from right frame extension. Discard lockwasher. Pull winch cables through splash shield front vehicle Winch Troubleshooting (Figure 9-159). Winch Inoperative 1. Check for jammed winch cable. CLAMP 2.
Page 608 ________________________________________ Axles, Suspension, and Frame 9-71 ® Winch Cable Replacement 5. Remove two bolts and clamps securing winch cables to winch. WARNING: To avoid injury, wear gloves when han- 6. Remove three bolts and control box cover from winch. dling winch cable. NOTE: It may be necessary to remove plastic coating com- Removal pound from winch in order to perform steps 7 and 8.
Page 609 _________________________________________ 9-72 Axles, Suspension, and Frame ® Winch Assembly Repair Remove clamps from motor. Mark motor end drum support, gear train assembly, and Disassembly gear end drum support for assembly (Figure 9-164). 1. Remove winch and winch cable. MOTOR (SHOWN WITHOUT CONTROL) NOTE: Tag leads for assembly.
Page 610 ________________________________________ Axles, Suspension, and Frame 9-73 ® 11. Loosen set screw that retains brake. 17. Remove clutch lever and O-ring seal from gear housing. Discard O-ring seal. 12. Push brake through open end of drum and remove (Figure 9-165). 18. Remove two retaining rings from gear housing (Figure 9-167).
Page 611 _________________________________________ 9-74 Axles, Suspension, and Frame ® Inspection INPUT OUTPUT Inspect drum for damage to splined end ﬂanges and tube GEAR CARRIER GEAR CARRIER (Figure 9-169). Replace winch if damaged. ASSEMBLY ASSEMBLY (FIRST STAGE) (THIRD STAGE) DRUM SUPPORT MOTOR END GEAR DRUM GASKET...
Page 612 ________________________________________ Axles, Suspension, and Frame 9-75 ® Assembly Install gasket and output ring gear on gear housing. Install intermediate gear carrier on gear housing. 1. Position 85 to 87 steel balls in groove of intermediate ring gear and install intermediate ring gear in gear housing 10.
Page 613 _________________________________________ 9-76 Axles, Suspension, and Frame ® 17. With drum horizontal, install brake into drum. CLAMP 18. Tighten brake retaining set screw to 18-22 ft-lb (24-30 N•m) torque. 19. Install two nylon thrust washers on drum. CONTROL 20. Install drum assembly on gear train assembly. Rotate drum assembly as needed to engage driveshaft, brake, and output spline (Figure 9-176).
Page 614 ________________________________________ Axles, Suspension, and Frame 9-77 ® Remove nut, lockwasher, washer, and insulator securing DRUM SUPPORT brush assembly power stud to motor housing. Discard lockwasher. 10. Remove three nuts, screws, and brush assembly from motor housing. CONTROL 11. Remove spacer, insulator, and washer from brush LEADS assembly power stud.
Page 615 _________________________________________ 9-78 Axles, Suspension, and Frame ® Winch Roller Fairlead (Option) 3. Secure brush assembly power stud to motor housing with insulator, washer, lockwasher, and nut. Replacement 4. Coat armature shaft with lubricant and install in brush The winch roller fairlead provides greater functional versatil- assembly.
Page 616 ________________________________________ Axles, Suspension, and Frame 9-79 ® WINCH (OPTION) VIN 186477 AND LATER Winch Replacement Removal NOTE: Individual parts may not be available for some of the following repair procedures. Assemblies must be used in place WARNING: To avoid personal injury or damage, sup- of individual parts.
Page 617 _________________________________________ 9-80 Axles, Suspension, and Frame ® Winch Cable Replacement 4. Remove four nuts, washers, bolts, and winch from front bumper (Figure 9-186). WARNING: To avoid injury, wear gloves when han- dling winch cable. POSITIVE WINCH CONTROL Removal CABLE COVER Unwind winch cable.
Page 618 ________________________________________ Axles, Suspension, and Frame 9-81 ® Winch Assembly Repair Remove clamps from motor. Mark motor end drum support, gear train assembly, and Disassembly gear end drum support for assembly (Figure 9-190). 1. Remove winch and winch cable. MOTOR (SHOWN WITHOUT CONTROL) NOTE: Tag leads for assembly.
Page 619 _________________________________________ 9-82 Axles, Suspension, and Frame ® 11. Loosen set screw that retains brake. 18. Remove two retaining rings from gear housing (Figure 9-193). 12. Push brake through open end of drum and remove (Figure 9-191). NOTE: Intermediate ring gear comes out with 85 to 87 steel 13.
Page 620 ________________________________________ Axles, Suspension, and Frame 9-83 ® Inspection OUTPUT 1. Inspect drum for damage to splined end ﬂanges and tube GEAR CARRIER (Figure 9-195). Replace winch if damaged. ASSEMBLY (THIRD STAGE) DRUM SUPPORT INPUT MOTOR END GEAR CARRIER ASSEMBLY (FIRST STAGE) THRUST WASHER OUTPUT...
Page 621 _________________________________________ 9-84 Axles, Suspension, and Frame ® Assembly NOTE: Be sure ring gear engages in gear housing. 1. Position 85 to 87 steel balls in groove of intermediate ring Install gasket and output ring gear on gear housing. gear and install intermediate ring gear in gear housing Install intermediate gear carrier on gear housing.
Page 622 ________________________________________ Axles, Suspension, and Frame 9-85 ® 17. With drum horizontal, install brake into drum CLAMP (Figure 9-201). 18. Tighten brake retaining set screw to 18-22 ft-lb (24-30 CONTROL N•m) torque. 19. Install two nylon thrust washers on drum. 20. Install drum assembly on gear train assembly. Rotate drum assembly as needed to engage driveshaft, brake, and output spline (Figure 9-202).
Page 623 _________________________________________ 9-86 Axles, Suspension, and Frame ® Remove nut, lockwasher, washer, and insulator securing DRUM SUPPORT brush assembly power stud to motor housing. Discard lockwasher. CONTROL 10. Remove three nuts, screws, and brush assembly from motor housing. 11. Remove spacer, insulator, and washer from brush assembly power stud.
Page 624 ________________________________________ Axles, Suspension, and Frame 9-87 ® Winch Roller Fairlead (Option) 3. Secure brush assembly power stud to motor housing with insulator, washer, lockwasher, and nut. Replacement 4. Coat armature shaft with lubricant and install in brush The winch roller fairlead provides greater functional versatil- assembly.
Page 625 _________________________________________ 9-88 Axles, Suspension, and Frame ® ESSENTIAL TOOLS J–24319-B J–8001 J–8092 J–8614-O1 J–44905 J–29162 J–42545 TOOL DESCRIPTION J–8092 Universal Driver Handle J–24319-B Steering Linkage and Tie Rod Puller J–8001 Dial Indicator J–29162 Rear Retainer Seal Installer J–44905 Input Seal Installer J–8614-O1 Yoke Holding Tool (includes J–8614-5 bolt kit) J–42545...
Page 626 ________________________________________ Axles, Suspension, and Frame 9-89 ® SPECIAL TOOLS J–33142 J–21786 J–21787 J–8611-01 J–29162 J–8608 J–39524 J–24385-01 J–35237 J–22610 J–3409-01 PART OF J–3409-01 TOOL DESCRIPTION J–33142 Axle Shaft and Seal Installer J–21786 Pinion Rear Bearing Cup Remover J–21787 Pinion Front Bearing Cup Remover J–8611-01 Rear Pinion Bearing Race Installer J–29162...
Page 627 _________________________________________ 9-90 Axles, Suspension, and Frame ® THIS PAGE INTENTIONALLY BLANK.
Page 628 _______________________________________________________________________________ 10-1 ® Section 10 Body TABLE OF CONTENTS Airlift to Hood Seal Replacement ..... . .10-51 Horn Armrest Replacement ....... .10-24 Horn Assembly Replacement .
Page 629: General Body Information
Wiper System and Components ....10-56 GENERAL BODY INFORMATION The HUMMER body is constructed from high strength T6 5. Steel pull-type lockbolt fasteners of 0.1875 in. (4.8 mm) aluminum.
Page 630: Body Inspection And Repair
______________________________________________________________________ Body 10-3 ® BODY INSPECTION AND REPAIR Non-negligible damage must be repaired; or the section must be replaced. Patches can often be applied over damaged body panels, provided the damaged area is first trimmed to remove General Information sharp edges or notches which could cause the start of new Damaged areas should be thoroughly cleaned and inspected to cracks.
Page 631: Rivet Replacement
_______________________________________________________________________ 10-4 Body ® Lockbolt Fastener Failure Blind Rivet Removal File a small, ﬂat surface on rivet head. Lockbolts are used to withstand tension loads and high-shear Center punch the flat surface. Support the back side of the loads. These fasteners are installed in their holes with an inter- rivet, if possible.
Page 632 ______________________________________________________________________ Body 10-5 ® Table 1: Drill Bit Sizes for Solid Shank Rivets Rivet Diameter Drill Bit Size Drill Bit Diameter 0.0625 in. (1.65 mm) # 51 0.0670 in. (1.70 mm) 0.0938 in. (2.38 mm) # 41 0.0960 in. (2.44 mm) 0.1250 in.
Page 633 _______________________________________________________________________ 10-6 Body ® Hole Countersinking Blind Rivet Driving Practices and Precautions Rivets should be inspected for proper installation. The grip NOTE: Some rivet installations in the body require the rivet to length of each rivet is marked on top of its head to provide be flush with the rivet material surface.
Page 634 ______________________________________________________________________ Body 10-7 ® Blind Rivet Installation NOTE: Ensure the proper rivet grip length is selected for each Insert rivet stem into pulling head of rivet gun or adapter. application (Table 6). Rivets can tolerate only 0.0468 in. (1.19 Hold rivet gun in line with axis of rivet as accurately as mm) variation in material thickness for each particular rivet possible.
Page 635: Aluminum Repair
_______________________________________________________________________ 10-8 Body ® Aluminum Repair CAUTION: Body repairs should not be made using welding or heat for forming. Heat will only weaken the material and lead D = DIAMETER to further problems. OF RIVET (PREFERABLY ABOUT Material 3X THICKNESS OF THICKER SHEET) Aluminum material used for repairs should be of the same al- loy and temper as the original if possible.
Page 636 ______________________________________________________________________ Body 10-9 ® RIVETS RIVET Figure 10-2: Rivet Loads in Shear BOLT BOLT Figure 10-3: Bolts Replacing Rivets Repair Parts Table 7: Stop-Drill Sizes for Negligible 1. Paint repair parts or patches with epoxy primer before Cracks installation. Apply sealing compound to mating surfaces to prevent SHEET THICKNESS MINIMUM STOP corrosion.
Page 637 ______________________________________________________________________ 10-10 Body ® Repair by Insertion DAMAGED AREA PATCH For damage that is large or more severe in nature than a crack or hole, it is often desirable to remove damaged area, insert a piece of material into removed area and reinforce with a dou- bler.
Page 638: Fiberglass Repair
Body 10-11 ® Fiberglass Repair General Information The HUMMER hood and engine access cover are made of fi- DAMAGED AREA berglass (sheet molding compound). Crack, splits, or holes may be repaired with a glass reinforced plastic laminate repair kit. Inspection NOTE: Hood surface has a thin layer of gel coat that may ap- pear cracked in a spider web-like pattern due to hood flexing.
Page 639 ______________________________________________________________________ 10-12 Body ® Repair WATER LEAK DETECTION AND REPAIR 1. Repairing cracks or splits. If water has leaked into the vehicle, inspect for leakage points. Spray water, under pressure, against the vehicle in the general WARNING: When sanding ﬁberglass, personal protec- area where the leak is believed to be located.
Page 640: Center Console Replacement
_____________________________________________________________________ Body 10-13 ® CENTER CONSOLE REPLACEMENT FRONT CONSOLE REPLACEMENT Removal Removal 1. Remove four screw/washers from center console. Remove right side crashpad. (Figure 10-12). Remove bolts securing front console to body brackets and 2. Slide center console back (toward rear seating area) far screws from top of console (Figure 10-13).
Page 641 ______________________________________________________________________ 10-14 Body ® INSTRUMENT PANEL, GAUGES, AND SWITCHES FRONT CONSOLE Instrument Panel (I.P .) Replacement Removal NOTE: Tag all leads prior to removal for installation. If re- placing instrument panel, refer to procedures in this section to remove and/or disconnect the various lamps, switches, and gauges.
Page 642 _____________________________________________________________________ Body 10-15 ® Crashpad Replacement (Right Side) Crashpad Replacement (Left Side) Removal Removal 1. Remove screw/washers, and crashpad from dashboard Remove screw/washers from top of crashpad. (Figure 10-16). Tug gently on crashpad toward steering wheel to free 2. Disconnect air hose from vent duct. crashpad clips from I.
Page 643 ______________________________________________________________________ 10-16 Body ® Gauge Replacement Instrument Panel Indicator Lamp Replacement NOTE: Gauge replacement is basically the same for all instru- ment panel gauges. NOTE: All instrument panel indicator lamps are replaced basi- cally the same. Removal Removal 1. Remove screws and pull gauge panel away from instru- ment panel (Figure 10-17).
Page 644 _____________________________________________________________________ Body 10-17 ® Instrument Panel Switch Replacement WIRING HARNESS NOTE: All instrument panel switches are replaced similarly, with the exception of the dimmer control switch. This proce- dure covers the main light switch. CAUTION: Some connectors can be installed incorrectly and CONNECTOR cause damage to the electrical system.
Page 645 ______________________________________________________________________ 10-18 Body ® Speedometer/Odometer Replacement 11. Remove the two speedometer/odometer hold-down bracket nuts and lockwashers and the hold-down bracket. Removal 12. Pull the speedometer/odometer from the dash and remove the two remaining nuts and lockwashers that secure the Remove the left A-pillar dash trim (closeout). ground and sending lead connections.
Page 646: Glovebox Replacement
_____________________________________________________________________ Body 10-19 ® Tachometer Replacement CIGARETTE LIGHTER REPLACEMENT Removal NOTE: Mark position of set screws in relationship to tachom- eter clock panel before disassembly. Tachometer mounting Pull front console away from dashpad enough to gain clamp must be installed in factory position to have proper access to wiring harness connector.
Page 647: Ashtray Replacement
______________________________________________________________________ 10-20 Body ® ASHTRAY REPLACEMENT FLEXIBLE LATCH Removal BODY 1. Pull front console away from dashpad to gain access to ashtray frame tabs. 2. Pull ashtray receptacle out of frame (Figure 10-25). 3. Straighten frame tabs and remove frame. HOLD-DOWN STRIKER Installation...
Page 648 _____________________________________________________________________ Body 10-21 ® Disassembly 1. Remove rivets, retainers, and insulation from engine RETAINING RING STUD access cover (Figure 10-28). RINGS ENGINE ACCESS COVER 2. Remove seal from access cover. 3. Remove retaining rings, washers, and ring studs from access cover (Figure 10-29). HOLD-DOWN BRACKET 4.
Page 649 ______________________________________________________________________ 10-22 Body ® SEAT BELT ASSEMBLY REPLACEMENT WEBBING NOTE: Replacement of the seat belt assembly is basically the GUIDE same for all seat locations on all vehicle models. This proce- COVER dure covers the left front seat belt on four-door hard top vehi- cles.
Page 650 _____________________________________________________________________ Body 10-23 ® Installation Installation 1. Secure bracket to B-pillar and body with washers and bolts Secure riser to slide set with bolts, lockwashers, and nuts (Figure 10-31). Tighten bolts to 12 lb-ft (16 N•m). (Figure 10-32). Tighten nuts to 24 lb-ft (33 N•m). 2.
Page 651 ______________________________________________________________________ 10-24 Body ® Reclining Driver’s and Front Passenger’s Installation Seat Replacement Install four spacers and seat pedestal in vehicle. Secure seat pedestal to floor with four washers, NOTE: Reclining driver’s and front passenger’s seats are re- lockwashers, and bolts. Tighten bolts to 24 lb-ft (33 N•m). placed similarly.
Page 652 _____________________________________________________________________ Body 10-25 ® REMOVABLE LOAD BARRIER AND MOUNTING INTERIOR TRIM BRACKETS REPLACEMENT (STATION WAGON) B-Bar Replacement Removal NOTE: This procedure covers replacement of the B-bar for all 1. Remove drive screws and carpet assembly from front and vehicles except open top models and 2-door models without an back of removable load barrier (Figure 10-35).
Page 653 ______________________________________________________________________ 10-26 Body ® Installation Remove covers, screws, and grab handle from trim. Remove screw/washer assemblies and upper B- bar trim 1. Secure trim mounting brackets to B-bar with four washers from roof. and screws (Figure 10-36). Remove screws, washers, and lower B-pillar trim from B- 2.
Page 654 _____________________________________________________________________ Body 10-27 ® Secure lower C-pillar trim to lower C-pillar with four WINDOW HEADLINER screw and washer assemblies (Figure 10-38). TRIM REAR COMPARTMENT Secure upper C-pillar trim to roof with nine screw and ROOF WALL washer assemblies. Secure C-pillar center trim to roof with eight screw and washer assemblies.
Page 655 ______________________________________________________________________ 10-28 Body ® Driver’s Compartment Trim Replacement Remove screw/washer assemblies and upper A-pillar trim from roof. Removal Remove screw/washer assembly and lower A-pillar trim 1. Remove overhead speakers from driver’s compartment and from A-pillar. passenger’s compartment (if applicable) (Section 12). Remove screw/washer assemblies and upper B-bar trim 2.
Page 656 _____________________________________________________________________ Body 10-29 ® Secure trim to upper rear compartment wall with screw/ UPPER REAR washer assemblies. COMPARTMENT WALL ROOF HEADLINER LOWER REAR COMPARTMENT WALL Figure 10-43: Rear Compartment Wall Location Figure 10-44: Headliner Positioning 13. Remove screw/washer assemblies, B-beam trim, and rear Install seats.
Page 657 ______________________________________________________________________ 10-30 Body ® Station Wagon Rear Compartment Trim Remove screw/washer assemblies and two trim panels from lower rear compartment wall (Figure 10-48). Replacement Removal PANEL FASTENERS 1. Remove rear seats. HEADLINER 2. Remove bolts, washers, upper seat belt bracket, and seat belt assembly from C-pillar (Figure 10-46).
Page 658 _____________________________________________________________________ Body 10-31 ® UPPER C-PILLAR TRIM TRIM PANEL SEAT BELT BRACKET B-PILLAR TRIM CENTER TRIM SEAT BELT ASSEMBLY HEADLINER C-PILLAR STATION WAGON COMPARTMENT SIDE WALLS LOWER C-PILLAR TRIM LOWER REAR COMPARTMENT WALL Figure 10-49: Station Wagon Side Wall Component Breakdown 05745159...
Page 659: Inner Kick Panels Replacement
______________________________________________________________________ 10-32 Body ® Inner Kick Panels Replacement REAR PANEL COMPARTMENT WALL Removal 1. Remove seats. NOTE: Remove one bolt, washer, and seat buckle for two-pas- REAR PANEL senger models. COMPARTMENT FASTENER WALL TRIM 2. Remove bolts, washers, and seat buckles from front and rear of tunnel (Figure 10-50).
Page 660 _____________________________________________________________________ Body 10-33 ® Installation PANEL FASTENER LOWER SEAT BELT NOTE: Perform step 1 for two-passenger models only. CENTER KICK BRACKET PANEL 1. Secure rear inner kick panel to right rear of tunnel with panel fastener (Figure 10-52). FRONT KICK PANELS 2.
Page 661 ______________________________________________________________________ 10-34 Body ® Tunnel Carpet, Padding, and Hardboard VISOR REPLACEMENT Replacement Removal Removal NOTE: Visor replacement is the same for each side of the ve- hicle. This procedure covers the driver’s side. NOTE: Tunnel carpet, padding, and hardboard replacement is basically the same for all models.
Page 662: Side Mirror Replacement
_____________________________________________________________________ Body 10-35 ® MIRRORS Installation Secure gasket and mirror to door hinge with screws Side Mirror Replacement (Figure 10-57). Removal POWER MIRRORS Remove screws, mirror, and gasket from door hinge (Figure 10-57). Power Mirror Assembly Replacement Removal DOOR Remove three screws securing power mirror assembly and MIRROR gasket to mounting plate (Figure 10-58).
Page 663: Rearview Mirror Replacement
______________________________________________________________________ 10-36 Body ® Rearview Mirror Replacement DOOR REPLACEMENT Door replacement varies in complexity depending on the type Removal and number of components that must be removed from the old 1. Remove screw and rearview mirror from mirror bracket door and installed on the new door. Removal and installation (Figure 10-59).
Page 664 _____________________________________________________________________ Body 10-37 ® Disassembly 1. Remove twelve-point bolts, washers, and upper and lower hinge plates from door (Figure 10-60). WINDOW SWITCH (REAR DOORS) MOISTURE BARRIER POWER FLAP WINDOW SWITCH INSIDE VAPOR DOOR OPERATING BARRIER POWER DOOR LOCK SWITCH INSIDE DOOR HANDLE Figure 10-62: Vapor Barrier and Moisture Barrier Flap...
Page 665 ______________________________________________________________________ 10-38 Body ® DOOR OUTSIDE DOOR HANDLE GASKET CLIP LOCK OPERATING OUTSIDE OPERATING DOOR LATCH ASSEMBLY LOCK CYLINDER Figure 10-64: Latch Assembly Figure 10-65: Lock Cylinder and CAUTION: Firmly support glass during regulator removal to Outside Door Handle avoid damage. NOTE: Vapor barrier must be completely sealed at all edges to Remove power window regulator (refer to procedure in this prevent water entry into the interior of the vehicle.
Page 666 _____________________________________________________________________ Body 10-39 ® Manual Window Regulator (Optional) NOTE: At this point it is assumed that door panel has been re- moved for access to window regulator. Removal UPPER DOOR Remove nuts and lockwashers securing regulator post to UPPER HINGE window assembly (Figure 10-67).
Page 667: Power Windows
______________________________________________________________________ 10-40 Body ® POWER WINDOWS Remove four screws and lockwashers cable and bracket assembly to door. Discard lockwashers. Power Window Regulator Replacement Remove two screws, lockwashers, and washers securing Removal regulator cable and bracket assembly to window bracket. Discard lockwashers. NOTE: Operate motor to position glass in opening to provide access to two screws securing glass and its bracket to regulator.
Page 668: Door Seals Replacement
_____________________________________________________________________ Body 10-41 ® DOOR SEALS REPLACEMENT NOTE: The door seals come in bulk and must be cut to the ap- propriate lengths. For hard top vehicles, cut 12 feet for the doors and 10 feet for the body opening. For soft-top vehicles, cut 6 feet for the doors and 5 feet for the body opening.
Page 669 ______________________________________________________________________ 10-42 Body ® A-PILLAR DOOR STOP BRACKET B-PILLAR DOOR STOP DOOR BRACKET STRAP FRONT DOOR DOOR STOP BRACKET REAR DOOR Figure 10-71: Door Stop Strap Assembly Cleaning and Inspection DOOR WINDOW SEAL NOTE: Clean all components, examine for wear or damage, and replace if necessary.
Page 670 Section 10 Body _____________________________________________________________________ Body 10-43 ® HOOD, HOOD LATCH, AND PROP ROD Hood Latch and Bracket Replacement Removal WINDOW GLASS NOTE: If only the rubber latch is to be replaced, the spring pin does not have to be completely out of base. Remove spring pin and rubber latch from base (Figure 10-74).
Page 671 ______________________________________________________________________ 10-44 Body ® CABLE LATCH MOUNTING PLATE BRACKET LATCH BRACKET CABLE ASSEMBLY HOOD WASHER HOOD LATCH HANDLE STOP BRACKET Figure 10-75: Hood Latch Bracket and Latch Plate Figure 10-76: Hood Release Handle Assembly Replacement Mounting Hood Release Cable Assembly Replacement Removal LOCK 1.
Page 672: Hood Prop Rod And Bracket Replacement
_____________________________________________________________________ Body 10-45 ® 6. Remove two nut and lockwasher assemblies, screws, cable clamp bracket, and spacer from bracket assembly. CABLE CLAMP BRACKET 7. Inspect three nylon bushings in bracket assembly. Remove and discard bushings if damaged. SPACER CABLE ASSEMBLY HOOD LATCH ASSEMBLY...
Page 673 ______________________________________________________________________ 10-46 Body ® Assembly Secure bushing to bracket with snapring (Figure 10-83). HOOD NOTE: Length of spring with bracket assembled is 2-1/4 in. (5.7 cm). Secure washer, eyebolt, spring, bushing, washer, and locknut to bracket. Install hood prop rod into eyebolt. HOOD PROP ROD SPRING...
Page 674 _____________________________________________________________________ Body 10-47 ® Hood and Hinge Replacement Installation NOTE: Perform steps 1 and 2 if hinges were removed. Removal 1. Raise and secure hood. Secure two spacers, two lower hinge halves and hinge plates to two brackets with four washers, bolts, washers, WARNING: To avoid injury, or damage to equipment, and locknuts.
Page 675 ______________________________________________________________________ 10-48 Body ® 2. Open hood and loosen center hood stop (Figure 10-85). 3. Gently close hood and loosen lower hinge half locknuts (Figure 10-86). LOWER HINGE HALF LOCKNUTS SIDE HOOD STOP HOOD LATCH Figure 10-88: Hood Latch and Stop Location Figure 10-86: Lower Hinge Half Locknut Location Outer Hood Seal Replacement 4.
Page 676: Side Hood Stop Replacement
_____________________________________________________________________ Body 10-49 ® Side Hood Stop Replacement GRILLE Removal Remove two locknuts, washers, bolts, washers, and side hood HOOD stop from body (Figure 10-90). Installation Secure side hood stop to body with two washers, bolts, wash- ers, and locknuts. Tighten bolts to 6 lb-ft (8 N•m) (Figure 10-90).
Page 677: Guide Bracket Assembly Replacement
______________________________________________________________________ 10-50 Body ® Guide Bracket Assembly Replacement Right Hood Retainer Bracket Replacement Removal Removal Remove six locknuts, twelve washers, guide bracket assembly, Remove four bolts, lockwashers, washers, right hood retainer guide plate, and six bolts from hood (Figure 10-93). bracket, and spacer from hood (Figure 10-95).
Page 678 _____________________________________________________________________ Body 10-51 ® Right Hood Close-Out Seal and Retainer Airlift Bracket Seal Replacement Replacement NOTE: Turbo Diesel models have thick foam pads around the inside of the hood grille. These pads help to direct air flow Removal through the radiator and provide better engine cooling. The up- 1.
Page 679 ______________________________________________________________________ 10-52 Body ® ENGINE SPLASH SHIELD REPLACEMENT Disassembly 1. Remove seven locknuts, washers, screws, seal, and two NOTE: Turbo Diesel models have thick foam pads around the retainers from splash shield (Figure 10-99). inside of the hood grille. These pads help to direct air flow Remove four rivets and bushing from splash shield.
Page 680 _____________________________________________________________________ Body 10-53 ® HORN WINDSHIELD ASSEMBLY Horn Replacement Windshield Glass and Weatherstrip Replacement Removal Removal 1. Remove harness connectors and adapters from horn. Remove windshield wiper arm and blade. 2. Remove horn from mounting bracket (Figure 10-101). Remove six bolts and upper retainer from windshield frame (Figure 10-102).
Page 681 ______________________________________________________________________ 10-54 Body ® Windshield Assembly Replacement WARNING: To avoid injury, or damage to equipment, support windshield during removal and installation. Removal WIPER MOTOR 1. Remove soft top or loosen roof assembly, as applicable. 2. Remove windshield wiper blade and arm. 3.
Page 682 _____________________________________________________________________ Body 10-55 ® HEATED WINDSHIELD The optional heated windshield is capable of defrosting the FORMER windshield glass in less than 10 minutes at 0° F. The system is comprised of a rocker switch with an integrated time delay SEAL module (Figure 10-106), two relays, and two fuses , and in- glass heating elements.
Page 683 ______________________________________________________________________ 10-56 Body ® Removal WINDSHIELD WIPER SYSTEM AND COMPONENTS NOTE: Wire harnesses behind console are long enough to al- low for power window master switch removal without remov- Windshield Wiper Motor Assembly ing console for access to electrical connectors. Replacement 1.
Page 684 _____________________________________________________________________ Body 10-57 ® Windshield Wiper Linkage Replacement Windshield Wiper Pivot Replacement Removal Removal NOTE: Left and right side windshield wiper linkage replace- NOTE: Left and right side windshield wiper pivot replacement ment procedure is the same. This procedure covers the left side. procedure is the same.
Page 685 ______________________________________________________________________ 10-58 Body ® WINDSHIELD WASHER SYSTEM AND Installation COMPONENTS Connect windshield washer hose to reservoir and pump assembly. Reservoir and Pump Assembly Secure reservoir assembly to reservoir support assembly Replacement with four lockwashers and bolts. Tighten bolts to 8 lb-ft (11 N•m) (Figure 10-111).
Page 686 _____________________________________________________________________ Body 10-59 ® NOZZLE Figure 10-112: Windshield Washer Nozzle Replacement CLAMPS ECU RETAINING BRACKET ECU ENCLOSURE 9-S10-004 PUMP ASSEMBLY Figure 10-113: Windshield Washer Hose Replacement 05745159...
Page 687 ______________________________________________________________________ 10-60 Body ® A-PILLAR FORMER ASSEMBLY REPLACEMENT Cleaning and Inspection (SOFT TOP ONLY) NOTE: Clean all components, examine for wear or damage, and replace if necessary. Removal 1. Remove soft top. Inspect wellnuts. Replace if defective or damaged. 2. Remove 12 screws and A-pillar former from A-pillar Installation (Figure 10-114).
Page 688 _____________________________________________________________________ Body 10-61 ® REAR SUPPORT BOW BRACKET REPLACEMENT REAR STRIKER ASSEMBLY REPLACEMENT Removal Removal 1. Remove rear support bow assembly. Remove two screws, washers, backing plate, and rear striker assembly from rear door pillar (Figure 10-117). 2. Remove two screws and support bow bracket from body (Figure 10-115).
Page 689: Front License Plate Bracket Replacement
______________________________________________________________________ 10-62 Body ® BODY BRACKET SPACER PROTECTIVE SHIELD SLEEVE UPPER CUSHION ATTACHMENT LOWER BOLTS CUSHION SPACER FRAME BRACKET Figure 10-119: Body Mount Cushions Replacement LICENSE PLATE SCREWS Figure 10-120: Rear License Plate Bracket Installation Front License Plate Bracket Replacement 1.
Page 690: Fuel Filler Housing Replacement
_____________________________________________________________________ Body 10-63 ® FUEL FILLER HOUSING REPLACEMENT Auxiliary Fuel Tank Removal Main Fuel Tank Remove ﬁve screws and fuel ﬁller tube splash shield from Removal inside of right rear wheelhouse. 1. Remove ﬁller cap from ﬁller spout (Figure 10-122). Remove filler cap from filler spout (Figure 10-123).
Page 691: Roadside Emergency Equipment
______________________________________________________________________ 10-64 Body ® ROADSIDE EMERGENCY EQUIPMENT Tire Jack and Optional Triangle Warning Kit Hold-Down Replacement Tire Jack and Optional Triangle Warning Kit (Four-Passenger Vehicle, Station Wagon, Hold-Down Bracket Replacement and Open Body) (For Two-Passenger Model) Removal Removal Remove triangle warning kit and tire jack from under right 1.
Page 692: Four-Passenger Soft Top
_____________________________________________________________________ Body 10-65 ® FOUR-PASSENGER SOFT TOP 11. Remove screw and washer assembly and center trim from rear compartment wall. Interior Trim Replacement Removal UPPER B-PILLAR TRIM 1. Remove front and rear seats. 2. Remove front and center consoles. 3. Remove speakers from rear wall (Section 12). 4.
Page 693 ______________________________________________________________________ 10-66 Body ® REAR WINDSHIELD PANEL FASTENER UPPER COMPARTMENT FRAME TRIM CENTER PANEL WALL CENTER TRIM FASTENER TRIM LOWER TRIM CENTER TRIM TRIM Figure 10-128: Rear Wall Compartment Location Installation 1. Secure center trim to rear compartment wall with screw and washer assembly (Figure 10-128).
Page 694 _____________________________________________________________________ Body 10-67 ® Soft Top Mounting Components and Removal Accessories Replacement Remove four-passenger soft top, tonneau cover, or station wagon soft top, if applicable. Refer to the owner’s manual NOTE: following removal installation for proper procedure. instructions include replacement of all soft top mounting com- Remove tonneau cover wood bow from two retainer ponents and accessories.
Page 695 ______________________________________________________________________ 10-68 Body ® 4. Remove velcro strips and patches from tonneau area 12. Remove 12 screws securing front attachment rail to the (Figure 10-131). top of the windshield frame, and remove rail. 13. Slide velcro strips in the two side rails rearward to remove, NOTE: Perform steps five and six for both sides of the vehi- set aside.
Page 696 _____________________________________________________________________ Body 10-69 ® 18. Remove three screws securing H-Rail to the vehicle safety 10. Install front upper corner filler piece with two rivets and cage. Leave the L brackets on the safety cage unless the sealer (Figure 10-137). cage is going to be replaced, remove the H-rail. 11.
Page 697 ______________________________________________________________________ 10-70 Body ® H-RAIL VELCRO FILLER FILLER INSTALLATION FRONT FILLER PIECE B-PILLAR REAR, SIDE, P-CHANNEL COVER C-PILLAR COVER B-PILLAR COVER LOWER BRACKET SUPPORT STRUCTURE 8-S10-001 Figure 10-137: Rail and Support Structure Locations MEASURE DISTANCE STRAIGHTEDGE WOOD BOW REAR SUPPORT BAR BRACE STRAIGHTEDGE WHEEL HOUSE...
Page 698 _____________________________________________________________________ Body 10-71 ® SOFT TOP SUPPORT ASSEMBLY Installation Apply sealer to rear support where body contact is made. Removal Lower structure assembly onto vehicle. 1. Remove soft top. Install hardware and strikers in B-pillar and front and rear 2. Remove interior grab handles. supports.
Page 699: Tailgate And Seals Replacement
______________________________________________________________________ 10-72 Body ® TAILGATE SCREW CARGO FLOOR Tailgate Chain and Latch Brackets Replacement Removal Remove four locknuts, eight washers, four bolts, chain bracket, and latch bracket from body (Figure 10-140). CARGO TIEDOWN Installation Secure chain bracket and latch bracket to body with four bolts, eight washers, and four locknuts.
Page 700 _____________________________________________________________________ Body 10-73 ® Installation CHAIN BRACKET BRACKET 1. Install two grommets on tailgate (Figure 10-143). NOTE: Perform steps 2 through 4 for station wagon and open body models. Perform step 5 for two- and four-door models. 2. Remove paper backing and install four vertical seals and one horizontal seal on tailgate.
Page 701: Window Replacement
______________________________________________________________________ 10-74 Body ® Assembly If alignment is necessary, loosen the seven screws on the interior side of the door hinge. The slots in the hinge will 1. Using three 0.187 in. x 0.626 in. rivets, fasten hinge to allow up and down adjustment. lower set of holes on tailgate.
Page 702 _____________________________________________________________________ Body 10-75 ® Door Handle Replacement Door Latch and Latch Rod Replacement Removal Removal 1. Remove rear door window. Remove rear door window. 2. Remove four screws and interior door handle from door Remove four screws and interior door handle from door (Figure 10-148).
Page 703 ______________________________________________________________________ 10-76 Body ® DOOR HINGE CONTACTS DOOR HINGE CONTACTS MOTOR LINK ROD AND LOCK CLIPS DOOR LOCK DOOR LOCK MOTOR HARNESS MOTOR Figure 10-150: Cargo Door Electric Locks...
Page 704 _____________________________________________________________________ Body 10-77 ® Door Stop Replacement Door Frame and Seal Replacement Removal Removal 1. Remove rear door window. Remove dome lamp fuse. 2. Remove four screws and interior door handle from door Remove seven screws securing inner portion of door hinge (Figure 10-149).
Page 705: Interior And Exterior Lighting
______________________________________________________________________ 10-78 Body ® INTERIOR AND EXTERIOR LIGHTING Remove three nuts, lockwashers, washers, and housing from hood. REPLACEMENT Installation Service Headlight Assembly Replacement NOTE: To install headlight only, perform steps 5 and 6. To in- Removal stall entire assembly, perform all steps. NOTE: To remove headlight only, perform steps 1 and 2.
Page 706 _____________________________________________________________________ Body 10-79 ® Side Marker Light Lens and Lamp LIGHT BRACKET Replacement Removal Remove two screws, cover, lens, and lamp from lamp holder (Figure 10-154). Installation 1. Install lamp. Secure lens, and cover to lamp holder with TABBED two screws (Figure 10-154). SIDE WIRING HARNESS 2.
Page 707: Front Turn Signal Light Replacement
______________________________________________________________________ 10-80 Body ® GROUND LEAD HOOD LIGHT LIGHT LEAD LENS DOOR GASKET MARKER LIGHT HARNESS LEAD Figure 10-157: Side Marker Light Assembly Installation 1. Secure gasket, lamp holder, and ground lead on hood with four screws, washers, and locknuts (Figure 10-157). 2.
Page 708: Rear Turn Signal Light Replacement
_____________________________________________________________________ Body 10-81 ® Rear Turn Signal Light Replacement SHIELD LEADS Removal HOUSING WIRING NOTE: To remove lamps only, perform steps 1 and 2. HARNESS Remove four screws, lens, and gasket from turn signal light (Figure 10-160). HOUSING GROMMET LIGHT LAMPS CONNECTORS BEAM...
Page 709 ______________________________________________________________________ 10-82 Body ® Domelight/Cargo Light Replacement (Models 83, 84, 89, & 91) FRONT OF CONNECTORS VEHICLE Removal Remove domelight lens (Figures 10-162 through 10-164). Remove lamp from domelight. Remove screws securing domelight to ground lead and connector. 4. Remove screw and domelight from roof bracket. ROOF BRACKET Installation Secure domelight, connector, and ground lead to roof...
Page 710: Maplight Replacement
_____________________________________________________________________ Body 10-83 ® Domelight Replacement (Model 90) Removal 1. Using a screwdriver, snap the dome light assembly from its base (Figure 10-165) LOWER B-PILLAR 2. Remove two screws securing domelight base and the TRIM support structure. 3. Slowly pull the light base until the connector for the roof harness is exposed.
Page 711: Lighted Visor Mirror Replacement
______________________________________________________________________ 10-84 Body ® Lighted Visor Mirror Replacement LIGHT LAMP Removal BRACKET Pull mirror assembly from visor (Figure 10-168). Remove lamp. VISOR MIRROR LEAD GROUND LEAD HOOD CONNECTORS LAMP Figure 10-169: Underhood Light Replacement Daytime Running Lights (DRL) Module Replacement (Canada Only) VISOR MIRROR ASSEMBLY Removal...
Page 712 _____________________________________________________________________ Body 10-85 ® Front Driver and Passenger Courtesy Light Headlight Electrical Connector and Replacement Grommet Replacement Removal Removal 1. Carefully pry courtesy light from mounting bracket Remove headlight and jumper harness. (Figures 10-171 and 10-172). Remove connector from grommet (Figure 10-173). 2.
Page 713: Backup Light Switch Replacement
______________________________________________________________________ 10-86 Body ® BACKUP LIGHT SWITCH REPLACEMENT STOPLIGHT SWITCH REPLACEMENT Removal Removal 1. Remove shift controls housing (Section 5). 1. Disconnect two harness leads from stoplight switch (Figure 10-175). 2. Pull neutral start switch leads, backup light switch leads, and light lead through boot and remove boot from shift Remove stoplight switch from bracket.
Page 714 _____________________________________________________________________ Body 10-87 ® SLANT BACK AND COMPONENTS SLANT DOOR WIRING HARNESS INTERMEDIATE C-PILLAR DOOR MOUNTING SLANT BACK BOLTS TORSION TORSION ASSEMBLY ASSEMBLY TORSION ASSEMBLY MOUNTING BOLTS ROOF SHELL 00-S10-003 Figure 10-176: Slant Door and Torsion Assembly Slant Door and Torsion Assembly Replace- Installation ment Using the torsion assembly mounting hardware, install the...
Page 715 ______________________________________________________________________ 10-88 Body ® Adjustments 4. Make sure that the top of the slant door has adequate clearance to the roof shell when opening and closing. Loosen the torsion assembly mounting bolts enough to 5. Tighten the torsion assembly mounting bolts to 15 lb-ft allow the slant door to move side to side (Figure 10-176).
Page 716 _____________________________________________________________________ Body 10-89 ® Slant Door Latch Adjustments Loosen the four latch bracket mounting bolts until the RETAINING latch moves horizontally and vertically (Figure 10-178). BOLT Position the latch so the striker is centered in the opening DOOR HANDLE of the latch. The door should latch easily and have ASSEMBLY minimal movement.
Page 717 ______________________________________________________________________ 10-90 Body ® Wiper Motor and Components WIPER BLADE WIPER PLASTIC NUT COVER RETAINER SHAFT RETAINING WASHER HARDWARE HOSE WIPER ELECTRICAL MOTOR CONNECTION WIPER MOTOR RETAINING BRACKET WIPER MOTOR BRACKET WIPER MOTOR MOUNTING BOLT MOUNTING SCREW 00-P12-013 WASHER Figure 10-180: Window Wiper Assembly Replacement Removal Installation Remove the protective nut cover from the base of the...
Page 718 _____________________________________________________________________ Body 10-91 ® GLASS AND BODY FOR SLANT BACK Installation Install the slant back side window and the window retaining Rear Window bracket. Secure the window to the bracket with the thirteen window retaining screws (Figure 10-182). Removal Remove the twenty two window retaining screws, the window retainer bracket and the window (Figure 10-181).
Page 719 ______________________________________________________________________ 10-92 Body ® THIS PAGE INTENTIONALLY BLANK.
Page 720: Heating/Ventilation
_______________________________________________________________________________ 11-1 ® Section 11 Heating/Ventilation/Air Conditioning (HVAC) TABLE OF CONTENTS A/C System Refrigerant and Capacity ....11-5 Essential Tools ........11-51 Air Conditioning/Heater Duct Replacement .
Page 721: Electrical
_______________________ 11-2 Heating/Ventilation/Air Conditioning (HVAC) ® SYSTEM PERFORMANCE CHECKS Before performing any air conditioning repair, perform the fol- Check water control valve operation. Heater Shutoff lowing: Valve should open completely when temperature control knob is rotated clockwise. Check drivebelt for wear, damage, or loss of tension. Replace drivebelt as necessary.
Page 722 ______________________ Heating/Ventilation/Air Conditioning (HVAC) 11-3 ® A/C System Leak Testing Electronic leak testing Recommended electronic leak detector is the D-Tek, pocket There are two methods of detecting refrigerant leaks. One portable model (Figure 11-2). It is self powered by NiCad bat- method is with the use of an electronic leak detector and the teries, extremely compact, and will locate leaks as small as 1/4 other uses a flourescent tracer dye in the refridgerant which is...
Page 723 _______________________ 11-4 Heating/Ventilation/Air Conditioning (HVAC) ® CONNECTOR IDENTIFICATION COMPRESSOR-OUT AUX EVAP - OUT CONDENSER - IN MAIN EVAP - IN CONDENSER - OUT MAIN EVAP - OUT DRYER - IN L/P AUX TEE - IN DRYER - OUT L/P AUX TEE - OUT H/P AUX TEE - IN COMPRESSOR - IN H/P AUX TEE - OUT...
Page 724: A/C System Refrigerant And Capacity
A/C SYSTEM REFRIGERANT AND CAPACITY Pressure Test Procedure Connect gauge hoses on service cart J–39500-A to service The required refrigerant for Hummer A/C systems is R-134a. ports on suction and discharge lines (Figure 11-4). Red This is a colorless, odorless non-flammable, liquefied gas.
Page 725 _______________________ 11-6 Heating/Ventilation/Air Conditioning (HVAC) ® A/C Servicing Precautions Recycling System Refrigerant There are precautions that should be followed when servicing The J–39500-A service cart (from Kent Moore), will recycle the A/C system. The precautions are necessary to avoid com- R-134a refrigerant when necessary.
Page 726 ______________________ Heating/Ventilation/Air Conditioning (HVAC) 11-7 ® Checking/Adding Refrigerant Oil Perform evacuation, recharging, and leak testing of system. It is not necessary to check or add oil as routine maintenance. It is necessary to add oil when the evaporator, condenser, com- Charging The A/C System pressor, or receiver/dryer has been replaced, or there was a NOTE: If A/C system requires replacement of a major compo-...
Page 727: System Diagnosis
_______________________ 11-8 Heating/Ventilation/Air Conditioning (HVAC) ® SYSTEM DIAGNOSIS System diagnosis should begin with the system performance The diagnosis charts outline common heater and A/C prob- checks described in this section. The checks will help verify lems. The potential causes are listed in order of probability that a problem actually exists as opposed to an incorrect setting (most-to-least probable).
Page 728 ______________________ Heating/Ventilation/Air Conditioning (HVAC) 11-9 ® Heater Diagnosis Condition Possible Cause Correction Inadequate or No Heat Heat control knob not set in heat mode, or Advise owner/driver. engine not warmed up. 2. Low engine coolant level. Add coolant as needed and check for leaks. 3.
Page 729 ______________________ 11-10 Heating/Ventilation/Air Conditioning (HVAC) ® Air Flow Diagnosis Condition Possible Cause Correction No Air Flow from Outlets Blower motor fuse blown. 1. Replace fuse. Blower motor harness damage (short, Check harness continuity with ohmmeter open, loose connection). and repair as needed. Blower motor fault.
Page 730 _____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-11 ® A/C Pressure Test Diagnosis Condition Possible Cause Correction Low Side High Condenser ﬁns obstructed or distorted. Clear obstruction with water spray and High Side High compressed air. Straighten distorted ﬁns (Discharge Air Warm - with tool J–36847 or equivalent.
Page 731 ______________________ 11-12 Heating/Ventilation/Air Conditioning (HVAC) ® Compressor Diagnosis Condition Possible Cause Correction Compressor Noise System overcharge. Recover all R-134a with J–39500-A ser- vice cart and recharge with proper charge. Drivebelt problem. 2. Replace belt if worn, frayed, cut or torn. Compressor clutch fault.
Page 732 _____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-13 ® SPECIFICATIONS System refrigerant — R-134a Compressor oil — PAG (polyalkaline glycol) Refrigerant capacity — 3 lbs.2oz. Compressor type — Harrison HT6 A/C System Test Pressures Ambient Temperature Low Side Pressure Range* High Side Pressure Range* F°...
Page 733 ______________________ 11-14 Heating/Ventilation/Air Conditioning (HVAC) ® R-134a Pressure-to-Temperature Relationship Chart (with Engine OFF) Temp (°F) Temp (°F) Temp (°F) Temp (°F) R-134a R-134a R-134a R-134a -14.7 29.3 69.6 130.1 -12.1 30.5 72.9 133.5 -9.6 31.7 76.1 136.7 -7.2 32.9 79.2 139.8 -4.9 34.0...
Page 734 _____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-15 ® FLOOR DOOR MOTOR (RED) DEFROST BLOCKOFF DOOR MOTOR(BLUE) RECIRCULATE DOOR MOTOR (ORANGE) FACE DOOR MOTOR(YELLOW AND BROWN) DEFROST DOOR MOTOR (SILVER) 7-S11-031 Figure 11-5: Vacuum Door Motors Vacuum Door Motor Arm Positioning Defrost/ A/C Blend Face Floor Defrost...
Page 735 ______________________ 11-16 Heating/Ventilation/Air Conditioning (HVAC) ® CLIMATE CONTROL HEAD REPLACEMENT Removal Installation 1. Remove front console. From behind support plate, angle climate control panel behind shorter of two side brackets. 2. Remove screw attaching climate control head to support plate side bracket (Figure 11-6). Push climate control head toward longer side bracket until flush, then secure it with a screw.
Page 736: Pressure Hose Torque Specifications
_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-17 ® PRESSURE HOSE TORQUE SPECIFICATIONS CAUTION: To avoid potential thread or fitting damage, hand start connections before using wrenches. Air conditioning system fittings are a common source of refrig- erant leaks. When service requires disconnecting and connect- ing fittings, observe the following: •...
Page 737 ______________________ 11-18 Heating/Ventilation/Air Conditioning (HVAC) ® AIR CONDITIONING PRESSURE HOSE REPLACEMENT SUCTION HOSE WARNING: Air conditioning system components are EXPANSION VALVE subject to high-pressure R-134a gas. Always discharge MANIFOLD BLOCK pressure and contain refrigerant using approved service equipment. Use extreme care when handling R-134a. Direct contact with skin may cause frostbite.
Page 738 _____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-19 ® Discharge Hose Replacement Condenser-to-Receiver/Dryer Hose Removal WARNING: Air conditioning system components are subject to high pressure R-134a gas. Always discharge 1. Disconnect discharge hose from condenser. Remove and pressure and contain refrigerant using approved service discard O-ring (Figure 11-12).
Page 739: Condenser Replacement
______________________ 11-20 Heating/Ventilation/Air Conditioning (HVAC) ® Receiver/Dryer-To-Evaporator Core Hose CONDENSER REPLACEMENT Removal WARNING: Air conditioning system components are subject to high pressure R-134a gas. Always discharge WARNING: Air conditioning system components are pressure and contain refrigerant using approved service subject to high pressure R-134a gas. Always discharge equipment.
Page 740 _____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-21 ® RECEIVER/DRYER REPLACEMENT RECEIVER/DRYER PRESSURE SWITCH REPLACEMENT Removal Removal WARNING: Air conditioning system components are Disconnect pressure switch jumper connector from subject to high-pressure R-134a gas. Always discharge receiver/dryer pressure switch (Figure 11-16). pressure and contain refrigerant using approved service equipment.
Page 741: Heater Hose Replacement
______________________ 11-22 Heating/Ventilation/Air Conditioning (HVAC) ® HEATER HOSE REPLACEMENT WATER CONTROL VALVE The water control valve determines when coolant will flow Engine coolant is routed through 5/8 inch diameter heater hose through the heater core(s). The design of the valve allows the from the engine water crossover to the bottom fitting of the engine coolant to flow around (bypass) the HVAC system heater shutoff valve.
Page 742: Water Control Valve Replacement
_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-23 ® WATER CONTROL VALVE REPLACEMENT Removal Installation 1. Place a drain container under the vehicle directly below CAUTION: Do not overtighten the clamp that secures the con- the control valve (Figure 11-19). trol valve to the mounting bracket. Overtightening the clamp can deform the valve housing and cause binding.
Page 743: Drain Tube Replacement
______________________ 11-24 Heating/Ventilation/Air Conditioning (HVAC) ® MAIN A/C - HEAT UNIT COWL INSULATION Installation REPLACEMENT 1. Position cowl insulation so that ﬂap side is inserted under surge tank bracket (Figure 11-20). Removal Install three nuts and washers to secure insulation to main 1.
Page 744: Air Conditioning/Heater Duct Replacement
_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-25 ® AIR CONDITIONING/HEATER DUCT Driver Floor Duct REPLACEMENT The driver floor vent and floor duct are both integrated as part Passenger Floor Duct of the closeout panel assembly. Failure of either component constitutes closeout panel assembly replacement. Removal Removal 1.
Page 745 ______________________ 11-26 Heating/Ventilation/Air Conditioning (HVAC) ® DEFROST DUCT AND WINDSHIELD NOZZLES Installation REPLACEMENT Install center windshield defrost duct into A-beam (Figure 11-24). Align both ends with adjacent duct and Center Defrost Duct insuring a leak-free overlap joint. Removal NOTE: Apply Silaprene Sealant 05593929 in a continuous 1.
Page 746 _____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-27 ® Passenger Side Windshield Defrost Nozzle Driver Side Windshield Defrost Nozzle Removal Removal 1. Remove right side crash pad (Section 10). Remove right side crash pad (Section 10). 2. Remove front console (Section 10). Remove front console (Section 10). 3.
Page 747 ______________________ 11-28 Heating/Ventilation/Air Conditioning (HVAC) ® COMPRESSOR REPLACEMENT Installation NOTE: Sealing washers, by design, do not require lubrication. WARNING: Air conditioning system components are Lubricating sealing washers during replacement will increase subject to high-pressure refrigerant R-134a gas. Always the possibility of contamination, which may result in refriger- discharge pressure and contain R-134a using approved ant leaks.
Page 748 _____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-29 ® 3. Keep the clutch plate and hub assembly from turning by Align the shaft key with the shaft keyway, and place the using the clutch hub holding tool. Remove the shaft nut clutch plate and hub assembly onto the compressor shaft. using nut socket.
Page 749 ______________________ 11-30 Heating/Ventilation/Air Conditioning (HVAC) ® COMPRESSOR CLUTCH ROTOR AND/OR To prevent damage to the pulley during bearing removal, the rotor hub must be properly supported. Remove the BEARING REPLACEMENT forcing screw from puller, and with the puller tangs still Removal engaged in the rotor slots, invert the assembly onto a solid flat surface or blocks (Figure 11-33).
Page 750 _____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-31 ® 2. Align the new bearing squarely with the hub bore, and using puller and bearing installer with driver handle, drive SCREW the bearing pulley into the hub. The installer will apply force to the outer race of the bearing if used as shown (Figure 11-34).
Page 751 ______________________ 11-32 Heating/Ventilation/Air Conditioning (HVAC) ® COMPRESSOR CLUTCH CORE REPLACEMENT When core is fully seated on the compressor, use a 1/8-in. diameter drift punch and stake the front head at three Removal places, 120 degrees apart, to ensure clutch core remains in positioning (Figure 11-41).
Page 752 _____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-33 ® shaft seal retainer ring.) Rotate the installer to seat the O- SEAL REMOVER/ ring and remove the installer. INSTALLER Dip new seal in clean PAG oil and assemble seal onto seal installer by turning handle clockwise. The stamped steel case side of the lip seal must be engaged with knurled tangs of installer so that the flared-out side of lip seal is facing and installed towards the compressor.
Page 753: Low Pressure Cutoff Switch
______________________ 11-34 Heating/Ventilation/Air Conditioning (HVAC) ® LOW PRESSURE CUTOFF SWITCH CONDENSER The low pressure cutoff switch is mounted on the receiver/ The condenser provides heat exchange for the A/C system. The dryer. The switch is wired in series with the compressor activa- condenser is located on the front of the radiator and cooler as- tion circuit.
Page 754: Blower Motor Resistor Replacement
_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-35 ® BLOWER MOTOR RESISTOR REPLACEMENT HIGH PRESSURE CUTOFF SWITCH The high pressure cutoff switch is located in the rear of the Removal compressor. The switch is wired in series with the compressor 1. Remove HVAC harness connector from resistor clutch and exposed to high side pressure in the compressor.
Page 755: Hvac Controls
______________________ 11-36 Heating/Ventilation/Air Conditioning (HVAC) ® HVAC CONTROLS Temperature Dial The temperature dial controls the temperature of the air exiting the HVAC unit. When the dial is rotated to the cold position, the water valve is shut off and the temperature door isolates the heater core.
Page 756: Unit Service
_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-37 ® UNIT SERVICE Diverter Doors Four diverter doors occupy the outlet area of the main unit. WARNING: When working with refrigerant, always Various positions and combinations of 4 doors provide the sys- use protective equipment to prevent injury. Refrigerant tem with the following mode selections: handling should be done only by technicians trained •...
Page 757: Heater Core
______________________ 11-38 Heating/Ventilation/Air Conditioning (HVAC) ® Heater Core Expansion Valve The heater core is composed of copper and brass with numer- The expansion valve controls the flow of refrigerant through ous passages allowing heated engine coolant to pass through, the evaporator. Refrigerant must be metered to prevent the liq- transferring heat into the passing air from the blower motor.
Page 758 _____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-39 ® MAIN UNIT REPLACEMENT Removal VACUUM CONTROL POWER MIRROR 1. Drain Coolant into an approved container. RELAYS 2. Recover refrigerant. 3. Remove raincap and adapter. ENGINE HVAC 4. Remove air intake elbow, air cleaner and splash shield. 5.
Page 759 ______________________ 11-40 Heating/Ventilation/Air Conditioning (HVAC) ® Installation CAUTION: Be sure to remove all of the devices used to plug the openings in the heater lines and the A/C lines. Lift HVAC unit into the vehicle. 1. Set the lower bracket on HVAC unit on top of the lower Install manifold block to expansion valve using a new body bracket.
Page 760: Vacuum Door Motor
_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-41 ® VACUUM DOOR MOTOR Replacement 1. Remove right front crash pad. 2. Locate and remove 2 screws securing vacuum motor cover to main HVAC unit. 3. Locate faulty vacuum motor and remove vacuum line. If multiple motors are to be replaced, tag vacuum lines as they are removed.
Page 761: Blend Door Motor
______________________ 11-42 Heating/Ventilation/Air Conditioning (HVAC) ® BLEND DOOR MOTOR Replacement HEATER CORE EXTENSION TUBES 1. Disconnect motor electrical connection. 2. Remove 3 nuts securing motor to bracket (Figure 11-68). MOUNTING PLATE DOOR SHAFT ADAPTER 7-S11-032 Figure 11-69: Heater Core Tube Removal TEMPERATURE BLEND DOOR MOTOR Cut sealer around heater core retaining plates (Figure 11-70).
Page 762 _____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-43 ® EVAPORATOR Replacement 1. Remove HVAC unit from vehicle (refer to HVAC unit replacement). 2. Remove heater core from main unit (refer to heater core replacement). 3. Remove lower support bracket from HVAC case 7-S11-043 (Figure 11-72).
Page 763 ______________________ 11-44 Heating/Ventilation/Air Conditioning (HVAC) ® 8. Remove arm retaining push clip, arm and 2 washers from the floor door and defrost door (Figure 11-78). SCREW DEFROST DOOR MOTOR PUSH CLIP 7-S11-040 FLOOR DOOR MOTOR Figure 11-78: Push Clip Removal 9.
Page 764: Cycling Switch Replacement
_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-45 ® Installation 19. Remove screws securing passthrough plate support bracket to the main unit (Figure 1-82). Obtain new evaporator. Ensure that any foam tape found on the previously removed unit is duplicated on the replacement. Install extension tubes onto new evaporator using new o- rings lubricated with refrigerant oil.
Page 765: Rear Console Replacement
______________________ 11-46 Heating/Ventilation/Air Conditioning (HVAC) ® REAR CONSOLE REPLACEMENT LARGE O-RING AUXILIARY UNIT A/C HOSE Removal Remove two screw/washers securing rear console to side brackets (Figure 1-85). DRAIN 2. Push console rearward so that the vents are clear from the TUBES plenum cutouts.
Page 766 _____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-47 ® AUXILIARY BLOWER SWITCH REPLACEMENT AUXILIARY HEATER HOSE REPLACEMENT NOTE: Heater hose replacement is the same for both heater Removal hoses. 1. Pull front console away from dashboard. NOTE: Production heater hose will have full underbody 2.
Page 767 ______________________ 11-48 Heating/Ventilation/Air Conditioning (HVAC) ® AUXILIARY A/C DRAIN TUBE(S) REPLACEMENT EXPANSION VALVE Removal MANIFOLD 1. Remove rear console. 2. Remove clamps from drain tube section being replaced (Figure 11-89). 3. Remove drain tube. DRAIN TUBE HEATER TUBE HIGH PRESSURE HOSE CONNECTION (AUX.) CLAMPS 7-S11-063...
Page 768 _____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-49 ® AUXILIARY LOW-PRESSURE HOSE AUXILIARY EVAPORATOR/HEATER CORE REPLACEMENT REPLACEMENT Removal Removal 1. Discharge air conditioning system. Remove auxiliary unit from vehicle. 2. Remove air cleaner assembly and air induction tube Remove four screws and plenum from housing. (Section 3).
Page 769 ______________________ 11-50 Heating/Ventilation/Air Conditioning (HVAC) ® PLASTIC LOCKING PIN TOP HOUSING BLOWER MOTOR ASSEMBLY EVAPORATOR/HEATER CLIP CORE ASSEMBLY MESH FILTER PLASTIC PIN EXPANSION VALVE BOTTOM HOUSING TUNNEL SUPPORT BRACKET PLENUM Figure 11-92: Auxiliary Air Conditioning Components AUXILIARY EXPANSION VALVE AUXILIARY EXPANSION REPLACEMENT UNIT...
Page 770 _____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-51 ® ESSENTIAL TOOLS 00-S11-010 00-S11-009 J–41995 J–42220 J–41459 Tool No. Description J–42551 Leak Detector, A/C R134a J–42549 HVAC Anemometer (not shown) J–42550 HVAC Flow Meter Adapter Kit (not shown) J–41459 Leak Detection Dye Injector J–42220 High Intensity Ultra Violet (Black) Light Procure from Kent-Moore.
Page 771 ______________________ 11-52 Heating/Ventilation/Air Conditioning (HVAC) ® SPECIAL TOOLS J–39500-20A J–34021-A J–39500-A J–39500-24A J–39037 J–6742-03 J–39183-C J–23738-A J–24182-2A J–36847 Tool No. Description J–39500-A A/C Recovery, Recycle, Evacuate and Discharge Service Cart (from Robinaire) J–34021-A Compressor Clutch Pulley, Core and Bearing Replacement Tool Set J–39500-20A High Side Coupler Adapter (Compact Proﬁle) J–39500-24A...
Page 772 _______________________________________________________________________________ 12-1 ® Section 12 Electrical System TABLE OF CONTENTS Audio Digital Ratio Adapter....... 12-74.1 Antenna System Test .
Page 773 _________________________________________________________ 12-2 Electrical System ® Power Locks Cargo Door Lock Inoperative ....12-113 Front Door Harness Replacement ....12-120 General Replacement .
Page 774: Electrical System
Parallel Circuits system being diagnosed. Refer to the connector legend for con- nector identification of system connectors. The Hummer electrical system is a parallel circuit. In a parallel circuit, the electrical devices form more than one current path Connector Legend to and from the power supply.
Page 775: Circuit Faults
Fuses can be found in range from 1A to 30A, and be Open mini or maxi types. All fuses used on the HUMMER® are blade type. An open circuit occurs whenever there is a break in the circuit continuity.
Page 776: Diagnostic Tests
A digital multimeter (J–39200) is required to safely test for tion multimeter leads on each side of the load (Figure 12-5). electrical malfunctions on the Hummer. Due to the complexity OHM Test of the electrical system, a test light should not be used to test electrical circuits.
Page 777 _________________________________________________________ 12-6 Electrical System ® MULTIMETER LOAD (I.E. LIGHT, MOTOR, CIRCUIT SOLENOID, ETC.) BATTERIES BREAKER GROUND GROUND SWITCH (CLOSED) Figure 12-4: Amperage Test MULTIMETER CIRCUIT BATTERIES BREAKER SWITCH GROUND GROUND (CLOSED) Figure 12-5: Voltage Drop Test MULTIMETER CIRCUIT BATTERIES BREAKER SWITCH GROUND GROUND...
Page 778 ________________________________________________________ Electrical System 12-7 ® CIRCUIT MAINTENANCE AND REPAIR Single Wire Repair (Exposed) Remove damaged area, removing as little wire as possi- All electrical connections must be kept clean and tight. Loose ble (Figure 12-8). or corroded connections may cause a discharged battery, weak starting, dim lights, or possible electrical system damage.
Page 779 _________________________________________________________ 12-8 Electrical System ® FUSIBLE LINK MAINTENANCE NOTE: Fusible link is a wire with special insulation. It is im- portant that replacement material be fusible link wire and it The following procedure covers the replacement of fusible should be labeled as such. The replacement fusible link should links encountered through circuit diagnosis.
Page 780 ________________________________________________________ Electrical System 12-9 ® HEAT SHRINK TUBING DAMAGED AREA Figure 12-8: Damaged Wire SPLICE CLIP Figure 12-13: Splice Clip HEAT SHRINK TUBING HEAT SHRINK TUBING STRIPPED WIRE ENDS Figure 12-9: Heat Shrink Tubing Figure 12-14: Heat Shrink Tubing HEAT SHRINK TUBING DAMAGED WIRE SPLICE CLIP Figure 12-10:...
Page 781: Accessories
Interior Fuse Box the actual wire suppling current to the device. The only inline fuse used on the Hummer is in the power feed to the HVAC The interior fuse box, is located under the instrument panel to high blower relay. This fuse is located on the passenger side of the left of the steering column.
Page 782 ______________________________________________________ Electrical System 12-11 ® MIRROR CUTOUT POWER REAR CTIS WINDOW WIPER ALARM SIGNAL FLASHER IGNITION WIPER 9-S12-083 Figure 12-19: Relay Location (Interior Fuse Box) 05745159 4-1-00...
Page 783 _______________________________________________________ 12-12 Electrical System ® Upper Mini-Fuse Location Lower Mini-Fuse Location FUSE AMPERAGE CIRCUIT PROTECTED FUSE AMPERAGE CIRCUIT PROTECTED Spare Fuse Spare Fuse – Blank Spare Fuse Spare Fuse – Blank – Blank Spare Fuse Spare Fuse Spare Fuse – Blank –...
Page 784: Ground Points
______________________________________________________ Electrical System 12-13 ® Exterior Fuse Box Fuse/ Amperage Circuit Protected EXTERIOR FUSE BOX Starter Circuit BLANK 20A CB Parking Lights VALVE WNG. BLANK 20A CB RELAY RLY. BLANK 30A CB Headlights 30A CB BLANK 30A CB HORN FUEL HEATED 30A CB Rear Defrost...
Page 785: Battery Charging
_______________________________________________________ 12-14 Electrical System ® BATTERY CHARGING Suggested charge times are outlined in the charge rate chart (Figure 12-25). Note that the chart suggested times and rates General Information are for a battery at 70°F (21°C). Charge times will be greater if battery temperature is below 55°F (13°C).
Page 786 ______________________________________________________ Electrical System 12-15 ® Install a jumper wire with a 10 amp fuse between the two Estimated Temperature Minimum Voltage terminals on the parasitic draw test switch. Open the switch and wait 10 seconds. If the fuse does not blow, the 70°F(21°C) parasitic load is less than 10 amps and the J–39200 can be 50°F(10°C)
Page 787 _______________________________________________________ 12-16 Electrical System ® BATTERY CABLE REPLACEMENT Battery Negative Cables - Removal Remove caps from battery negative cable (Figure 12-27). Remove battery cable bolts. Disconnect winch negative cable, if equipped (Figure 12-27). BATTERY NEGATIVE CABLE TO STARTER WINCH CABLE NEGATIVE CABLE BOLT BOOT...
Page 788 ______________________________________________________ Electrical System 12-17 ® WITH WINCH ONLY BATTERY CABLE BOLT STARTER BATTERY POSITIVE CABLE BATTERY BRACKET POSITIVE CABLE WINCH POSITIVE CABLE STARTER CABLE BATTERY STARTER CABLE CABLE BATTERY BOLT CABLE BOLT Figure 12-29: Battery Positive Cable Connections Battery Positive Cables - Installation 1.
Page 789 _______________________________________________________ 12-18 Electrical System ® BATTERY REPLACEMENT BATTERY TRAY REPLACEMENT/INSTALLATION 1. Disconnect and remove batteries. WARNING: Battery electrolyte contains sulfuric acid 2. Remove splash shield and battery tray shield. which can cause severe burns. If acid contacts eyes or skin, ﬂush affected areas liberally with water and ob- 3.
Page 790 ______________________________________________________ Electrical System 12-19 ® BATTERY SPLASH SHIELD AND SEAL SERVICE Splash Shield Removal 1. Remove upper splash shield and seal (Figure 12-32). 2. Remove retainer bolts, and remove seal from battery tray and lower shield (Figure 12-33). 3. Remove lower splash shield bolts and remove lower splash shield.
Page 791 _______________________________________________________ 12-20 Electrical System ® Splash Shield Installation Position lower shield on bracket and install fasteners (Figure 12-34). Install retainer on upper shield. Install upper shield on tray. Install seals and retainers (Figure 12-33). AIRLIFT BRACKET BATTERY TRAY BRACKET FRAME RAIL LOWER SPLASH SHIELD...
Page 792 ______________________________________________________ Electrical System 12-21 ® MAJOR POWER DISTRIBUTION The following charts and illustrations convey how power is Power is supplied to an individual fuse by the buss indicated in distributed from the vehicle batteries to the fuse/relay centers. the left buss column. The circuit number (CKT No.) contains two entries for a fuse: the power supply buss and the outgoing Power is supplied to the fuse boxes from the batteries through circuit number.
Page 793 _______________________________________________________ 12-22 Electrical System ® ALTERNATOR Removal Disconnect battery negative cable. BATTERY Remove serpentine drivebelt from alternator pulley. TERMINAL Loosen pivot bolt and remove front and rear alternator bolts (Figure 12-36). Pull alternator away from engine. Remove nut and lockwasher and disconnect battery wires from battery alternator terminal (Figure 12-37).
Page 794: Alternator Overhaul
______________________________________________________ Electrical System 12-23 ® ALTERNATOR OVERHAUL Alternator Disassembly 1. Remove alternator. Remove standard screws, insulated screws, and washer from components in slip ring end frame. 2. Mark drive end frame and slip ring end frame for assembly alignment reference. Remove nut and output stud with insulator from slip ring end frame.
Page 795: Inspection And Repair
_______________________________________________________ 12-24 Electrical System ® Alternator Parts Stator Check the stator leads for continuity to ground (laminations). Cleaning Any continuity indicates a grounded stator which should be re- Use part cleaning solvents on metal parts only. The insulating placed (Figure 12-40). coatings on wires in the field coil and stator can be damaged by Examine the stator winding for discoloration due to overheat- cleaning solvents.
Page 796 ______________________________________________________ Electrical System 12-25 ® OHMMETER LEADS OHMMETER LEADS GROUNDED SIDE STUDS STRAP STRAP POSITIVE SIDE Figure 12-41: Rectifier Bridge Check Regulator NOTE: The pin that retains the brushes temporarily can be made from locally obtained parts. A standard paper clip can be REGULATOR used.
Page 797 _______________________________________________________ 12-26 Electrical System ® Output Stud Assembly Inspect the fan for distortion, cracked blades, or broken blades. Inspect the output stud assembly for cracked, or broken insula- Minor bending repair is permissible. For broken or missing tor, distortion, or damaged threads. Replace the stud assembly blade ends, cracks or breaks, replace the fan (Figure 12-45).
Page 798 ______________________________________________________ Electrical System 12-27 ® Alternator Assembly 1. Install bearing on rotor shaft. Seat bearing against shoul- der (Figure 12-38). 2. Assemble springs and brushes in brush holder and retain with fabricated pin. Pin holds brushes compressed in brush holder and will be removed after assembly. 3.
Page 799 _______________________________________________________ 12-28 Electrical System ® Alternator Inoperative (No Charge) Step Action Value(s) Perform visual inspection on belt, pulleys and Go to step 2. Repair and battery cables. Is everything in normal operating recheck system. condition Using a battery load tester, place amp pickup on >100 amps Go to step 7.
Page 800 ______________________________________________________ Electrical System 12-29 ® TO POSITIVE HOT IN RUN AND START TO EXTERIOR BATTERY CABLE FUSE BOX TO INTERIOR FUSIBLE FUSE BOX LINK FUSE 3B EXTERIOR 20 AMP EXTERIOR LOW COOLANT POWER BUS SENSOR FUSIBLE LINK C4-3 IGN FEED BATTERY TERMINAL ALTERNATOR 9-S12-089...
Page 801 _______________________________________________________ 12-30 Electrical System ® STARTER Installation 1. Position shim pack on starter. Removal 2. Position starter in converter housing. Disconnect battery negative cable(s) and winch negative 3. Slide starter stud into chassis bracket. Be sure stud nut and cable, if equipped. washer are behind bracket.
Page 802 ______________________________________________________ Electrical System 12-31 ® SOLENOID CONNECTOR FRAME STARTER CABLES ARMATURE (FROM BATTERY) SHAFT PLATE FELT WICK SPACER SOLENOID SOLENOID THRUST SCRIBE WIRE TO GLOW PLUG WASHER MARK CONTROLLER GASKET Figure 12-54: Starter Connections SCRIBE SOLENOID MARK CONNECTOR STARTER OVERHAUL Figure 12-56: End Plate Removal Disassembly Remove solenoid screws and remove solenoid.
Page 803 _______________________________________________________ 12-32 Electrical System ® PINION SHIFT LEVER HOUSING FIELD COIL FRAME BRACKET POSITIVE BRUSH LEAD SNAP RING PINION STOP CLUTCH PLUG (2) NEGATIVE BRUSH LEAD SPRING ARMATURE BRUSH HOLDER GASKET ARMATURE Figure 12-60: Brush and Holder PLATE Removal/Installation Figure 12-58: Starter Drive Disassembly 20.
Page 804 ______________________________________________________ Electrical System 12-33 ® Inspection Inspect clutch for broken spring, damaged gear or splines, and SOLENOID SPRING CONTACT non-lockup. Replace clutch if damaged (Figure 12-63). HOUSING Inspect brushes for cracks, roughness, galling, wear, or dam- aged lead. If one brush length is less than 0.315 in. (8 mm) or has other damage, replace all brushes as a set.
Page 805 _______________________________________________________ 12-34 Electrical System ® 16. Install O-ring and gasket in pinion housing (Figure 12-66). SOLENOID 17. Coat end plate-to-frame screws with adhesive sealant. CONTACT HOUSING CAUTION: As armature is inserted into frame assembly, care- CORE SPRING fully align brushes on commutator. Brushes chip and break easily.
Page 806 ______________________________________________________ Electrical System 12-35 ® FRAME PINION HOUSING ARMATURE BRUSHES SCRIBE MARK GASKET O-RING COMMUTATOR SCRIBE MARK COMMUTATOR Figure 12-66: Assembling Frame, Armature, and Pinion Housing Starter Pinion Clearance BOOT (COAT SOLENOID WITH GREASE) Adjustment Connect battery and jumper to starter as shown (Figure 12-68).
Page 807 _______________________________________________________ 12-36 Electrical System ® MEASURE CLEARANCE ARMATURE SHAFT HERE WITH FEELER GAUGE ADD OR SUBTRACT THRUST WASHERS TO ADJUST CLEARANCE PLATE PINION HOUSING Figure 12-69: Starter Pinion Clearance Measurement and Adjustment Starter Test SWITCH Connect voltmeter, ammeter, switch and battery to starter as shown (Figure 12-70).
Page 808 ______________________________________________________ Electrical System 12-37 ® Starter Inoperative Step Action Value(s) Inspect battery condition and charge (Refer to Go to step 2 Recharge/Replace battery checking procedure this section). Are bat- batteries as neces- teries in good working condition and charged? sary Using a DVOM set to measure voltage, place the Repair or replace Go to step 3...
Page 809 _______________________________________________________ 12-38 Electrical System ® Starter Inoperative (Continued) Step Action Value(s) Repair open or bad connection in CKT32 Repair complete Go to step 1. between neutral saftey switch and start relay. Is condition repaired Remove lower cover of steering column to access Repair open or Go to step 12 the ignition switch connector.
Page 810 Section 12 Electrical System ______________________________________________________ Electrical System 12-39 ® MAXIFUSE #1 40A EXTERIOR NEUTRAL SAFETY SWITCH C2-12 33 WHT C2-13 C1-6 IGNITION STARTER SWITCH RELAY C1-7 C4-1 MAXIFUSE #8 40A EXTERIOR STARTER SOLENOID BATTERY 9-S12-087.2 Figure 2-71: Starter System Schematic 05745159 4-1-00...
Page 811 _______________________________________________________ 12-40 Electrical System ® Glow Plugs Inoperative Step Action Value Before clearing any DTC’s, use the scan tool Cap- Go to step 2. ture Info to save the Freeze Frame and Failure Records for reference. The PCM’s data is deleted once the Clear Info function is used.
Page 812 ______________________________________________________ Electrical System 12-41 ® Glow Plugs Inoperative (Cont’d) Step Action Value Turn the ignition ON with the engine OFF. Verify 9-12 Volts Go to step 12. Go to step 11. that the glow plug relay control harness is discon- nected.
Page 813 _______________________________________________________ 12-42 Electrical System ® Glow Plugs Inoperative (Cont’d) Step Action Value Inspect the glow plug relay control circuit (CKT Go to step 30. Go to step 29. 466 YL) for a proper connection at the PCM and replace the terminal if necessary. Did you ﬁnd an improper connection and make the necessary repair? Inspect the glow plug relay signal circuit (CKT...
Page 814 ______________________________________________________ Electrical System 12-43 ® Glow Plugs Inoperative (Cont’d) Step Action Value Use a scan tool to clear the DTC’s. Start the Go to step 31. Go to step 2. engine. Allow the engine to idle until the engine reaches normal operating temperature. Select the DTC and the speciﬁc DTC function.
Page 815 _______________________________________________________ 12-44 Electrical System ® Fuel Lift Pump Inoperative VIN Z Step Action Value(s) Important: Before clearing the DTC’s use the scan Go to step 2. Go to Power- tool Capture Info in order to record the Freeze train OBD sys- Frame and the failure records for reference, as the tem check.
Page 816 ______________________________________________________ Electrical System 12-45 ® Fuel Lift Pump Inoperative VIN Z (Cont’d) Step Action Value(s) <.2 Ω Disconnect fuel lift pump relay.Using a DVOM Repair open or Go to step 10. set to measure ohms, measure resistance between bad connection C27-D5, and the fuel lift pump relay dark green in CKT 238 wire (CKT238).
Page 817 _______________________________________________________ 12-46 Electrical System ® FUSE 2D INTERIOR C1-10 537 OR FUEL PUMP RELAY EXTERIOR FUSE BOX TO FUEL SELECTOR SWITCH 787 GY 787 GY C27-D5 C27-D8 FUEL LIFT FUEL PUMP PUMP SIGNAL RELAY CONTROL POWERTRAIN CONTROL FUEL MODULE LIFT PUMP 9-S12-051 Figure 2-73: Fuel Lift Pump Schematic...
Page 818 ______________________________________________________ Electrical System 12-47 ® Fuel Tank Selector System Inoperative (No Tank Switch) Step Action Value(s) Important: Before clearing the DTC’s use the Go to step 2. Go to Power- scan tool Capture Info in order to record the train OBD sys- Freeze Frame and the failure records for refer- tem check.
Page 819 _______________________________________________________ 12-48 Electrical System ® Fuel Tank Selector System Inoperative (No Tank Switch) Step Action Value(s) Relocate the ground lead of the DVOM set to 12 v Go to step 8. Repair open, measure voltage to a known good ground. Turn bad connection the ignition OFF for 10 seconds.
Page 820 ______________________________________________________ Electrical System 12-49 ® 786 RD 789 BR Training 8F TANK TANK CHANGE CHANGE CONTROL CONTROL FUEL FUEL SELECTOR SELECTOR SWITCH VALVE MAIN TANK AUX TANK FUEL LEVEL FUEL LEVEL FUEL LEVEL SIGNAL SIGNAL SIGNAL OUT C26-C C26-B GAUGE FUSE C3-N6 C3-M8...
Page 821 _______________________________________________________ 12-50 Electrical System ® 30 GY HOT IN RUN AND START C9-J C3-N7 WATER IN FUSE 4B FUSE 3B FUEL LIGHT DRAIN 5AMP 20AMP LEFT HAND FILTER INTERIOR EXTERIOR STATUS CENTER FUSE BOX FUSE BOX IGNITION C9-D SWITCH C3-F4 C1-45 291 PK WATER IN...
Page 822: Brake Shift Interlock Cable Inoperative
______________________________________________________ Electrical System 12-51 ® IGNITION SWITCH REPLACEMENT Brake Shift Interlock Cable System Descrip- tion (Figure 2-76) Removal The purpose of the brake shift interlock cable is to prevent a Remove steering column covers. driver from engaging a transmission gear before the brakes are Remove multi switch.
Page 823 _______________________________________________________ 12-52 Electrical System ® INTERLOCK CABLE SOLENOID TURN SIGNAL SWITCH 22 RD BRAKE SWITCH INTERIOR FUSE BOX FUSE FUSE 15 AMP 5 AMP INTERIOR INTERIOR FUSE FUSE BATTERY IGNITION 9-S12-001 Figure 2-77: Shift Interlock Cable Schematic 4-1-00...
Page 824: Ctis Compressor Inoperative
______________________________________________________ Electrical System 12-53 ® CTIS Compressor Inoperative Step Action Value(s) Using a DVOM set to measure voltage, probe the Replace the Go to step 2. terminals on the CTIS compressor. With the CTIS compressor compressor switch set to inﬂate, and the ignition on, is voltage present? Move the ground lead to a known good ground Repair open or...
Page 825: Ctis Exhaust Valve Inoperative
_______________________________________________________ 12-54 Electrical System ® CTIS Exhaust Valve Inoperative Step Action Value(s) Disconnect exhaust solenoid. Using a DVOM set Replace exhaust Go to step 2. to measure voltage, probe the light green solenoid. wire(CKT47) with the positive lead, and the black wire(CKT57) with the negative lead.
Page 826: Ctis Front Inflate Valve Inoperative
______________________________________________________ Electrical System 12-55 ® CTIS Front Inflate Valve Inoperative Step Action Value(s) Disconnect front inﬂate solenoid. Using a DVOM Replace front Go to step 2. set to measure voltage connect the positive lead to inﬂate solenoid. the tan wire(CKT91), and the negative lead to the black wire(CKT57).
Page 827: Ctis Rear Inflate Valve Inoperative
_______________________________________________________ 12-56 Electrical System ® CTIS Rear Inflate Valve Inoperative Step Action Value(s) Disconnect front inﬂate solenoid. Using a DVOM Replace rear Go to step 2. set to measure voltage connect the positive lead to inﬂate solenoid. the grey wire(CKT92), and the negative lead to the black wire(CKT57).
Page 828 ______________________________________________________ Electrical System 12-57 ® TIRE 57 BK SELECTOR REAR C1-24 C3-C4 C12-F 92 GY 57 BK DEFLATE C3-C2 C1-58 C12-D 47 LG 57 BK FRONT C1-63 C3-C3 C12-E 91 TN C12-G C3-B4 INFLATE/ DEFLATE TO BUZZER C12-H C3-B3 (fuse box) C1-23 C12-J C3-B4...
Page 829 _______________________________________________________ 12-58 Electrical System ® CLEARANCE PARK/TURN PARK/TURN CLEARANCE HEAD LIGHTS 13TN 12 DR SIDE MARKER SIDE MARKER 58 BK 20 RD UNDER HOOD IDENTIFICATION LAMP HOOD HARNESS TO IP INDICATOR LAMPS C2-2 C1-73 C2-3 C1-65 C2-4 C1-66 C2-5 C1-47 C2-6 C2-7 C1-41...
Page 830 ______________________________________________________ Electrical System 12-59 ® 15 WH BUSS L1A 14 LB FUSE 3F FUSE 4F FUSE 6F 7.5 A 7.5 A INTERIOR INTERIOR INTERIOR MASTER LIGHT SWITCH C1-67 C1-51 MAXI MAXI FUSE 2M FUSE 3M EXTERIOR EXTERIOR TO BATTERY TO BATTERY 298 BR C2-27 C1-43...
Page 831 _______________________________________________________ 12-60 Electrical System ® KEY SWITCH MASTER LIGHT SWITCH KEY, HEADLIGHT, SEATBELT CHIME SEAT BELT (STEERING COLUMN) SWITCH FUSE 85 GY 5 AMP C1 C3 INTERIOR RIGHT SIDE DOME WARNING SEAT LIGHT BELT LIGHT-1P DOOR TO TURN SWITCHES SIGNAL SWITCH/ DIMMER FUSE...
Page 832: Horn Replacement
______________________________________________________ Electrical System 12-61 ® HORN Horn Replacement Removal 1. Remove harness connectors and adapters from horn. 2. Remove horn from mounting bracket (Figure 2-81). NOTE: Overtightening horn mounting nut will distort the horn bellows and result in an “off-key” horn tone. Installation 1.
Page 833: Horns Inoperative
_______________________________________________________ 12-62 Electrical System ® Horns Inoperative Step Action Value <.2 Ω Locate the horn assemblies under the hood. Go to step 2. Repair the open Disconnect the harness from the horn assemblies. or bad connection With a DVOM check the black wires (CKT 58) for on CKT 58 resistance to ground.
Page 834 ______________________________________________________ Electrical System 12-63 ® 460 BK HORN SWITCH REMOTE ENTRY MODULE C39-C C1-62 7 RD HORN RELAY EXTERIOR FUSE BOX FUSE 20 AMP EXTERIOR FUSE 7 RD BATT HORN ADAPTER HORN ADAPTER 6 WH 58 BK 00-S12-007 Figure 2-82: Horn Schematic 05745159 4-1-00...
Page 835 _______________________________________________________ 12-64 Electrical System ® INSTRUMENT PANEL, GAUGES, AND SWITCHES RIGHT SIDE MOUNTING BOLT I. P. CLIPS Instrument Panel (I.P .) Replacement SIDE WINDOW Removal DEFROST VENT NOTE: Tag all leads prior to removal for installation. If re- HOSE placing instrument panel, refer to procedures in this section to remove and/or disconnect the various lamps, switches, and gauges.
Page 836 ______________________________________________________ Electrical System 12-65 ® Crashpad Replacement (Right Side) Gauge Replacement Removal NOTE: Gauge replacement is basically the same for all instru- ment panel gauges. 1. Remove screw/washers, and crashpad from dashboard (Figure 2-84). Removal 2. Disconnect air hose from vent duct. Remove screws and pull gauge panel away from instru- 3.
Page 837 _______________________________________________________ 12-66 Electrical System ® Instrument Panel Indicator Lamp Installation Replacement 1. Install connector on switch (Figure 2-87). 2. Install switch in switch housing. NOTE: All instrument panel indicator lamps are replaced basi- 3. Install closeout panel. cally the same. Removal CONNECTOR Remove instrument panel.
Page 838 ______________________________________________________ Electrical System 12-67 ® Speedometer/Odometer Replacement Pull the speedometer/odometer from the dash Remove the wire connector from the backside of the speedometer. Removal Installation 1. Remove the left A-pillar dash trim (closeout). Insert speedometer/odometer into instrument panel 2. Remove the left footwell closeout panel and disconnect (Figure 2-89).
Page 839: Cigarette Lighter Replacement
_______________________________________________________ 12-68 Electrical System ® Tachometer Replacement CIGARETTE LIGHTER REPLACEMENT Removal NOTE: Mark position of set screws in relationship to tachom- eter clock panel before disassembly. Tachometer mounting 1. Pull front console away from dashpad enough to gain clamp must be installed in factory position to have proper access to wiring harness connector.
Page 840: Low Coolant Lamp Inoperative
______________________________________________________ Electrical System 12-69 ® LOW COOLANT LAMP INOPERATIVE The coolant level sensor is a solid-state semi-conductor device. The sensor’s resistance varies as a function of its temperature. As voltage/current flows through the sensor, sensor tempera- ture increases. In the presence of a liquid, in this case engine coolant, the temperature of the sensor is controlled by transfer- ring heat to the coolant.
Page 841 _______________________________________________________ 12-70 Electrical System ® LOW COOLANT SENSOR IGNITION FUSE 4B 5 AMP INTERIOR FUSE BOX IGNITION FUSE 3B 20 AMP C4 3 EXTERIOR C1-55 30 GY C3 N7 C9 J LOW COOLANT LAMP 9-S12-092 RIGHT STATUS CENTER Figure 2-92: Low Coolant Sensor Schematic 4-1-00...
Page 842: Oil Pressure Gauge Inoperative
______________________________________________________ Electrical System 12-71 ® Oil Pressure Gauge Inoperative Step Action Value(s) Is gauge maxed out? Repair open or Go to step 2. bad connection in CKT31 or gauge sending. Using a DVOM set to measure voltage, check for Go to step 4. Go to step 3.
Page 843: Fuel Gauge Inoperative
_______________________________________________________ 12-72 Electrical System ® Fuel Gauge Inoperative Step Action Value(s) Using a DVOM set to measure voltage, check for Go to step 3. Go to step 2. voltage at the rear of the fuel gauge on the grey wire(CKT30) connect negative meter lead to ground on black wire(CKT59).
Page 844: Engine Temperature Gauge Inoperative
______________________________________________________ Electrical System 12-73 ® Engine Temperature Gauge Inoperative Step Action Value(s) Is gauge maxed out with ignition on? Repair short to Go to step 2. ground in CKT 39 or faulty sending unit. Using a DVOM set to measure voltage, check for Go to step 4.
Page 845 _______________________________________________________ 12-74 Electrical System ® FUEL TACHOMETER TEMP VOLT SPEEDO G L S I 59 BK 30 GY TO CTIS HARNESS 17 PP C3-N6 C3-N7 C3-P8 C3-L7 DIMMER SWITCH C1-30 C3-P9 C1-36 C3-P7 C3-K9 FUSE C1-I8 C5-C10 C5-A1 5 AMP C1-35 C1-49 349 YL...
Page 846 Section 12 Electrical System ____________________________________________________ Electrical System 12-74.1 ® Digital Ratio Adapter Location Pull the digital ratio adapter off of the hook and loop and remove from the center console. The digital ratio adapter is located under the center console on the engine cover, just above the powertrain control module.
Page 847 _____________________________________________________ 12-74.2 Electrical System ® VEHICLE SPEED SENSOR (VSS) IGNITION SPEEDO FUSE 15 AMP EXTERIOR FUSE TWISTED PAIR POWERTRAIN CONTROL MODULE ( PCM ) 570 BK GROUND 570 BK GROUND C3-P9 40 PULSE OUTPUT SHAFT 565 BR REVOLUTION C1-18 SIGNAL TO PCM 4000 PPM CRUISE...
Page 848: Hvac Main Blower Inoperative All But High
Section 12 Electrical System ______________________________________________________ Electrical System 12-75 ® HVAC Main Blower Inoperative ALL BUT High Step Action Value(s) Ignition on, blower switch set to Med2, mode dial 8 -10v Replace the Go to step 2. set to face. Measure voltage on the yellow blower relay.
Page 849 _______________________________________________________ 12-76 Electrical System ® HVAC Compressor Inoperative (Continued) Step Action Value(s) Using a DVOM set to measure voltage, place the Go to step 8. Go to step 9. positive lead on a battery power source. Place the ground lead in cavity 6F(CKT440). Using the scan tool, command the compressor clutch on.
Page 850: Hvac Temperature Door Inoperative
______________________________________________________ Electrical System 12-77 ® HVAC Compressor Inoperative (Continued) Step Action Value(s) Ignition on, mode dial set to MAX A/C. Discon- Go to step 15. Repair open, nect the high pressure cutout switch on the com- bad connection, pressor. Using a DVOM set to measure voltage, or short in check for voltage on the tan wire(CKT198).
Page 851 _______________________________________________________ 12-78 Electrical System ® HVAC Temperature Door Inoperative (Continued) Step Action Value(s) With ignition on, using a DVOM set to measure Go to step 5. Repair open or voltage and using J–35616-92 test adapters probe short to ground the GN wire (CKT 399) with the positive lead. between tem- Place the negative lead on a known good ground.
Page 852 ______________________________________________________ Electrical System 12-79 ® HVAC Temperature Door Inoperative (Continued) Step Action Value(s) <.2 Ω Using a DVOM set to measure ohms, check resis- Replace faulty Locate and tance between pin B (CKT 58) of the HVAC con- HVAC control repair open or trol head connector and a good ground.
Page 853 _______________________________________________________ 12-80 Electrical System ® HOT IN RUN AND START TO ALTERNATOR BATTERY TERMINAL 30A FUSE FUSE 7C BUILT IN HARNESS INTERIOR FUSE FUSE BOX C36-A BLOWER 364 RD RESISTOR 754 YL BLOWER RELAY BLOWER MOTOR C36-B C6-G1 8 PIN HVAC CONTROL HEAD...
Page 854 ______________________________________________________ Electrical System 12-81 ® HOT IN RUN AND START REAR HVAC BLOWER FUSE 7C INTERIOR TEMPERATURE DOOR MOTOR HOT IN RUN AND START FUSE 6C INTERIOR REAR HVAC BLOWER SWITCH RESISTOR MODULE (62K Ω) C6-G1 C6-C3 346 PK C6-J1 8 PIN HVAC TEMP BLEND...
Page 855 _______________________________________________________ 12-82 Electrical System ® AMBIENT TEMPERATURE PRESSURE SWITCH SWITCH DIODE HIGH COMPRESSOR PRESSURE CUTOUT CLUTCH C4-5 SWITCH C27-C2 POWERTRAIN REQUEST CONTROL MODULE COMPRESSOR (PCM) ENABLE C28-D5 C1-39 C4-8 348 BR C4-2 TEMP CUTOUT HOT IN RUN HVAC SWITCH AND START U N I T FUSE 2C COMPRESSOR...
Page 856 ______________________________________________________ Electrical System 12-83 ® Windshield Wiper Motor Inoperative All Speeds Step Action Value(s) <.2 Ω Gain access to the wiper motor connector under Go to step 2. Repair open or the windshield trim. Using a DVOM set to mea- bad connection sure resistance, check resistance to ground on the in CKT 59...
Page 857 _______________________________________________________ 12-84 Electrical System ® Windshield Wiper Motor Inoperative on High Step Action Value(s) Remove the wiper switch from the instrument Go to step 3. Go to step 2. panel. Turn the ignition to the “RUN” position and the wiper switch to “HIGH”. Using a DVOM set to measure voltage, back probe the red wire (CKT 61).
Page 858 ______________________________________________________ Electrical System 12-85 ® Windshield Wipers Intermittent Speeds Inoperative (Continued) Step Action Value(s) Ignition should be in the “RUN” position. Using a Replace the Repair the open DVOM set to measure the voltage, back probe the intermittent or bad connec- yellow wire (CKT 65) at the intermittent wiper wiper switch.
Page 859 _______________________________________________________ 12-86 Electrical System ® WIPER/WASHER WIPER MOTOR FUSE 25 AMP INTERIOR FUSE BOX INTERMITTENT RELAY IGNITION FUSE 5 AMP INTERIOR FUSE BOX 9-S12-012 IGNITION SWITCH Figure 12-97: Wiper/Washer Schematic 4-1-00...
Page 860 ______________________________________________________ Electrical System 12-87 ® Rear Window Wiper Inoperative Steps Action Values <.2 Ω Gain access to the wiper motor connector under Go to step 2. Repair the open the slant door trim.Using a DVOM check resis- or bad connec- tance on the black wire (CKT 59).
Page 861 _______________________________________________________ 12-88 Electrical System ® Rear Window Wiper Inoperative (Continued) Steps Action Values Remove the rear wiper switch from the instru- Go to step 11. Repair the open ment panel. Disconnect the wiper switch harness or bad connec- from the switch. Turn the ignition switch to the tion on CKT 65.
Page 862 ______________________________________________________ Electrical System 12-89 ® REAR WIPER MOTOR BATT MAXI 20 AMP FUSE INTERMITTENT 25 AMP RELAY SWITCHED HEAD- LAMP SWITCH SWITCHED FUSE 25 AMP REAR WIPER SWITCH Figure 12-98: Rear Wiper Motor Schematic 05745159 4-1-00...
Page 863: Left Heated Windshield Inoperative
_______________________________________________________ 12-90 Electrical System ® Left Heated Windshield Inoperative Step Action Value(s) Gain access to the heated windshield connections. Replace the Go to step 2. With the ignition in the “RUN” position, preform a heated voltage drop test between the yellow wire (CKT 740) windshield.
Page 864: Right Heated Windshield Inoperative
______________________________________________________ Electrical System 12-91 ® Right Heated Windshield Inoperative Step Action Value(s) Gain access to the heated windshield connections. Replace the Go to step 2. With the ignition in the “RUN” position and the heated heated windshield switch on, preform a voltage drop windshield.
Page 865: Both Heated Windshields Inoperative
_______________________________________________________ 12-92 Electrical System ® Both Heated Windshields Inoperative Step Action Value(s) <.2 Ω Gain access to the heated windshield connections. Go to step 2. Repair the open Using a DVOM check the resistance to ground on or bad connection the black wires at both windshields.
Page 866 ______________________________________________________ Electrical System 12-93 ® HEATED WINDSHIELDS COMPASS/MIRROR HEATED LEFT WINDSHIELD RIGHT WINDSHIELD DIMMER SWITCH RELAY MIRRORS C6-F3 C6-M8 C1-33 59 BK C1-3 C1-2 580 BR HEATED WINDSHIELD SWITCH LEFT RIGHT C6-M6 WINDSHIELD WINDSHIELD RELAY RELAY C6-M7 HEATED WINDSHIELD RELAYS FUSE 5 AMP INTERIOR...
Page 867: Rear Window Defroster Inoperative
_______________________________________________________ 12-94 Electrical System ® Rear Window Defroster Inoperative Step Action Value(s) Gain access to the male side of connector C45 on Replace the Go to step 2. the C-pillar intermediate. Turn the key to the heated rear win- “RUN” position and the heated rear window switch dow.
Page 868 ______________________________________________________ Electrical System 12-95 ® IGNITION REAR WINDOW DEFROSTER ( HMC4 & HMSB ) FUSE 30 AMP INTERIOR FUSE TEMPERATURE REAR DOOR CONTROL TO HVAC CONTROL PANEL BATTERY FUSE 30 AMP EXTERIOR FUSE REAR WINDOW DEFROST SWITCH C1-13 9-S12-157 Figure 12-100: Rear Window Defroster Schematic 05745159 4-1-00...
Page 869 _______________________________________________________ 12-96 Electrical System ® Power Windows Inoperative, All Windows Step Action Value(s) <.2 Ω Remove relay R4 from the interior fuse box. With Go to step 2. Repair the open a DVOM check cavity G7 for resistance to or bad connection ground.
Page 870 ______________________________________________________ Electrical System 12-97 ® Drivers Window Inoperative Step Action Value(s) Do all the other windows operate as designed? ––– Go to step 2. Refer to proper chart. <.2 Ω Remove the drivers power window switch and Go to step 3. Repair the open harness from the bezel.
Page 871 _______________________________________________________ 12-98 Electrical System ® Power Windows Only Operate Using The Console Switches Step Action Value(s) Does the drivers door window operate as ––– Go to step 2. Refer to the designed? proper chart. If the window lock out switch is in the “Lock” –––...
Page 872 ______________________________________________________ Electrical System 12-99 ® Passenger Front Door Power Window Inoperative Step Action Value(s) Do all the other windows operate as designed? ––- Go to step 2. Refer to the proper chart. Gain access to the passenger front power window Go to step 3.
Page 873 ______________________________________________________ 12-100 Electrical System ® (Passenger/Drivers) Rear Door Power Window Inoperative NOTE: Refer to the wiring diagram for the circuit numbers. Step Action Values Do all the other windows operate as designed? ––- Go to step 2. Refer to the proper chart.
Page 874 _____________________________________________________ Electrical System 12-101 ® POWER WINDOWS LEFT FRONT DOOR RIGHT FRONT DOOR WINDOW SWITCH LEFT FRONT DOOR RIGHT FRONT DOOR WINDOW SWITCH BATT ( ALL MODELS ) WINDOW MOTOR WINDOW MOTOR ( ALL MODELS ) 30 AMP EXTERIOR CIRCUIT FUSE BOX BREAKER 226 YL...
Page 875 ______________________________________________________ 12-102 Electrical System ® POWER DOOR LOCK SWITCH REPLACEMENT POWER DOOR LOCK ACTUATOR REPLACEMENT NOTE: Switch replacement is the same for all doors. Removal Removal NOTE: Actuator replacement is the same for all doors. Remove mounting plate, capscrews, and remove switch from switch bezel (Figure 12-102).
Page 876 _____________________________________________________ Electrical System 12-103 ® Door Lock Actuator Replacement For Rear Cargo Door (HMCS Only) CLIP Removal ACTUATOR Remove window from primary rear door. Remove (4) screws and interior door handle. Remove (12) screws securing inner door panel to door. Remove inner door panel.
Page 877 ______________________________________________________ 12-104 Electrical System ® Rear Cargo Door Lock Module Replace- Rear Cargo Door Lock Harness Jumper ment (HMCS Only). Replacement Removal Removal Remove right rear seat. 1. Remove right rear seat. Remove right rear seat belt ratchet assembly. 2. Remove right rear seat belt ratchet assembly. Remove right rear corner trim assembly (Figure 12-106).
Page 878 _____________________________________________________ Electrical System 12-105 ® KEYLESS ENTRY & THEFT DETERRENT SYSTEM Locking the Doors OPERATING INSTRUCTIONS To lock the vehicle doors, press the lock button on the remote transmitter once. A red L.E.D. on the remote transmitter will il- Keyless Entry & Theft Deterrent System luminate while the button is depressed, indicating that the re- mote transmitter is functioning.
Page 879: Automatic Door Lock
The system can be programmed red L.E.D. on the remote transmitter stop functioning, the bat- by an authorized HUMMER dealer to unlock all the doors. tery will need to be replaced.To replace the batteries: 1.
Page 880 _____________________________________________________ Electrical System 12-107 ® REMOTE ENTRY SYSTEM Remote Entry Receiver Replacement Removal Installation 1. Remove front console enough to gain access to receiver Install receiver on two velcro strips. (Section 10). Connect receiver harness connectors to receiver. 2. Disconnect two receiver harness connectors from receiver Program receiver to accept remotes.
Page 881 To re-synchronize the remote the HUMMER remote entry system transmitter to the receiver, stand close to the vehicle and 1. Auto Door Lock press and release the LOCK button 2 times within one 2.
Page 882 _____________________________________________________ Electrical System 12-109 ® 5. Immediately turn the ignition key off (3 chirps indicates change the feature or proceed to the next step if no change exit remote transmitter program mode) and then back on. is desired The vehicle's horn will sound 2 chirps indicating that the Turn the ignition key off or allow 15 seconds to pass, and system is in feature programming mode.
Page 883 ______________________________________________________ 12-110 Electrical System ® Power Locks Inoperative w/o Keyless Step Action Value(s) Remove the passenger door lock switch from the Go to step 2. Repair the open, bezel. Using a DVOM measure voltage on pin 3 or bad connection (CKT 517).
Page 884 _____________________________________________________ Electrical System 12-111 ® Power Door Locks Inoperative, W/ Remote Entry Step Action Value(s) Remove the passenger door lock switch from the Go to step 2. Repair the open, bezel. Using a DVOM measure voltage on pin 3 or bad connection (CKT 517).
Page 885: Slant Door Lock Inoperative
______________________________________________________ 12-112 Electrical System ® Power Door Locks Inoperative, W/ Remote Entry (Continued) Step Action Value(s) <.2 Ω Using a DVOM measure resistance to ground at Repair the open Repair the open C30 pin A (CKT 58). Does the resistance meet or bad connection or bad connec- the speciﬁed value?
Page 886: Cargo Door Lock Inoperative
_____________________________________________________ Electrical System 12-113 ® Cargo Door Lock Inoperative Step Action Value(s) Does power the lock system on vehicle operate Go to step 2. Refer to the correctly? diagnostic charts that apply. Open the primary cargo door. Using a DVOM +12v then –12v Go to step 3.
Page 887: Remote Entry System Inoperative
______________________________________________________ 12-114 Electrical System ® Remote Entry System Inoperative Step Action Value(s) Does the panic feature operate when the button is Go to step 6. Go to step 2. depressed on the transmitter? Does the L.E.D. illuminate on the keyless Go to step 4.
Page 888 _____________________________________________________ Electrical System 12-115 ® LEFT FRONT DOOR RIGHT FRONT DOOR LOCK SWITCH LOCK SWITCH BATT FUSE 3H INTERIOR 119 TN 120 LG 517 OR 56 BK REMOTE ENTRY MODULE (REM) DRIVER LOCK COMMON DOOR COMMON DOOR COMMON UNLOCK UNLOCK UNLOCK UNLOCK UNLOCK...
Page 889 ______________________________________________________ 12-116 Electrical System ® LOCK SWITCH LOCK SWITCH BATT FUSE 3H INTERIOR 119 TN 120 LG 517 OR 56 BK C31 (JUMPER) 122 PP 121 YL 517 OR 118 BR C20-A 517 OR BATT L/F DOOR R/F DOOR LOCK ACTUATOR LOCK ACTUATOR 118 BR 117 PK...
Page 890 _____________________________________________________ Electrical System 12-117 ® HOT AT ALL TIMES FUSE 3H INTERIOR 119 TN 120 LG 517 OR 121 YL 121 YL COMMON BATT COMMON UNLOCK INPUT UNLOCK REMOTE ENTRY DRIVER’S PASSENGER MODULE DOOR DOOR COMMON LOCK ALL (REM) UNLOCK UNLOCK LOCK DOORS...
Page 891 ______________________________________________________ 12-118 Electrical System ® RIGHT FRONT DOOR LEFT FRONT DOOR LOCK SWITCH LOCK SWITCH BATT FUSE 3H INTERIOR 119 TN 120 LG 517 OR 56 BK C31 (JUMPER) 122 PP 121 YL 118 BR 117 PK L/F DOOR R/F DOOR LOCK ACTUATOR LOCK ACTUATOR 118 BR...
Page 892 _____________________________________________________ Electrical System 12-119 ® TO DOME TO CHIME LAMPS LF DOOR RF DOOR JUMP JUMP SWITCH SWITCH 54 DG FUSE 15 AMP INTERIOR BATT TO HORN TO PARK SWITCH ON LAMP TO PARK TO HORN STEERING SWITCH BATT IGNITION LIGHT RELAY COLUMN...
Page 893 ______________________________________________________ 12-120 Electrical System ® POWER DOOR LOCK FRONT DOOR HARNESS NOTE: Lubricate bushings, grommet, and door harness teflon cover with silicone spray. REPLACEMENT Removal 10. Pull harness through A-pillar rubber grommet. 11. Remove and inspect A-pillar rubber grommet. Discard if NOTE: Left and right front power door lock harness replace- damaged.
Page 894 Section 12 Electrical System _____________________________________________________ Electrical System 12-121 ® POWER DOOR LOCK REAR DOOR AND Remove two-lead connector from rear door harness with pin extraction tool. JUMPER HARNESS REPLACEMENT 10. Remove capscrew, washer, nut and lockwasher assembly, Removal and P-clamp from rear door harness and B-pillar. 11.
Page 895 ______________________________________________________ 12-122 Electrical System ® Installation 7. Route rear door harness along bottom of rear door. Secure harness to door reinforcement with clip. NOTE: Lubricate bushings, rubber grommet, and door harness 8. Attach door harness connector to actuator. Tighten power teflon cover with silicone spray.Install clip and support bracket window motor mounting screws, if loose.
Page 896 _____________________________________________________ Electrical System 12-123 ® POWER WINDOW AND DOOR LOCKS FRONT 10. Disconnect two harness connectors from power mirrors door jumper harness connectors (Figure 2-120). DOOR HARNESS REPLACEMENT 11. Remove self-tapping screw and clamp securing harness to Removal door reinforcement (Figure 2-120). 1.
Page 897 ______________________________________________________ 12-124 Electrical System ® POWER MIRRORS BODY HARNESS FRONT DOOR HARNESS POWER WINDOWS AND DOOR LOCKS BODY HARNESS 6-WAY CONNECTOR TEFLON TUBE 4-WAY CONNECTOR A-PILLAR GROMMET Figure 2-119: Power Windows and Door Locks Connections Installation NOTE: When connecting harness wires to 4-way and 6-way connectors, ensure wire colors align with mating connector wires.
Page 898 _____________________________________________________ Electrical System 12-125 ® POWER DOOR LOCKS ACTUATOR POWER WINDOW REGULATOR MOUNTING BRACKET WINDOW BRACKET BUSHING DOOR ASSEMBLY RETAINER FRONT DOOR HARNESS DOOR REINFORCEMENT MOUNTING DOOR BRACKET BUSHING Figure 2-121: Power Windows and Door Locks Door Harness 05745159 4-1-00...
Page 899 ______________________________________________________ 12-126 Electrical System ® POWER WINDOWS AND DOOR LOCKS REAR 5. Remove harness wires from 6-way connector. DOOR HARNESS REPLACEMENT 6. Remove screw, nut and lockwasher assembly, and clamp securing harness to B-pillar. Discard nut and lockwasher Removal assembly. Remove center outer kick panel and lower B-pillar trim NOTE: Lubricate bushings, grommet, and harness teflon (Section 10).
Page 900 _____________________________________________________ Electrical System 12-127 ® TIE STRAP MOUNTING POWER DOOR BRACKET LOCK ACTUATOR BUSHING POWER DOOR BUSHING WINDOW REGULATOR DOOR ASSEMBLY MOUNTING BRACKET RETAINER DOOR REINFORCEMENT DOOR HARNESS CLAMP Figure 2-123: Rear Door Harness Installation GROMMET “B” PILLAR NOTE: Lubricate bushings, grommet, and harness teflon cover with silicone spray.
Page 901 ______________________________________________________ 12-128 Electrical System ® Connect harness connector to power window regulator 14. Install crash pad (Section 10). (Figure 2-123). 15. Check power windows and door lock for proper operation 8. Connect harness connector to power door lock actuator. Secure harness to door reinforcement with clamp and self- tapping screw.
Page 902 _____________________________________________________ Electrical System 12-129 ® AUTO-DIMMING REAR VIEW MIRROR WITH Installation ELECTRONIC COMPASS AND TEMPERATURE Grasp the mirror head with both hands (OPTION) Slide the mirror down onto the window mount and gently rock side to side until mirror base is seated. Do not force Description the mirror onto the mount.
Page 903 ______________________________________________________ 12-130 Electrical System ® Figure 2-128: Magnetic Zone Chart 4-1-00...
Page 904: Ambient Temperature Sensor
Section 12 Electrical System _____________________________________________________ Electrical System 12-131 ® AMBIENT TEMPERATURE SENSOR Removal Installation 1. Remove existing nut, cushioned clamp, and ambient tem- Install ambient temperature sensor to the frame with self- perature sensor jumper harness from the body harness tapping screw (Figure 12-129).
Page 905: Compass Mirror Display Inoperative
______________________________________________________ 12-132 Electrical System ® Compass Mirror Display Inoperative Step Action Value(s) Turn the ignition to the ON position, and heated No problem Go to step 2. windshields OFF. found, or inter- Is compass mirror display operating? mittent. Gain access to C13, with the ignition ON measure Approximate Go to step 4.
Page 906 _____________________________________________________ Electrical System 12-133 ® COMPASS MIRROR TO HEATED WINDSHIELD SWITCH C2-26 C1-61 C2-8 COMPASS BACK-UP CUTOUT LIGHT TEMP RELAY SWITCH SENSOR C2-27 C1-43 FUSE INTERIOR FUSE FUSE 7.5 AMP 10 AMP IGNITION IGNITION 00-S12-003.1 SWITCH SWITCH Figure 12-130: Compass Mirror Schematic 05745159 4-1-00...
Page 907: Power Side Mirror
______________________________________________________ 12-134 Electrical System ® POWER SIDE MIRROR Description The side mirrors have an option of an internal heater element to aid in defrosting. Heated side mirrors will only be available if the truck is equipped with a heated windshield. The power side mirror system components are: two side mir- rors with internal vertical and horizontal control motors (and optional heater elements), the power mirror switch, and the...
Page 908 ___________________________________________________ Electrical System 12-134.1 ® POWER MIRROR ASSEMBLY DOOR JUMPER HARNESS CONNECTOR CONNECTOR DOOR JUMPER MOUNTING HARNESS SCREW GASKET MOUNTING PLATE Figure 12-130.2 Power Mirror Assembly Removal 05745159 3-1-01...
Page 909 ____________________________________________________ 12-134.2 Electrical System ® Power Side Mirrors Inoperative Step Action Value(s) Are both mirrors INOP? Go to step 2. Go to step 4. Remove the power mirror switch. With a DVOM check > 12.6v Go to step 3. Repair circuit 517 circuit 517 (PK) for battery voltage.
Page 910 ___________________________________________________ Electrical System 12-134.3 ® LH POWER MIRROR RH POWER MIRROR INTERIOR FUSE BOX FUSE 20 AMP DIMMER MODULE BATTERY POWER MIRROR SWITCH 9-S12-010 Figure 12-131: Power Side Mirror Schematic 05745159 3-1-01...
Page 911: Cruise Control Systems
____________________________________________________ 12-134.4 Electrical System ® CRUISE CONTROL SYSTEMS In addition, the cruise control is automatically disabled each WARNING: Testing of cruise control should only be time you turn the engine off, Or shift into “P” (Park) “N” (Neu- preformed in areas were trafﬁc is light and the road tral) position, or if the “Check Throttle Light”...
Page 912: Cruise Control Inoperative Vin Z
Section 12 Electrical System _____________________________________________________ Electrical System 12-135 ® Cruise Control Inoperative VIN Z Step Action Value(s) Important: Before clearing the DTC’s, use the Go to step 2. Perform on- scan tool Capture Info in order to record the board diagnos- Freeze Frame and the failure records for refer- tic system check.
Page 913 ______________________________________________________ 12-136 Electrical System ® Cruise Control Inoperative VIN Z (Continued) Step Action Value(s) Using a DVOM set to measure voltage, place the Check for loose Repair open, bad ground lead on the IP ground point. Back probe or poor connec- connection or cavity A11 in C29(CKT151) with the positive tion at PCM if...
Page 914 _____________________________________________________ Electrical System 12-137 ® POWERTRAIN ACCELERATIOR CONTROL PEDAL POSITION MODULE SENSOR (PCM) 722 PP C29-A12 GROUND 721 LB C27-C5 APP 2 SIGNAL 719 BR C29-B1 GROUND 718 DB C29-B2 APP 1 SIGNAL 725 GY C27-D6 GROUND 724 DG C27-D4 APP 3 SIGNAL 723 YL...
Page 915 ______________________________________________________ 12-138 Electrical System ® FUSE 2D FUSE 3A FUSE 4D FUSE 6B 20 AMP 20 AMP 15 AMP 5 AMP INTERIOR EXTERIOR INTERIOR INTERIOR BRAKE TCC/ LAMP CRUISE TO BRAKE LAMP C28-D13 C28-C13 C28-C12 C28-C11 C29-B10 C29-B9 BATTERY IGNITION BRAKE LIGHT TCC / CRUISE POSITIVE...
Page 916 The standard system (Figure 12-133), available on all models, is mounted in the overhead console. The amplifier is activated consists of a radio head with cassette player (Hummer logo), by output on the left rear channel from the radio. The 6 disc either two or four coaxial speakers and an optional 6 disc CD CD changer is standard with the Monsoon system.
Page 917: Radio (Delco) Replacement
______________________________________________________ 12-140 Electrical System ® RADIO (DELCO) REPLACEMENT FRONT SUPPORT BEZEL BRACKET Removal Insert a radio removal key in the holes in each side of the face of the radio to disengage locking clips from the mounting sleeve (Figure 12-136). 2.
Page 918 _____________________________________________________ Electrical System 12-141 ® REAR SEAT AUDIO (RSA) UNIT REPLACEMENT 7. Disconnect green wire connection and remove console. Disconnect 32 pin connector from amplifier and four screws Removal securing amplifier to mounting bracket (Figure 12-139). 9. Remove amplifier. Remove the cup holders from the auxiliary A/C unit cover (Figure 12-140).
Page 919 ______________________________________________________ 12-142 Electrical System ® AUDIO (DELCO MONSOON) ELECTRICAL Installation HARNESS 1. Route audio harness to approximate mounting position. (MODELS 83, 84 & 91) REPLACEMENT 2. Secure audio harness to vehicle with duct tape, where necessary. Removal 3. Connect two leads to right rear speaker. 1.
Page 920 _____________________________________________________ Electrical System 12-143 ® AUDIO (DELCO STANDARD) ELECTRICAL Install right speaker and cover on trim with four clips and screws. HARNESS (MODEL 89) REPLACEMENT Repeat steps 4 and 5 for left speaker. Removal Connect harness lead to audio harness connector Remove engine cover console.
Page 921: Identifying Concerns
______________________________________________________ 12-144 Electrical System ® AUDIO (DELCO STANDARD) ELECTRICAL Installation HARNESS (MODEL 90) REPLACEMENT 1. Route audio harness to approximate mounting position. 2. Secure harness to vehicle with duct tape, where necessary. Removal 3. Install trim. Remove engine cover console. Connect two leads to right rear speaker (Figure 12-145).
Page 922: Corrective Action
_____________________________________________________ Electrical System 12-145 ® 1. Identify ignition switch key position in which the noise • Coated screws or bolts can act as poor grounds. appears, such as: accessory, key on engine not running, • Always use a braided ground strap when applying and key on engine running.
Page 923: Test Antenna
______________________________________________________ 12-146 Electrical System ® TEST ANTENNA The test antenna is simply an antenna that is not mounted on the vehicle. This tool is used as a substitute for the antenna mounted on the vehicle. The technician should connect the test antenna to the antenna input of the radio.
Page 924 _____________________________________________________ Electrical System 12-147 ® REAR SEAT AUDIO A5 A8 AMPLIFIER RADIO LF SPEAKER – 4Ω 819 BK – 818 PP RF SPEAKER – 821 BK – 4Ω 820 DG 813 BK – LEFT CONSOLE SPKR – 804 WT 4Ω 811 BK –...
Page 925 ______________________________________________________ 12-148 Electrical System ® RADIO 839 YL CELL PHONE MUTE 819 BK – RR SPEAKER 4Ω 818 TN 821 BK – LR SPEAKER 4Ω 820 TN – 813 BK LF SPEAKER 4Ω 804 TN – 811 BK RF SPEAKER 4Ω...
Page 926 _____________________________________________________ Electrical System 12-149 ® RADIO LF SPEAKER – 813 BK 4Ω 804 TN – 811 BK 4Ω 805 TN RF SPEAKER 59 BK GROUND 476 GY BATT 12V 17 PP DIMMER 137 RD IGNITION 14 LB ILLUMINATION HEADLIGHT PANEL SWITCH LIGHT DIMMER...
Page 927 ______________________________________________________ 12-150 Electrical System ® CD CHANGER RADIO LEFT LEFT AUDIO AUDIO SIGNAL SIGNAL RIGHT RIGHT AUDIO AUDIO SIGNAL SIGNAL AUDIO COMMON AUDIO COMMON SHIELD DRAIN BATT BATT GROUND GROUND DATA DATA 00-S12-002 Figure 12-149: CD Changer To Radio Harness, All Models. 3-1-01...
Page 928: Symptom Table
_____________________________________________________ Electrical System 12-151 ® SYMPTOM TABLE SYMPTOM PROCEDURE PAGE NUMBER Display inoperative, no sound from any Chart #1 12-152 speaker. No sound from one speaker (Delco Chart #2 12-152 std.). No sound from one speaker (Monsoon). Chart #3 12-153 No sound from any speaker, radio dis- Chart #4 12-154...
Page 929 ______________________________________________________ 12-152 Electrical System ® DISPLAY IS INOPERATIVE, NO SOUND FROM ANY SPEAKER CHART #1 STEP ACTION VALUE(S) Disconnect connector C56. +12v Go to step 2. Repair the poor connection Turn the ignition switch to the “Run” or open the gray wire (CKT position.
Page 930 _____________________________________________________ Electrical System 12-153 ® NO SOUND FROM ONE SPEAKER (DELCO MONSOON) CHART #3 STEP ACTION VALUE(S) Turn ignition switch to the “Run” position. > 0v AC Go to step 2. Go to step 3. Turn radio “On”. Insert cassette or compact disc from Delco Audio system Diagnostic Kit J–39916-A.
Page 931 ______________________________________________________ 12-154 Electrical System ® NO SOUND FROM ANY SPEAKER, RADIO DISPLAY OPERATES NORMALLY (DELCO MONSOON) CHART #4 STEP ACTION VALUE(S) Disconnect connector C62. > 0v AC Go to step 2. Go to step 4. Turn ignition switch to the “Run” position. Turn radio “On”.
Page 932 _____________________________________________________ Electrical System 12-155 ® COMPACT DISC CHANGER DOES NOT OPERATE PROPERLY NOTE: Steps 1-4 cover the CD changer having no function with the radio operating normally NOTE: Step 5 is used to diagnose a skipping or muted complaint. NOTE: Step 6 is used if the display reads “FOCUS” or the disc ejected. CHART #5 STEP ACTION...
Page 933 ______________________________________________________ 12-156 Electrical System ® CASSETTE PLAYER DOES NOT OPERATE PROPERLY CHART #6 STEP ACTION VALUE(S) Tape plays weak, slow or garbled. Go to step 1. Tape inoperative. Go to step 3. Inspect and clean moving parts and tape Advise periodic cleaning. Go to step 2.
Page 934: Antenna System Test
_____________________________________________________ Electrical System 12-157 ® ANTENNA SYSTEM TEST CHART #7 STEP ACTION VALUE(S) Disconnect negative battery cable. > .15 ohms Check the base of the Go to step 2. Disconnect antenna lead-in cable at the antenna for a good connec- radio receiver.
Page 935 ______________________________________________________ 12-158 Electrical System ® REAR SEAT AUDIO (RSA) DOES NOT OPERATE CHART #8 STEP ACTION VALUE(S) With ignition on, check for voltage at +12v Go to step 2. Check/repair open circuit C59 pin A8 (CKT 819 BK). Is voltage between C59 pin A8 and present? C56 pin 4.
Page 936 _____________________________________________________ Electrical System 12-159 ® CONNECTOR LEGEND NOTE: Connector gender is determined by the terminals. 76 WAY BULKHEAD LOCATION: LEFT SIDE FIREWALL PIN 1 PIN 12 PIN 13 PIN 26 PIN 27 PIN 38 PIN39 PIN 50 PIN 51 PIN 64 PIN 65 PIN 76 C1 MALE...
Page 937 ______________________________________________________ 12-160 Electrical System ® COLOR CIRCUIT DESCRIPTION Fuel pump + to selector valve Ignition relay feed Rear window defrost feed APP 3 5volt reference APP 3 signal + FROM DIMMER MODULE APP 1 signal Speedometer signal ABS module diagnostic line APP 1 5volt reference TT4 lamp activation APP 2 5volt reference...
Page 938 _____________________________________________________ Electrical System 12-161 ® COLOR CIRCUIT DESCRIPTION Left front turn signal PCM class 2 communication line to DLC Tachometer signal Low washer ﬂuid level lamp activation Headlight switch feed ABS lamp activation APP 1 ground Low coolant lamp activation Low air warning lamp activation Brake ﬂuid level sensor feed CTIS buzzer activation...
Page 939 ______________________________________________________ 12-162 Electrical System ® 42 WAY UNDERBODY LOCATION: LOWER LEFT FOOTWELL NEAR ENGINE PIN 34 PIN 42 PIN 28 PIN 33 PIN 22 PIN 27 PIN 16 PIN 21 PIN 10 PIN 15 PIN 1 PIN 9 C2 MALE 9-S12-015 CAV 42 CAV 34...
Page 940 _____________________________________________________ Electrical System 12-163 ® COLOR DESCRIPTION Light power from dimmer module Right front wheel speed sensor high signal Right front wheel speed sensor low signal Right rear wheel speed sensor low signal Right rear wheel speed sensor high signal Parking brake lamp activation Rear marker lamp feed Backup lamp switch feed...
Page 941 ______________________________________________________ 12-164 Electrical System ® 56 WAY INSTRUMENT PANEL LOCATION: BEHIND INSTRUMENT PANEL PIN H6 PIN A1 C3 MALE 9-S12-050 CAV A1 CAV H6 C3 FEMALE 9-S12-049 COLOR DESCRIPTION Headlight switch feed Dome lamp switch feed Dome lamps feed Headlamp switch feed Headlamp feed to dimmer module CTIS switch ignition feed CTIS compressor indicator lamp activation...
Page 942 _____________________________________________________ Electrical System 12-165 ® COLOR DESCRIPTION Glow plug wait lamp activation Right turn indicator lamp activation TT4 indicator lamp activation Brake indicator lamp activation ABS indicator lamp activation Low washer ﬂuid activation Rear Wiper feed (not used 99) High Beam indicator lamp activation Left turn indicator lamp activation Check engine lamp activation Drain Filter lamp activation...
Page 943 ______________________________________________________ 12-166 Electrical System ® COLOR DESCRIPTION Fuel selector switch feed from fuel pump relay Right hand power mirror up/down signal Ground Ignition feed to gauges Windshield wiper washer pump activation Intermittent wiper relay activation Rear cargo lamp activation Fuel gauge signal Engine temperature gauge signal Speedometer signal Ground...
Page 944: Section 12 Electrical System
Section 12 Electrical System _____________________________________________________ Electrical System 12-167 ® 12 WAY AMG ENGINE LOCATION: LEFT INTAKE MANIFOLD 9-S12-077 9-S12-072 C4 FEMALE C4 MALE COLOR DESCRIPTION Starter solenoid activation A/C request from control head Ignition feed to alternator and low coolant sensor A/C request to PCM A/C compressor clutch activate Low coolant lamp activation...
Page 945 ______________________________________________________ 12-168 Electrical System ® 40 WAY GM ENGINE LOCATION: LEFT INTAKE MANIFOLD PIN A1 PIN A8 CAV A8 CAV A1 PIN B1 PIN B12 CAV B12 CAV B1 PIN C1 PIN C12 CAV C12 CAV C1 PIN D1 PIN D8 CAV D8 CAV D1 9-S12-020...
Page 946 _____________________________________________________ Electrical System 12-169 ® COLOR DESCRIPTION Engine coolant temperature signal Intake air temperature signal Oil pressure signal to gauge Glow plug feedback signal Optical sensor ground Wastegate solenoid control 05745159 4-1-00...
Page 947 ______________________________________________________ 12-170 Electrical System ® 56 WAY CONSOLE LOCATION: CENTER CONSOLE PIN H6 PIN A1 C6 MALE 9-S12-050 CAV H6 CAV A1 9-S12-049 C6 FEMALE COLOR DESCRIPTION Feed to RF, RR, LR power window switches Rear window defrost activation Medium 1 HVAC blower speed Cigarette lighters battery feed Battery feed to radio Ignition feed to radio...
Page 948 _____________________________________________________ Electrical System 12-171 ® COLOR DESCRIPTION Ignition feed to rear HVAC blower switch Battery feed to auxiliary power outlet To right rear power window master switch To right rear power window master switch Rear HVAC blower low fan speed activation Rear HVAC blower high fan speed activation Feed from dimmer module Ignition feed to HVAC control head...
Page 949 ______________________________________________________ 12-172 Electrical System ® COLOR DESCRIPTION Ignition feed to heated windshield switch/timer Heated windshield relay activation Battery feed for rear defrost Battery feed to radio Battery feed to power window lockout switch To right front power window master switch To right front power window master switch 4-1-00...
Page 950 _____________________________________________________ Electrical System 12-173 ® 35 WAY ABS ECU LOCATION: WSW RESERVOIR RECESS D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16 D17 D18 D19 D20 D21 D22 D23 D24 D25 D26 D27 D28 D29 D30 D31 D32 D33 D34 D35 9-S12-043 C7 FEMALE ONLY COLOR...
Page 951 ______________________________________________________ 12-174 Electrical System ® COLOR DESCRIPTION Left front outlet valve activation Shuttle valve switch signal ABS warning lamp activation Ground Pump motor monitor Reference ground Left front wheel speed sensor high Right rear wheel speed sensor high Right front wheel speed sensor high Left rear wheel speed sensor high 4-1-00...
Page 952 _____________________________________________________ Electrical System 12-175 ® 6 WAY ROOF HARNESS LOCATION: CENTER WINDSHIELD PILLAR TRIM C8 FEMALE C8 MALE 9-S12-078 9-S12-078 COLOR DESCRIPTION Dome lamps feed Cargo lamp feed Map light feed Ground 05745159 4-1-00...
Page 953 ______________________________________________________ 12-176 Electrical System ® 10 WAY STATUS CENTER-RH LOCATION: INSTRUMENT PANEL 9-S12-018 9-S12-017 C9 MALE C9 FEMALE COLOR DESCRIPTION Wait lamp Right turn lamp TT4 (atc) lamp Brake lamp Transfer case lock lamp Low tire air lamp Low coolant lamp Washer ﬂuid low lamp Ignition feed Ground...
Page 954 _____________________________________________________ Electrical System 12-177 ® 10 WAY STATUS CENTER-LH LOCATION: INSTRUMENT PANEL 9-S12-018 9-S12-017 C10 MALE C10 FEMALE COLOR DESCRIPTION Headlamp high beam lamp Left turn lamp Check engine lamp Drain ﬁlter lamp ABS lamp Seat belt lamp CTIS pump lamp Check throttle lamp Ignition feed Ground...
Page 955 ______________________________________________________ 12-178 Electrical System ® 13 WAY ABS MODULATOR LOCATION: BELOW BRAKE MASTER CYLINDER CAV 5 CAV 1 CAV 9 CAV 6 CAV 13 CAV 10 9-S12-014 C11 FEMALE ONLY COLOR DESCRIPTION Left front outlet valve activation Left front inlet valve activation Right rear inlet valve activation Right rear outlet valve activation Reference ground...
Page 956 _____________________________________________________ Electrical System 12-179 ® 10 WAY CTIS LOCATION: INSTRUMENT PANEL, RIGHT 9-S12-017 9-S12-018 C12 FEMALE C12 MALE COLOR DESCRIPTION Light power from dimmer module Ground Deﬂate solenoid activation Front inﬂate/deﬂate solenoid activation Rear inﬂate/deﬂate solenoid activation Compressor Relay activation Ignition feed Ignition feed 05745159...
Page 957 ______________________________________________________ 12-180 Electrical System ® 8 WAY COMPASS MIRROR LOCATION: WINDSHIELD CENTER PILLAR TRIM 9-S12-030 9-S12-029 CI3 MALE CI3 FEMALE COLOR DESCRIPTION Ground Ignition feed Battery feed Temperature signal from sensor Dome lamp feed 4-1-00...
Page 958 _____________________________________________________ Electrical System 12-181 ® 6 WAY LF DOOR LOCATION: LEFT FRONT OUTSIDE KICK PANEL 9-S12-031 9-S12-032 C14 FEMALE C14 MALE COLOR DESCRIPTION Ground G4 Oscillating power/ground circuit Unlock signal to the drivers door lock actuators Lock signal to the drivers door lock actuators Oscillating power/ground circuit Ground G4 05745159...
Page 959 ______________________________________________________ 12-182 Electrical System ® 4 WAY LF DOOR LEFT FRONT OUTSIDE KICK PANEL 9-S12-034 9-S12-033 C15 MALE C15 FEMALE COLOR DESCRIPTION Fused battery input to the drivers door lock switch Ground G4 Ground G4 Fused ignition feed to the power window circuit 4-1-00...
Page 960 _____________________________________________________ Electrical System 12-183 ® 6 WAY RF DOOR RIGHT FRONT OUTSIDE KICK PANEL 9-S12-031 9-S12-032 C16 MALE C16 FEMALE COLOR DESCRIPTION Oscillating power/ground circuit Unlock signal to the module from the switch Unlock signal to the passenger front door lock actuator Lock signal to the passenger front door lock actuator Lock signal to the module from the switch Oscillating power/ground circuit...
Page 961 ______________________________________________________ 12-184 Electrical System ® 4 WAY RF DOOR RIGHT FRONT OUTSIDE KICK PANEL 9-S12-034 9-S12-033 C17 MALE C17 FEMALE COLOR DESCRIPTION Fused battery input to the passenger door lock switch Up/down signal to the power window motor Down/up signal to the power window motor Fused ignition input to the power window switch 4-1-00...
Page 962 _____________________________________________________ Electrical System 12-185 ® 8 WAY RR DOOR RIGHT FRONT OUTSIDE KICK PANEL 9-S12-036 9-S12-035 C18 FEMALE C18 MALE COLOR DESCRIPTION Map light activation Up/down signal to the power window motor Down/up signal to the power window motor Unlock signal to the power lock actuator Lock signal to the power lock actuator Dome lamps activation Fused ignition input to the power window switch...
Page 963 ______________________________________________________ 12-186 Electrical System ® 8 WAY LR DOOR LEFT FRONT OUTSIDE KICK PANEL 9-S12-036 9-S12-035 C19 MALE C19 FEMALE COLOR DESCRIPTION Map lights activation Up/down signal to the power window motor Down/up signal to the power window motor Lock signal to the drivers side rear door lock actuator Unlock signal to the drivers side rear door lock actuator Dome lamps activation Fused ignition input to the power window switch...
Page 964 _____________________________________________________ Electrical System 12-187 ® 6 WAY CARGO DOOR-MODEL 84 RIGHT LOWER B PILLAR 9-S12-037 9-S12-038 C20 MALE C20 FEMALE COLOR DESCRIPTION Fused battery input to the cargo lock delay module (HMCS only) Ground G4 Fused battery voltage to the rear wiper motor (HMSB only) Empty Rear wiper motor intermittent 12 volt supply (HMSB only) Rear wiper motor intermittent (HMSB only)
Page 965 ______________________________________________________ 12-188 Electrical System ® 6 WAY RR DOOR JUMPER LOCATION: RIGHT LOWER B PILLAR 9-S12-031 9-S12-032 C21 MALE C21 FEMALE COLOR DESCRIPTION Unlock signal to the passenger side rear door lock actuator Lock signal to the passenger side rear door lock actuator Up/down signal to the power window motor Down/up signal to the power window motor Fused ignition input to the power window switch...
Page 966 _____________________________________________________ Electrical System 12-189 ® 6 WAY LR DOOR JUMPER LOCATION: LEFT LOWER B PILLAR 9-S12-031 9-S12-032 C22 FEMALE C22 MALE COLOR DESCRIPTION Lock signal to the drivers side rear door lock actuator Unlock signal to the drivers side rear door lock actuator Up/down signal to the power window motor Down/up signal to the power window motor Fused ignition input to the power window switch...
Page 967 ______________________________________________________ 12-190 Electrical System ® 10 WAY POWER MIRROR SWITCH LOCATION: INSTRUMENT PANEL, LEFT 9-S12-017 9-S12-018 C23 MALE C23 FEMALE COLOR DESCRIPTION Ground G4 Fused battery input to the power mirror switch DG/YL Left power mirror vertical control Right power mirror vertical control DG/YL Left power mirror horizontal control Right hand power mirror horizontal control...
Page 968 _____________________________________________________ Electrical System 12-191 ® 4 WAY LH POWER MIRROR LOCATION: LEFT DOOR 9-S12-039 9-S12-040 C24 MALE C24 FEMALE COLOR DESCRIPTION OR/BK Left power mirror common DG/YL Left power mirror horizontal control DG/YL Left power mirror vertical control. 05745159 4-1-00...
Page 969 ______________________________________________________ 12-192 Electrical System ® 4 WAY RH POWER MIRROR LOCATION: RIGHT DOOR 9-S12-039 9-S12-040 C25 MALE C25 FEMALE COLOR DESCRIPTION Right power mirror common Right power mirror horizontal control Right power mirror vertical control 4-1-00...
Page 970 _____________________________________________________ Electrical System 12-193 ® 6 WAY FUEL TANK JUMPER LOCATION: C BEAM ABOVE PROP SHAFT 9-S12-031 9-S12-032 C26 MALE C26 FEMALE COLOR DESCRIPTION Ground Fuel level signal to fuel gauge Fuel level signal from auxiliary tank Fuel selector valve control +/– Fuel selector valve control –/+ 05745159 4-1-00...
Page 971 ______________________________________________________ 12-194 Electrical System ® 32 WAY PCM-BROWN LOCATION: CENTER CONSOLE, PCM 9-S12-042 C27 MALE COLOR DESCRIPTION Crankshaft position sensor ground – A/C request+ Intake air temp sensor signal APP sensor (2) signal Glow plug enable + Pressure Control Solenoid (Hi) Fuel temperature signal Transmission ﬂuid temp signal Engine coolant temp signal...
Page 972 _____________________________________________________ Electrical System 12-195 ® COLOR DESCRIPTION APP (3) ground Glow plug feedback signal Lift pump relay enable + Optical sensor ground – Cruise control resume/accelerate Transmission input speed signal (hi) APP (1) 5 volt ref. Boost sensor/crankshaft position sensor 5 volt ref. Optical sensor 5 volt reference 05745159 4-1-00...
Page 973 ______________________________________________________ 12-196 Electrical System ® 32 WAY PCM-BLUE LOCATION: CENTER CONSOLE, PCM 9-S12-042 C28 MALE COLOR DESCRIPTION APP (2) 5 volt ref. Fuel inject signal 1-2 shift solenoid control Torque converter clutch solenoid control 2-3 shift solenoid control Wait to start lamp control Class 2 communications (dlc) Ignition / axle switch jumper Ignition...
Page 974 _____________________________________________________ Electrical System 12-197 ® COLOR DESCRIPTION Ground G2 Ground G2 Check throttle lamp control Battery Waste gate solenoid control 05745159 4-1-00...
Page 975 ______________________________________________________ 12-198 Electrical System ® 24 WAY PCM-BROWN LOCATION: CENTER CONSOLE, PCM 9-S12-028 C29 MALE DESCRIPTION Closure ground High resolution sensor signal Transmission output speed sensor/VSS Cam sensor signal Crankshaft position sensor signal Vehicle speed sensor Injection timing stepper motor (HI) Injection timing stepper motor (LO) Injection timing stepper motor (LO) Injection timing stepper motor (HI)
Page 976 _____________________________________________________ Electrical System 12-199 ® 8 WAY REMOTE ENTRY, GRAY LOCATION: CENTER CONSOLE 9-S12-026 C30 FEMALE COLOR DESCRIPTION Module ground G4 Dome lamp activation Horn Activation Fused ignition input to the remote entry module Fused battery input to the remote entry module Parking lamps activation 05745159 4-1-00...
Page 977 ______________________________________________________ 12-200 Electrical System ® 8 WAY REMOTE ENTRY, BLACK LOCATION: CENTER CONSOLE 9-S12-036 C31 FEMALE COLOR DESCRIPTION Lock signal to the door lock actuators Lock signal from the switch to the module Fused battery input Unlock signal to the door lock actuators Unlock signal from the switch to the module Unlock signal to the drivers door lock actuator Unlock signal from the switch to the module...
Page 978 _____________________________________________________ Electrical System 12-201 ® 10 WAY TRANSMISSION-GREY LOCATION: A BEAM, LEFT NEAR LIFT PUMP 9-S12-023 9-S12-024 C32 MALE C32 FEMALE COLOR DESCRIPTION Transmission Input Speed Sensor low Transmission Input Speed Sensor high 1-2 shift solenoid control 2-3 shift solenoid control Torque Converter Clutch solenoid activation Pressure Control Solenoid high Pressure Control Solenoid low...
Page 979 ______________________________________________________ 12-202 Electrical System ® 10 WAY TRANSMISSION-BLACK LOCATION: A BEAM, LEFT NEAR LIFT PUMP 9-S12-023 9-S12-024 C33 MALE C33 FEMALE COLOR DESCRIPTION Vehicle Speed Sensor high Vehicle Speed Sensor low Transfer case lock switch light activation Transmission ignition feed Transmission Fluid Temperature signal Transmission Fluid Temperature sensor ground Transfer case range switch signal...
Page 980 _____________________________________________________ Electrical System 12-203 ® 20 WAY TRANSMISSION PASS THROUGH LOCATION: TRANSMISSION, LEFT 9-S12-022 C34 FEMALE COLOR DESCRIPTION 1-2 Shift Solenoid activation 2-3 Shift Solenoid activation Pressure Control Solenoid high Pressure Control Solenoid low Transmission ignition feed Transmission Fluid Temperature signal Transmission Fluid Temperature sensor ground Transmission ﬂuid pressure manual valve position switch range “A”...
Page 981 ______________________________________________________ 12-204 Electrical System ® 3 WAY LOW COOLANT SENSOR LOCATION: SURGE TANK 9-S12-090 9-S12-091 C35 FEMALE C35 MALE COLOR DESCRIPTION Ignition power Signal output Ground 2 WAY HVAC BLOWER LOCATION: RIGHT A-PILLAR 9-S12-106 9-S12-105 C36 FEMALE C36 MALE COLOR DESCRIPTION Blower relay power Blower motor ground...
Page 982 _____________________________________________________ Electrical System 12-205 ® 4 WAY HVAC BLOWER RESISTOR HARNESS LOCATION: RIGHT A-PILLAR 9-S12-104 9-S12-103 C 37 FEMALE C 37 MALE COLOR DESCRIPTION Blower activation Medium 1 blower Low blower Medium 2 blower 3 WAY LOCATION: LEFT A-BEAM NEAR FUEL MANAGER 9-S12-151 9-S12-152 C 38 FEMALE...
Page 983 ______________________________________________________ 12-206 Electrical System ® 7 WAY TURN SIGNAL SWITCH HARNESS LOCATION: STEERING COLUMN 00-S12-014 C 39 FEMALE COLOR DESCRIPTION Left front turn signal, status center signal. Left rear turn signal Horn circuit ground Low beam circuit High beam signal Head lamp feed Empty 6 WAY TURN SIGNAL SWITCH HARNESS LOCATION: STEERING COLUMN...
Page 984 _____________________________________________________ Electrical System 12-207 ® 8 WAY LIFT GATE JUMPER HARNESS LOCATION: 9-S12-036 9-S12-035 C 41 MALE C41 FEMALE COLOR DESCRIPTION Ground G4 Rear wiper 12 v common supply Rear wiper 12 v start supply Rear wiper 12 v run supply Unlock/lock signal to power door lock motor Lock/unlock signal to power door lock motor Empty...
Page 985 ______________________________________________________ 12-208 Electrical System ® 3 WAY FRONT WIPER HARNESS NEAR MOTOR BEHIND A-PILLAR TRIM 9-S12-155 C 43 MALE C 43 FEMALE COLOR DESCRIPTION Intermittent Power Supply Low Speed Power Supply High Speed Power Supply 2 WAY WIPER MOTOR CONNECTOR NEAR MOTOR BEHIND THE A-PILLAR TRIM 9-S12-156 C 44 MALE C 44 FEMALE...
Page 986 _____________________________________________________ Electrical System 12-209 ® 2 WAY REAR WINDOW DEFROSTER HARNESS LOCATION: C-PILLAR INTERMEDIATE 9-S12-106 9-S12-105 C45 FEMALE C45 MALE COLOR DESCRIPTION Ground for the rear window defroster G4 Rear window defroster 12 volt supply 4 WAY REAR WINDOW DEFROSTER SWITCH CONNECTOR LOCATION: BACK OF THE HVAC 9-S12-158 C46 FEMALE COLOR...
Page 987 ______________________________________________________ 12-210 Electrical System ® 10 WAY CARGO DOOR LOCK DELAY MODULE CONNECTOR LOCATION: ON MODULE 00-S12-022 C47 FEMALE COLOR DESCRIPTION Empty Empty Ground G4 Empty Lock signal to the cargo door lock delay module Unlock signal to the cargo door lock delay module Empty Empty Fused battery input to the cargo door lock delay module...
Page 988 _____________________________________________________ Electrical System 12-211 ® 5 WAY PASSENGER DOOR LOCK SWITCH CONNECTOR LOCATION: IN THE PASSENGERS DOOR 00-S12-021 C49 FEMALE COLOR DESCRIPTION Lock signal from the switch to the module Oscillating power/ground circuit Fused battery input to the passenger door lock switch Oscillating power/ground circuit Unlock signal from the switch to the module 05745159...
Page 989 ______________________________________________________ 12-212 Electrical System ® 16 WAY RADIO HARNESS LOCATION: BACK OF THE RADIO 00-S12-004 C56 FEMALE COLORS DESCRIPTION Empty Empty Radio illumination Fused battery input to the radio (Ignition) Dimmer Circuit Fused radio memory feed (Battery) Ground G4 Right rear speaker signal (Positive) Right rear speaker signal (Negative) Right front speaker signal (Positive) Right front speaker signal (Negative)
Page 990 _____________________________________________________ Electrical System 12-213 ® 6 WAY RADIO ACCESSORY CONNECTOR LOCATION: BACK OF THE RADIO 00-S12-102 C57 FEMALE COLOR DESCRIPTION Ampliﬁer sense Rear seat audio enable Cell phone mute Rear seat audio control 8 WAY RADIO JUMPER CONNECTOR LOCATION: BACK OF THE RADIO 29 32 35 30 33 36 01-S12-029...
Page 991 ______________________________________________________ 12-214 Electrical System ® A1 B1 C59 FEMALE 01-S12-028 COLOR DESCRIPTION Right rear speaker signal (Negative) Right rear speaker signal (Positive) Left rear speaker signal (Negative) Left rear speaker signal (Positive) Rear seat audio control Fused battery input to the rear seat audio (Ignition) Rear seat audio enable Ground G4 Rear seat audio illumination...
Page 992 _____________________________________________________ Electrical System 12-215 ® 8 WAY BODY TO CONSOLE CONNECTOR LOCATION: BEHIND THE CENTER CONSOLE 9-S12-036 9-S12-035 C60 MALE C60 FEMALE COLOR DESCRIPTION Fused radio memory input (Battery) Fused battery input to the radio (Ignition) Ground G4 Dimmer Circuit Radio Illumination Fused battery input to the ampliﬁer Ground G4...
Page 993 ______________________________________________________ 12-216 Electrical System ® CD CHANGER CONNECTOR LOCATION: BACK OF THE CD CHANGER C61 FEMALE 01-S12-029 COLOR DESCRIPTION –– –– –– Shielding for the audio circuits –– Right audio signal –– Left audio signal –– Audio common –– Ground G4 ––...
Page 994 _____________________________________________________ Electrical System 12-217 ® AMPLIFIER CONNECTOR LOCATION: ON THE AMPLIFIER 01-S12-027 C62 FEMALE COLOR DESCRIPTION Right front channel positive input Left front channel positive input Left front channel negative input Right rear channel negative input Right rear channel positive input Left rear channel positive input Left rear channel negative input Ground G4...
Page 995 ______________________________________________________ 12-218 Electrical System ® COLOR DESCRIPTION Front subwoofer negative signal Front subwoofer positive signal Right rear speaker negative signal Right rear speaker positive signal Left rear speaker positive signal Left rear speaker negative signal 3-1-01...
Page 996 _____________________________________________________ Electrical System 12-219 ® INTERIOR MINI FUSE BLOCK 1 (LOWER) Buss Cavity CKT. No. Color & Ga. Fuse – – ES (5 AMP) -1A- – – – – ET (7.5 AMP) -2A- – – – – – – – -3A- –...
Page 997 ______________________________________________________ 12-220 Electrical System ® INTERIOR MINI FUSE BLOCK 2 (UPPER) Buss Cavity CKT. No. Color & Ga. Fuse – – ES (5 AMP) -1E- – – – – – -2E- – – – – ET (7.5 AMP) – – -3E- –...
Page 998 _____________________________________________________ Electrical System 12-221 ® INTERIOR MINI FUSE BLOCK 2 (UPPER) (Cont’d) Buss Cavity CKT. No. Color & Ga. Fuse 517 A 12 OR EX (20 AMP) -3H- 37 D (BUSS B1) 14 RD 70 A 12 YL EZ (30 AMP) -4H- (BUSS B1) –...
Page 999 ______________________________________________________ 12-222 Electrical System ® INTERIOR FUSE BOX RELAYS IGNITION RELAY RY-1 Cavity CKT. No Color & Ga. Relay 687 A 12 GY MINI- FUSE / 59 H 18 BK RELAY BLOCK 59 A 18 BK 37 C 10 RD –...
Page 1000 _____________________________________________________ Electrical System 12-223 ® RELAY/MINI-FUSE COLUMNS MICRO-RELAY ROWS 2 4 3 MAIN FUSE/ MINI-RELAY ROWS MINI-FUSE ROWS 8 9 10 11 12 13 14 MINI-FUSE 9-S12-080.1 COLUMNS Figure 2-150: Interior Fuse Box Fuse/Relay Cavity I.D. 05745159 3-1-01...

Hummer H1 Service Manual

1-1 Section 1 General Information, Lubrication and Maintenance

Section 2 Engine

Section 3 Fuel, Emissions, and Exhaust

Section 10 Body

Section 12 Electrical System

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