Hummer H1 Manuals

Manuals and User Guides for Hummer H1. We have 1 Hummer H1 manual available for free PDF download: Service Manual

Hummer H1 Service Manual

Hummer H1 Service Manual (1203 pages)

Brand: Hummer | Category: Automobile | Size: 54.35 MB

Table of Contents

1-1 Section 1 General Information, Lubrication and Maintenance

2
- Table of Contents
  2
- Carbon Monoxide
  3
  - Service Manual Revisions
    3
- P.O. Box
  3
- Emission Control Information Label
  4
- Safety Certification Label
  5
  - Transmission Identification
    5
- Engine Identification
  6
- Vehicle Identification Number
  6
- Component Data
  8
  - Transfer Case
    9
    
    Fluid Capacities
    11
    
    Vehicle Dimensions
    12
- Abbreviations
  13
- Bolt Identification and Torque Limits (Dry*)
  14
- Bolt Identification and Torque Limits (Wet*)
  15
- U.s./Metric Conversions and Equivalents
  16
  - Metric Conversions
    16
  - Paint and Trim Colors
    17
  - Towing, Lifting, Jump Starting
    18
    
    Vehicle Lifting/Jacking Points
    18
    
    Conventional Towing Procedures
    20
    
    Jump Starting
    21
    
    Maintenance Schedule
    22
    
    Scheduled Maintenance Chart
    23
- Recommended Fuel/Fluids/Lubricants/Capacities
  25
  - Lubrication and Maintenance Items
    26
    
    Engine Oil and Filter Change
    26
    
    Engine Oil Level
    26
    
    Transfer Case Fluid
    27
    
    Axle and Geared Hub
    28
    
    Universal and Slip Joint Lubrication
    28
    
    Cooling System Fluid Level Check
    30
    
    Master Cylinder Fluid Level Check
    30
  - Serpentine Belt
    30
    
    Body Lubrication Points
    31
    
    Fuel, Emissions and Exhaust
    32
- Miscellaneous Essential Tools
  34
  - Special Tools
    35
Section 2 Engine

38
- Cooling System
  39
  - Engine Oil
    40
- Cleaning Materials
  41
- Fuel Filter Warning Lamp
  41
  - Compression Test
    41
  - Piston and Connecting Rod
    42
    
    Diagnosis Equipment
    43
  - Glow Plug Test
    43
  - Scan Tool Use
    43
- General Information
  44
  - Oil Pump Pressure Test
    44
  - Turbocharger Operation
    53
- Boost Pressure Test
  53
- Torsional Damper
  58
- Front Cover Oil Seal Replacement
  59
- Front Cover and Timing Chain
  60
  - Cover Removal
    60
- Rear Main Oil Seal Replacement
  66
  - Intake Manifold
    80
  - Engine Installation
    85
- A/C Compressor Removal
  87
- Turbocharger and Center Manifold Removal
  89
  - Fuel Supply and Return Line Removal
    90
  - Glow Plug Removal
    91
- Front Cover Removal
  94
- Oil Pan Removal
  95
- Flywheel Removal
  97
  - Crankshaft and Main Bearings Removal
    97
  - Cylinder Bore and Piston Measurement
    99
- Section 2 Engine
  104
- Front Cover and Oil Filler Tube
  108
  - Lifter, Pushrod, Rocker Arm Service
    113
- Damper and Flywheel Service
  113
- Flushing Engine Cooler
  115
- Engine Assembly and Adjustment
  117
  - Crankshaft Main Bearing Selection
    117
  - Crankshaft and Main Bearing Installation
    117
- Timing Chain-Sprocket-Gear Installation
  122
- Front Cover and Baffle Installation
  123
- Cylinder Head Installation
  126
- Pushrod, Rocker Arm and Shaft Installation
  127
- Rocker Cover Installation
  128
  - Torque Specifications
    132
  - Engine Specifications
    133
Section 3 Fuel, Emissions, and Exhaust

138
- Fuel Lift Pump
  139
  - Fuel Filter-Water Separator
    140
  - Electronic Injection Pump
    140
  - Fuel Injectors
    141
  - Fuel Tanks, Lines, and Valves
    141
  - Glow Plugs
    141
    
    Preliminary Inspection
    143
    
    Road Test
    143
    
    Engine Coolant Temperature
    149
    
    Crankshaft Position Sensor
    154
- Air Cleaner Service
  156
  - Air Cleaner Filter Element Service
    158
- Air Horn
  158
  - Air Induction Hose Replacement
    159
  - Weathercap Replacement
    159
- Air Intake Vent Line Replacement
  160
- Main Fuel Tank
  161
  - Tank Cleaning
    162
  - Fuel Tank Vent Line Service
    166
  - Fuel Selector Valve
    167
- Diesel Fuel Injection System
  173
- Fuel Injection Pump
  175
- Sensor and Switch Service
  177
  - Muffler Replacement
    179
  - Crossover Pipe Replacement
    181
  - Catalytic Converter Replacement
    181
  - Shroud Shield Assembly Replacement
    190
- Low Coolant Sensor
  195
- Thermostat Replacement
  196
  - Transmission/Transfer Case
    200
  - Shift Solenoids
    206
  - Engine Sensor Inputs
    208
  - Torque Converter
    208
    
    Line Pressure Test
    214
  - Recommended Fluid
    214
  - Vent Line Service
    333
  - Valve Body Switch and Solenoid Service
    335
  - Shifter Boot Cover Replacement
    345
- Shift Linkage Adjustment
  347
  - Rear Mount Replacement
    347
  - Recommended Lubricant
    349
  - Operating Ranges
    350
  - Vent Line Replacement
    352
  - Guide Cable Replacement
    353
- Oil Pump
  365
- Input Gear Bearing Replacement
  367
- Mainshaft Pilot Bearing Replacement
  367
  - Wheels and Tires
    384
  - Removal and Disassembly
    385
- Steering Stop Adjustment
  412
- Central Tire Inflation System
  413
  - Compressor Service
    419
  - Inflate/Deflate and Tire Selector Switches
    421
  - Air Pressure Gauge
    423
  - Front Cti Line Replacement
    433
  - Rear Cti Line Replacement
    433
  - Tube Shield Replacement
    434
- Brake System
  440
- Component Inspection
  441
- Road Testing
  441
- Brake Noise
  443
- Steering System
  444
  - Hydro-Boost System Diagnosis
    446
    
    Accumulator Leakdown Test
    447
    
    Booster Functional Test
    447
    
    Bleeding the Hydro-Boost System
    452
    
    Hydro-Boost Replacement
    452
  - Brake Line Replacement
    453
  - Rear Dual Service/Parking Brake
    459
    
    Caliper Replacement
    459
  - Left Parking Brake Cable Replacement
    463
    
    Body
    465
  - Brake Rotor
    471
    
    Parking Brake Lever Adjustment
    472
    
    Parking Brake Switch Replacement
    472
  - Abs/Auto-Matic Traction Control/Torqtrac 4
    473
  - Abs/Tt4 Diagnostics
    473
  - Fault Diagnostic Procedure
    473
- System Description
  473
  - System Operation
    473
  - Fault Code List
    474
  - Abs Modulator Replacement
    487
- Speed Sensor Replacement
  488
  - Abs Ecu Replacement
    489
  - Fuse and Relay Replacement
    489
- Tone Wheel Replacement
  489
  - Center Link Replacement
    494
  - Tie Rod End Replacement
    495
  - Idler Arm Replacement
    497
  - Steering Wheel Replacement
    497
    
    Steering Column Repair
    500
    
    Ignition Interlock Cable Replacement
    502
    
    Steering Gear Replacement
    503
    
    Power Steering Gear Service
    509
- Steering Specifications
  535
  - Steering Gear Adjustment Preload Torques
    535
  - Stabilizer Bar Replacement
    539
  - Upper Ball Joint Replacement
    541
  - Geared Hub Replacement
    545
  - Halfshaft Boot Replacement
    558
  - Pinion Seal Replacement
    563
- Axle Assembly
  569
  - Front Bumper Mounting Bracket
    583
  - Radiator Front Mount Bracket
    583
  - Lifting Shackle Replacement
    584
  - Front Suspension Brace Replacement
    587
  - Rear Bumper Replacement
    589
  - Right Engine Mount Bracket
    592
  - Right Front Body Mount Bracket
    592
  - Transmission Crossmember Support
    593
  - Right Intermediate Body Mount Bracket
    594
  - Left Intermediate Body Mount Bracket
    594
  - Rear-Rear Tiedown Bracket
    595
  - Rear Upper Control Arm Bracket
    595
  - Rear-Front Tiedown Bracket
    596
  - Front Suspension Front Crossmember
    597
  - Front Suspension Rear Crossmember
    598
  - Rear Suspension Front Crossmember
    599
Section 10 Body

628
- General Body Information
  629
- Body Inspection and Repair
  630
  - Rivet Failure
    630
  - Rivet Replacement
    631
  - Aluminum Repair
    635
  - Fiberglass Repair
    638
- Center Console Replacement
  640
- Front Console Replacement
  640
- Glovebox Replacement
  646
- Ashtray Replacement
  647
- Engine Access Cover
  647
  - Inner Kick Panels Replacement
    659
  - Side Mirror Replacement
    662
- Power Mirrors
  662
  - Rearview Mirror Replacement
    663
- Power Windows
  667
  - Door Seals Replacement
    668
  - Hood Prop Rod and Bracket Replacement
    672
  - Side Hood Stop Replacement
    676
  - Grille and Screen Replacement
    676
  - Guide Bracket Assembly Replacement
    677
  - Front Hood Screen Replacement
    677
- Front License Plate Bracket Replacement
  689
- Rear License Plate Bracket Replacement
  689
- Fuel Filler Housing Replacement
  690
- Roadside Emergency Equipment
  691
  - Four-Passenger Soft Top
    692
  - Tailgate and Seals Replacement
    699
  - Window Replacement
    701
  - Rear Vertical Door Replacement
    701
  - Interior and Exterior Lighting
    705
- Front Turn Signal Light Replacement
  707
  - Rear Turn Signal Light Replacement
    708
  - Maplight Replacement
    710
  - Lighted Visor Mirror Replacement
    711
    
    Underhood Light Replacement
    711
- Backup Light Switch Replacement
  713
  - Stoplight Switch Replacement
    713
  - Heating/Ventilation
    720
- Electrical
  721
  - System Performance Checks
    721
    
    A/C System Refrigerant and Capacity
    724
    
    System Diagnosis
    727
- Pressure Hose Torque Specifications
  736
  - Condenser Replacement
    739
  - Heater Hose Replacement
    741
    
    Water Control Valve
    741
    
    Water Control Valve Replacement
    742
    
    Drain Tube Replacement
    743
    
    Air Conditioning/Heater Duct Replacement
    744
    
    Ambient Temperature Switch
    753
    
    Low Pressure Cutoff Switch
    753
    
    Blower Motor Resistor Replacement
    754
    
    High Pressure Cutoff Switch
    754
    
    Hvac Controls
    755
    
    Mode Dial
    755
    
    Diverter Doors
    756
    
    Main Hvac Unit
    756
    
    Unit Service
    756
    
    Blower Motor
    757
    
    Expansion Valve
    757
    
    Heater Core
    757
    
    Thermostatic Cycling Switch
    757
    
    Vacuum Door Motor
    760
    
    Blend Door Motor
    761
  - Cycling Switch Replacement
    764
  - Air Intake Assembly Replacement
    764
  - Rear Console Replacement
    765
Section 12 Electrical System

772
- Circuit Breakers
  774
- Electrical System
  774
- Fusible Links
  774
- Preliminary Checks
  774
- Wiring Diagrams
  774
- Circuit Faults
  775
- Diagnostic Tests
  776
- Accessories
  781
- Fuse/Relay Location and Identification
  781
- Ground Points
  784
- Battery Charging
  785
  - Alternator Overhaul
    794
  - Inspection and Repair
    795
  - Brake Shift Interlock Cable Inoperative
    822
  - Ctis Compressor Inoperative
    824
  - Ctis Exhaust Valve Inoperative
    825
  - Ctis Front Inflate Valve Inoperative
    826
  - Ctis Rear Inflate Valve Inoperative
    827
- Horn Replacement
  832
- Horns Inoperative
  833
- Cigarette Lighter Replacement
  839
- Tachometer Replacement
  839
- Low Coolant Lamp Inoperative
  840
- Oil Pressure Gauge Inoperative
  842
- Fuel Gauge Inoperative
  843
- Engine Temperature Gauge Inoperative
  844
- Hvac Compressor Inoperative
  848
- Hvac Main Blower Inoperative All but High
  848
- Hvac Temperature Door Inoperative
  850
  - Left Heated Windshield Inoperative
    863
- Right Heated Windshield Inoperative
  864
  - Both Heated Windshields Inoperative
    865
  - Rear Window Defroster Inoperative
    867
    
    Automatic Door Lock
    879
    
    Automatic Door Unlock
    879
    
    Battery Replacement
    879
  - Slant Door Lock Inoperative
    885
  - Cargo Door Lock Inoperative
    886
  - Remote Entry System Inoperative
    887
  - Ambient Temperature Sensor
    904
  - Compass Mirror Display Inoperative
    905
  - Power Side Mirror
    907
- Cruise Control Systems
  911
  - Cruise Control Inoperative Vin Z
    912
- Radio (Delco) Replacement
  917
- Identifying Concerns
  921
- Corrective Action
  922
- Generator Whine Concerns
  923
- Test Antenna
  923
- Symptom Table
  928
- Antenna System Test
  934
- Section 12 Electrical System
  944
- Brushguard Assembly Replacement
  1015
  - Skid Plate Replacement
    1019
  - Front Shield Replacement
    1020
  - Intermediate Shield Replacement
    1021
- Rocker Panel Protection Replacement
  1023
- Running Board Replacement
  1026
- Roof Rack
  1029
- Auxiliary Seat
  1032
- Off Road Light Package
  1036
- Air Restriction Gauge
  1039
- Delco Compact Disc Changer Replacement
  1041
- Index
  1052
14-2 Index

1053
- Auxiliary Hvac Unit
  1057
14-8 Index

1059
- Pcm Function
  1066
- Verifying Vehicle Repair
  1066
- Low Voltage
  1131

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