Hummer H1 Service Manual page 86

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19. Remove protective tape from A/C suction/discharge hose
adapter and connect it to compressor. Install new seal washers.
HOSE ADAPTER
SEAL
WASHERS
COMPRESSOR
PORTS
Figure 2-61: Suction/Discharge Hose Connection
20. Connect glow relay cable and wires.
21. Position support on back of alternator. Then install gen-
erator, mounting bracket, idler pulley, support, and tensioner
assembly.
22. Position remaining cables for battery installation.
23. Connect heater hoses to water pump and water crossover.
Mount idler pulley on generator bracket.
24. Install fan and clutch assembly.
25. Install serpentine belt.
26. Connect air inlet hose to turbocharger.
27. Attach radiator upper hoses and tube to thermostat
housing.
28. Connect battery positive cable and solenoid wire to starter
motor.
29. Position radiator, shroud, condenser, and oil cooler
assembly on frame and between air lift brackets, with aid
of helper. Then secure assembly and supports to frame and
air lift brackets. Tighten support bolts to 26 lb-ft (35 N•m)
torque. Tighten frame mount bracket bolt to 30 lb-ft (41
N•m) torque.
NOTE: Verify that fan-to-shroud clearance is at least 1/4 inch
(3.18 mm) at all points around shroud before proceeding.
Loosen bolts and adjust position if necessary.
30. Connect radiator upper and lower hoses.
31. Connect surge tank hose to radiator.
32. Install return lines onto power steering pump.
33. Connect power steering pump return lines to oil cooler.
34. Remove protective wrapping or caps and connect hoses to
A/C condenser and oil coolers. Use new O-rings on cooler
and A/C hoses (Figure 2-61).
35. Install passenger and driver side splash shields.
05745159
36. Install battery tray and batteries. Connect positive and
negative cables to batteries.
37. Install seals and cover plates on air lift brackets. Notched
side of seals face engine.
38. Refill engine cooling system, refill engine crankcase with
recommended oil, and top off transmission and power
steering fluids.
39. Evacuate A/C system for 30 minutes, and recharge.
40. Leakcheck A/C system.
41. Start and run engine. Bleed injectors at line fittings if
necessary. Then stop engine, recheck coolant and lubricant
levels, and add as necessary.
42. Bleed cooling system with air bleeds on engine and
radiator.
43. Test drive vehicle and check for leaks or vibrations.
ENGINE DISASSEMBLY
Serpentine Belt Removal
1. Rotate belt tensioner counterclockwise with 1/2 in. drive
breaker bar.
2. Slide belt off tensioner pulley and remove belt.
CLUTCH
WRENCH
PUMP WATER
PULLEY
PULLEY BOLT (4)
CRANKSHAFT PULLEY
7-S02-017.2
Figure 2-62: Fan and Pulley Removal
Engine 2-49
FAN
SPANNER
PUMP