Hummer H1 (2002+). Manual — part 265

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Index 14-7

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05745159

I

Identification Numbers

Engine Identification Number . . . . . . . . . . . 1-5
Transfer Case Identification Number . . . . . . 1-5
Transmission Identification Number . . . . . . 1-4
Vehicle Identification Number

Decoding Chart . . . . . . . . . . . . . . . . . . . 1-6

Vehicle Identification Number (VIN) . . . . . 1-5

Indicator Lights

Compressor/Low Pressure . . . . . . . . . . . . . 6-39

Information Labels

Emission Control Information Label . . . . . . 1-3
EPA Noise Emission Label . . . . . . . . . . . . . 1-5
Safety Certification Label . . . . . . . . . . . . . . 1-4

Input Gear Bearing Replacement . . . . . . . . . . 5-168
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . 12-64

Dashpad Replacement . . . . . . . . . . . . . . . 10-15
Engine Temperature Gauge Inoperative . 12-73
Fuel Gauge Inoperative . . . . . . . . . . . . . . 12-72
Gauge Replacement . . . . . . . . . . . .10-16, 12-65
Gauges and Switches . . . . . . . . . . .10-14, 12-64
Gauges Schematic . . . . . . . . . . . . . . . . . . 12-74
Indicator Lamp Replacement . . . . . . . . . . 10-16
Instrument Panel Replacement . . . . . . . . 10-14
Low Coolant Lamp Inoperative . . . . . . . . 12-69
Oil Pressure Gauge Inoperative . . . . . . . . 12-71
Replacement . . . . . . . . . . . . . . . . . . . . . . . 12-64
Switch Replacement . . . . . . . . . . . . . . . . . 10-17

Instrument Panel, 56 way . . . . . . . . . . . . . . . . . 5-31
Intake and Exhaust Manifolds . . . . . . . . . . . . . 2-79
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . 2-43

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

Interior Trim

B-Bar Replacement . . . . . . . . . . . . . . . . . 10-25
Driver’s Compartment Trim Replacement 10-28
Floor Carpeting and Padding

Replacement . . . . . . . . . . . . . . . . . . . . . . 10-34

Inner Kick Panels Replacement . . . . . . . . 10-32
Outer Kick Panel Replacement . . . . . . . . 10-33
Passenger’s Compartment Trim . . . . . . . . 10-26

Replacement . . . . . . . . . . . . . . . . . . . . . . . 10-25
Station Wagon Rear Compartment Trim . 10-30

Interior Trim, Four-Passenger Soft Top . . . . . 10-65
Intermediate Steering Shaft

Dust Boot Replacement . . . . . . . . . . . . . . . 8-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
In-Vehicle Service, Diesel Engine . . . . . . . . . . 2-19

J

Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

K

Keys

Replacement Keys . . . . . . . . . . . . . . . . . . . 1-16

L

License Plate Brackets . . . . . . . . . . . . . . . . . . 10-62
Lift Gate Assembly . . . . . . . . . . . . . . . . . . . . 10-74
Lifter, Pushrod, Rocker Arm Service . . . . . . . 2-76
Lighting Systems

Key/Headlight Chime Schematic . . . . . . . 12-60
Lights Schematic . . . . . . . . . . . . . . . . . . . 12-58

Lights

Backup Light Switch Replacement . . . . . 10-86
Front Courtesy Light . . . . . . . . . . . . . . . . 10-85
Interior and Exterior Lighting . . . . . . . . . 10-78

Backup Light Switch . . . . . . . . . . . . . 10-84
Cargo Light . . . . . . . . . . . . . . . . . . . . 10-82
Courtesy Light . . . . . . . . . . . . . . . . . . 10-84
Domelight Replacement . . . . . . . . . . . 10-82
Front Turn Signal Light Replacement 10-80
Identification Light Replacement . . . 10-79

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14-8

Index

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Maplight Replacement . . . . . . . . . . . . 10-83
Optional Trouble Light Replacement 10-84
Rear Turn Signal Light Replacement 10-81
Service Headlight Assembly . . . . . . . 10-78
Service Headlight Electrical Connector

and Grommet Replacement . . . . . . . 10-85

Side Marker Light Assembly . . . . . . . 10-79
Side Marker Light Lens and Lamp . . 10-79
Underhood Light Replacement . . . . . 10-84

Rear Seat Courtesy Light . . . . . . . . . . . . . 10-83
Stoplight Switch Replacement . . . . . . . . . 10-86

Load Barrier and Mounting Brackets . . . . . . 10-25
Low Coolant Sensor . . . . . . . . . . . . . . . . . . . . . 4-12
Lubricants/Sealants/Coolant . . . . . . . . . . . . . . . 2-3
Lubrication and Maintenance Items . . . . . . . . . 1-25

Axle and Geared Hub . . . . . . . . . . . . . . . . . 1-27
Body Lubrication Points . . . . . . . . . . . . . . 1-30
Cooling System Fluid Level Check . . . . . . 1-29
Engine Oil and Filter Change . . . . . . . . . . 1-25
Engine Oil Level . . . . . . . . . . . . . . . . . . . . 1-25
Master Cylinder Fluid Level Check . . . . . . 1-29
Power Steering Fluid . . . . . . . . . . . . . . . . . 1-29
Steering and Suspension Lubrication

Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Transfer Case Fluid . . . . . . . . . . . . . . . . . . 1-26
Transmission Fluid . . . . . . . . . . . . . . . . . . 1-26
Universal and Slip Joint Lubrication . . . . . 1-27

M

Main Fuel Tank

Fuel Level Transmitter . . . . . . . . . . . . . . . . 3-25
Tank Cleaning . . . . . . . . . . . . . . . . . . . . . . 3-25

Mainshaft Pilot Bearing Replacement . . . . . . 5-168
Maintenance

Inspection Groups . . . . . . . . . . . . . . . . . . . 1-21
Maintenance Schedule . . . . . . . . . . . . . . . . 1-21
Scheduled Maintenance Chart . . . . . . . . . . 1-22

Maintenance Items

Serpentine Belt . . . . . . . . . . . . . . . . . . . . . . 1-29
Wheels/Tires/CTIS . . . . . . . . . . . . . . . . . . 1-29

Metric System and Equivalents . . . . . . . . . . . . 1-15

Metric Conversions . . . . . . . . . . . . . . . . . . 1-15

Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35

Lighted Visor Mirror Replacement . . . . . 10-84
Power Mirrors . . . . . . . . . . . . . . . . . . . . . 10-35
Rearview Mirror Replacement . . . . . . . . . 10-36
Side Mirror Replacement . . . . . . . . . . . . . 10-35

O

Off Road Light Package . . . . . . . . . . . . . . . . . 13-31
Oil Filter

Adapter Service . . . . . . . . . . . . . . . . . . . . . 2-78
Filter, Adapter, Fittings . . . . . . . . . . . . . . . 2-87

Oil Filter/Adapter/Oil Pressure Sending Unit . 2-57
Oil Pan Removal . . . . . . . . . . . . . . . . . . . . . . . 2-58
Oil Pump

Oil Pump and Drive Removal . . . . . . . . . . 2-58
Oil Pump and Pump Drive Service . . . . . . 2-77
Oil Pump Drive . . . . . . . . . . . . . . . . . . . . . 2-22
Oil Pump Pressure Test . . . . . . . . . . . . . . . . 2-7
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Oil Pump, Oil Pan, Flywheel Installation . . . . 2-84

P

Paint and Trim Colors . . . . . . . . . . . . . . . . . . . 1-16
PCM, 24 Way, Brown . . . . . . . . . . . . . . . . . . . 5-39
PCM, 32 Way, Blue . . . . . . . . . . . . . . . . . . . . . 5-37
PCM, 32 Way, Brown . . . . . . . . . . . . . . . . . . . 5-35
Piston/Connecting Rod

Installation and Bearing Fit . . . . . . . . . . . . 2-83
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

Piston/Connecting Rod Overhaul . . . . . . . . . . 2-67

Piston and Connecting Rod Assembly . . . . 2-69
Piston Ring Installation . . . . . . . . . . . . . . . 2-70
Piston Selection and Fit . . . . . . . . . . . . . . . 2-68

Power Door Locks

Front Door Harness Replacement . . . . . 12-120

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Index 14-9

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05745159

Power Locks

Cargo Door Lock Inoperative . . . . . . . . 12-113
General Replacement . . . . . . . . . . . . . . . 12-102
Keyless Entry & Theft Detterent

System Operating Instructions . . . . . . . 12-105

Keyless Entry Programming . . . . . . . . . 12-108
Keyless Entry System Features . . . . . . . 12-106
Power Locks HMC4, XLC2 , HMSB . . 12-117
Power Locks HMCS W/ Remote Entry . 12-115
Power Locks Inoperative . . . . . . . . . . . . 12-110
Rear Door and Jumper Harness . . . . . . . 12-121
Remote Entry Module Power/Ground . . 12-119
Remote Entry System Inoperative . . . . . 12-114
Slant Door Lock Inoperative . . . . . . . . . 12-112

Power Mirrors

Ambient Temperature Sensor . . . . . . . . 12-131
Auto-Dimming Compass Mirror

Calibration and Zone Adjustments . . . . 12-129

Auto-Dimming Rear View Mirror . . . . . 12-129
Compass Mirror Display Inoperative . . . 12-132
Compass Mirror Schematic . . . . . . . . . . 12-133
Power Side Mirror . . . . . . . . . . . . . . . . . 12-134

Power Steering Pump

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
Cleaning and Inspection . . . . . . . . . . . . . . . 8-41
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 8-39
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

Power Steering Pump and Bracket . . . . . . . . . 2-50
Power Window and Door Locks

Front Door Harness Replacement . . . . . 12-123

Power Windows

Power Window Schematic . . . . . . . . . . . 12-101
Power Windows Inoperative, All

Windows . . . . . . . . . . . . . . . . . . . . . . . . . 12-96

Power Windows and Door Locks

Rear Door Harness Replacement . . . . . . 12-126

Powertrain Control Module . . . . . . . . . . . . . . . . 3-6
Pressure Hose Torque Specifications . . . . . . . 11-17
Propeller Shaft

Torque Specifications . . . . . . . . . . . . . . . 5-181

Pushrod, Rocker Arm and Shaft Installation . . 2-90

R

Radiator

Lower Hose Replacement . . . . . . . . . . . . . . 4-9
Lower Tube Assembly Replacement . . . . . 4-10
Rear Support Bracket . . . . . . . . . . . . . . . . . . 4-7
Shroud Shield Assembly Replacement . . . . 4-7
Upper Hose Replacement . . . . . . . . . . . . . . 4-9

Radiator and Fan Shroud Assembly . . . . . . . . . 4-4
Rear License Plate Bracket Replacement . . . 10-62
Rear Main Oil Seal Replacement . . . . . . . . . . . 2-29
Rear Main Seal Installation . . . . . . . . . . . . . . . 2-82
Rear Striker Assembly Replacement . . . . . . . 10-61
Rear Support Bow Bracket, Station Wagon . 10-61
Rear Vertical Door

Door Frame and Seal Replacement . . . . . 10-77
Door Handle Replacement . . . . . . . . . . . . 10-75
Door Latch and Latch Rod Replacement . 10-75
Door Replacement . . . . . . . . . . . . . . . . . . 10-74
Door Stop Replacement . . . . . . . . . . . . . . 10-77
Window Replacement . . . . . . . . . . . . . . . 10-74

Road Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Roadside Emergency Equipment . . . . . . . . . . 10-64
Rocker Arm

Cover Removal . . . . . . . . . . . . . . . . . . . . . 2-54
Cover Service . . . . . . . . . . . . . . . . . . . . . . . 2-30
Shaft and Pushrod Removal . . . . . . . . . . . . 2-54
Shaft and Pushrod Service . . . . . . . . . . . . . 2-33

Rocker Cover Installation . . . . . . . . . . . . . . . . 2-91
Rocker Panel Protection Replacement . . . . . . 13-18
Roof Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-24

Clamp Replacement . . . . . . . . . . . . . . . . . 13-26
Crossbar Replacement . . . . . . . . . . . . . . . 13-25
End Replacement . . . . . . . . . . . . . . . . . . . 13-25

Runflat

Compressor Belt Replacement . . . . . . . . . . 6-12

Running Board Replacement . . . . . . . . . . . . . 13-21

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14-10

Index

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S

Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Non-approved accessories . . . . . . . . . . . . . . 1-1
Warnings, cautions, and notes . . . . . . . . . . . 1-1

Scan Tool Diagnosis . . . . . . . . . . . . . . . . . . . . 3-11
Seat Belts

Seat Belt Assembly Replacement . . . . . . 10-22

Seat Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-37
Seats

Front Seats . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Reclining Seat Replacement . . . . . . . . . . 10-24
Standard Seat Pedestal Repair . . . . . . . . . 10-23

Sensor and Switch Service . . . . . . . . . . . . . . . . 3-40
Sensor, Oil Pressure Switch, and Transmitter . 3-40
Serpentine Belt Removal . . . . . . . . . . . . . . . . . 2-49
Serpentine Belt Replacement . . . . . . . . . . . . . . 4-16
Shift Control Assembly

Installation . . . . . . . . . . . . . . . . . . . . . . . . 5-147
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5-143
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-144

Shift Linkage Adjustment . . . . . . . . . . . . . . . 5-148
Slant Back

Glass and Body . . . . . . . . . . . . . . . . . . . . 10-91
Slant Door and Torsion Assembly

Replacement . . . . . . . . . . . . . . . . . . . . . . 10-87

Slant Door Handle, Latch, And

Lock Actuator . . . . . . . . . . . . . . . . . . . . . 10-88

Wiper Motor and Components . . . . . . . . . 10-90

Soft Top

Mounting Components and Accessories . 10-67
Soft Top Support/Roll Cage Assembly . . 10-71

Spare Tire Carrier

Cargo DeckMounted . . . . . . . . . . . . . . . . 13-13
Swing-Away . . . . . . . . . . . . . . . . . . . . . . 13-10

Specifications

Bolt Identification and Torque

Limits (Dry) . . . . . . . . . . . . . . . . . . . . . . . 1-13

Bolt Identification and Torque

Limits (Wet) . . . . . . . . . . . . . . . . . . . . . . . 1-14

Cooling System . . . . . . . . . . . . . . . . . . . . . . 1-7
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Engine Dimensions . . . . . . . . . . . . . . . . . . . 1-7
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . 1-10
Fuel/Air System . . . . . . . . . . . . . . . . . . . . . . 1-7
General

A/C Refrigerant and Compressor Oil . 1-25
Air Conditioner . . . . . . . . . . . . . . . . . . . 1-9
Axle/Differential . . . . . . . . . . . . . . . . . . 1-8
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Body Lubrication . . . . . . . . . . . . . . . . . 1-24
Brake Fluid . . . . . . . . . . . . . . . . . . . . . . 1-24
Engine Coolant . . . . . . . . . . . . . . . . . . . 1-24
Engine Oil . . . . . . . . . . . . . . . . . . . . . . 1-24
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Front/Rear Axle and Geared Hub . . . . 1-24
Geared Hub . . . . . . . . . . . . . . . . . . . . . . 1-8
Recommended Fuel . . . . . . . . . . . . . . . 1-24
Service Brake Caliper (Front) . . . . . . . . 1-9
Service/Parking Brake Caliper (Rear) . . 1-9
Service/Parking Brake Rotor (Rear) . . . 1-9
Steering Gear and Pump Fluid . . . . . . . 1-24
Steering Linkage and Suspension . . . . 1-24
Steering System . . . . . . . . . . . . . . . . . . . 1-9
Transfer Case . . . . . . . . . . . . . . . . . . . . . 1-8
Transmission . . . . . . . . . . . . . . . . . . . . . 1-8
Transmission/Transfer Case . . . . . . . . . 1-24
Wheels and Tires . . . . . . . . . . . . . . . . . . 1-9
Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Governed Speed . . . . . . . . . . . . . . . . . . . . . . 1-7
Lubricating System . . . . . . . . . . . . . . . . . . . 1-7
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Vehicle Dimensions . . . . . . . . . . . . . . . . . . 1-11
Vehicle Weights . . . . . . . . . . . . . . . . . . . . . 1-10

Speed Sensor Replacement . . . . . . . . . . . . . . . 7-49

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49

Speedometer/Odometer Replacement . . . . . . 10-17
Splash Shield (Engine) Replacement . . . . . . . 10-52
Splash Shield Support Bracket Replacement . . 9-51
Spring Seat Replacement . . . . . . . . . . . . . . . . . 9-53
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 12-37
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . 12-31

Status Center, 8 Way, LH . . . . . . . . . . . . . . . . 5-34

3-1-01