Hummer H1 (2002+). Manual — part 264

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Index 14-3

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05745159

Rear CTI Line Replacement . . . . . . . . . . . 6-50
Rear Tube Connection Shield . . . . . . . . . . 6-53
Spindle Extension and Seal . . . . . . . . . . . . 6-54
Supply Line . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 6-31
Tube Shield Replacement . . . . . . . . . . . . . 6-51

Charging System

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . 12-22
Alternator Overhaul . . . . . . . . . . . . . . . . . 12-23
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 12-28

Cigarette Lighter Replacement . . . . . .10-19, 12-68
Climate Control System

A/C Pressure Hose Replacement . . . . . . . 11-18
Condenser Replacement . . . . . . . . . . . . . . 11-20
Control Head Replacement . . . . . . . . . . . 11-16
Heater Hose Replacement . . . . . . . . . . . . 11-22
Heater/A/C Diagnosis . . . . . . . . . . . . . . . . 11-2
System Performance Checks . . . . . . . . . . . 11-2

Compressor

Clutch Core Replacement . . . . . . . . . . . . 11-32
Clutch Rotor and/or Bearing Replacement 11-30
Replacement . . . . . . . . . . . . . . . . . . . . . . . 11-28
Shaft Seal Replacement . . . . . . . . . . . . . . 11-32

Converter Housing

Lower Cover Replacement . . . . . . . . . . . 5-135
Upper Cover Replacement . . . . . . . . . . . . 5-135

Crankshaft

Bearing Replacement . . . . . . . . . . . . . . . . . 2-42
Connecting Rod Journal Diameter . . . . . . . 2-97
Crankshaft and Main Bearings Removal . . 2-60
End Play Check . . . . . . . . . . . . . . . . . . . . . 2-81
Main Journal Diameter . . . . . . . . . . . . . . . 2-97
Pulley Replacement . . . . . . . . . . . . . . . . . . 2-20

Cruise Control

Cruise Control Inoperative VIN Z . . . . . 12-135
Cruise Control Schematic . . . . . . . . . . . 12-137

Cruise Control Systems . . . . . . . . . . . . . . . . 12-134
CTIS

CTIS Compressor Inoperative . . . . . . . . . 12-53
CTIS Exhaust Valve Inoperative . . . . . . . 12-54
CTIS Front Inflate Valve Inoperative . . . 12-55
CTIS Rear Inflate Valve Inoperative . . . . 12-56
CTIS Schematic . . . . . . . . . . . . . . . . . . . . 12-57

Customer Assistance

Hummer Service Hotline . . . . . . . . . . . . . . . 1-2
Service Manual Revisions . . . . . . . . . . . . . . 1-2

Cylinder Block

Cylinder Bore and Piston Measurement . . 2-62
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

Cylinder Head

Cylinder Head And Gasket Service . . . . . . 2-37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

D

Damper and Flywheel Service . . . . . . . . . . . . . 2-76
Delco Compact Disc Changer Replacement . 13-36
Diesel Fuel Injection System . . . . . . . . . . . . . . 3-36
Digital Ratio Adapter . . . . . . . . . . . . . . . . . . 12-74.1
Dimmer Control Switch Replacement . . . . . . 10-17
Door Glass

“Wind Noise” . . . . . . . . . . . . . . . . . . . . . . 10-43
Replacement . . . . . . . . . . . . . . . . . . . . . . . 10-41

Door Stop Strap Assembly Replacement . . . . 10-41
Doors

Disassembly, Replacement and Repair . . 10-36
Door Glass . . . . . . . . . . . . . . . . . . . . . . . . 10-41
Door Seals Replacement . . . . . . . . . . . . . 10-41
Rear Vertical Door Replacement . . . . . . . 10-74

Drainage Bracket Replacement . . . . . . . . . . . . 3-23
Dual Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . 13-35

E

Engine

Assembly and Adjustment . . . . . . . . . . . . . 2-80
Block, Camshaft and Bearing Sizes . . . . . . 2-98
Cleaning Materials . . . . . . . . . . . . . . . . . . . . 2-4
Compression Test . . . . . . . . . . . . . . . . . . . . . 2-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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14-4

Index

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Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . 2-7
Engine Noise

Diagnosis Equipment . . . . . . . . . . . . . . . 2-6

Essential Tools . . . . . . . . . . . . . . . . . . . . . . 2-99
Identification . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Identification Number . . . . . . . . . . . . . . . . . 1-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Lubricants/Sealants/Coolant

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . 2-3
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Mounting Bracket/Insulator . . . . . . . . . . . . 2-19
Noise Diagnosis . . . . . . . . . . . . . . . . . . . . . . 2-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Scan Tool Use . . . . . . . . . . . . . . . . . . . . . . . 2-6
Service Piston and Cylinder Bore . . . . . . . 2-97
Special Service Tools . . . . . . . . . . . . . . . . . . 2-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . 2-96

Engine Access Cover . . . . . . . . . . . . . . . . . . . 10-20

Hold-Down Striker Replacement . . . . . . . 10-20
Inner Flexible Latch Replacement . . . . . . 10-20

Engine Access Cover Maintenance . . . . . . . . 10-20
Engine Assembly and Adjustment

Crankshaft and Main Bearing Installation . 2-80
Crankshaft Main Bearing Selection . . . . . . 2-80

Engine Cooling System

Description . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Diagnosis and Troubleshooting . . . . . . . . . . 4-3
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Engine Temperature Sender Replacement . . . . 3-40
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43

Air Intake Assembly Replacement . . . . . 11-45
Cycling Switch Replacement . . . . . . . . . . 11-45

Exhaust Manifold

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Exhaust System

Catalytic Converter Replacement . . . . . . . 3-44
Crossover Pipe Replacement . . . . . . . . . . . 3-44
Muffler Replacement . . . . . . . . . . . . . . . . . 3-42

Extension Housing Bushing and Seal . . . . . . 5-169

F

Fan and Clutch Assembly Service . . . . . . . . . . 4-16
Fan-Pulley-Damper Removal . . . . . . . . . . . . . 2-50
Flexplate Replacement . . . . . . . . . . . . . . . . . . 5-139
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Fuel/Fluids/Lubricants . . . . . . . . . . . . . . . . 1-24

Flushing Engine Cooler . . . . . . . . . . . . . . . . . . 2-78
Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . 2-60
Former Assembly Replacement, “A” Pillar . . 10-60
Frame

Front Suspension Brace Replacement . . . . 9-50
Front Suspension Front Crossmember . . . . 9-60
Front Suspension Rear Crossmember . . . . 9-61
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64
Left Engine Mount Bracket . . . . . . . . . . . . 9-54
Left Intermediate Body Mount Bracket . . . 9-57
Lifting Shackle Replacement . . . . . . . . . . . 9-47
Radiator Front Mount Bracket . . . . . . . . . . 9-46
Rear Suspension Front Crossmember . . . . 9-62
Rear Suspension Rear Crossmember . . . . . 9-63
Rear-Front Tiedown Bracket . . . . . . . . . . . 9-59
Rear-Rear Tiedown Bracket . . . . . . . . . . . 9-58
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-67
Right Engine Mount Bracket . . . . . . . . . . . 9-55
Right Front Body Mount Bracket . . . . . . . 9-55
Right Intermediate Body Mount Bracket . . 9-57
Transmission Crossmember Support . . . . . 9-56
Transmission Mount Crossmember . . . . . . 9-56
Transmission Mount Replacement . . . . . . 9-56

Front Console Replacement . . . . . . . . . . . . . . 10-13
Front Cover and Baffle Installation . . . . . . . . . 2-86
Front Cover and Oil Filler Tube . . . . . . . . . . . 2-71
Front Cover And Timing Chain . . . . . . . . . . . . 2-23
Front Cover Oil Seal Replacement . . . . . . . . . 2-22
Front Cover Removal . . . . . . . . . . . . . . . . . . . . 2-57
Front License Plate Bracket Replacement . . . 10-62
Front Output Shaft

Bearing and Seal Replacement . . . . . . . . 5-166
Seal Replacement . . . . . . . . . . . . . . . . . . . 5-155

Front Striker Replacement . . . . . . . . . . . . . . . 10-61

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Index 14-5

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05745159

Fuel Filler Housing Replacement . . . . . . . . . 10-63
Fuel Filter

Drain Hose and Valve Replacement . . . . . 3-32
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Fuel Filter Warning Lamp . . . . . . . . . . . . . . . . . 2-4
Fuel Injection Line

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

Fuel Injection Pump

Fuel Supply and Return Line Removal . . . 2-53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Fuel Injection Pump Boot Replacement . . . . . 3-33
Fuel Injection System

Injection Line Bracket and Clamp . . . . . . . 3-36

Fuel Lift Pump Service . . . . . . . . . . . . . . . . . . 3-33
Fuel System

Contamination . . . . . . . . . . . . . . . . . . . . . . 3-41
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Electronic Accelerator Pedal . . . . . . . . . . . . 3-4
Electronic Injection Pump . . . . . . . . . . . . . . 3-3
Essential Tools . . . . . . . . . . . . . . . . . . . . . . 3-45
Fuel Filter-Water Separator . . . . . . . . . . . . . 3-3
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . 3-2
Fuel Lift Pump Inoperative . . . . . . . . . . . 12-44
Fuel Lift Pump Schematic . . . . . . . . . . . . 12-46
Fuel Manager Schematic . . . . . . . . . . . . . 12-50
Fuel Selector Valve . . . . . . . . . . . . . . . . . . 3-30
Fuel Selector Valve Schematic . . . . . . . . 12-49
Fuel Tank Selector System Inoperative . . 12-47
Fuel Tanks, Lines, and Valves . . . . . . . . . . . 3-4
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Fuel Tank

Auxiliary Fuel Tank . . . . . . . . . . . . . . . . . . 3-26
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Fuel Level Transmitter and Tank

Access Plate Service . . . . . . . . . . . . . . . . . 3-28

Fuel Tank Vent Line Service . . . . . . . . . . . 3-29
Main Fuel Tank . . . . . . . . . . . . . . . . . . . . . 3-24
Main/Auxiliary Tank Fuel Line . . . . . . . . . 3-29
Vent Filter Replacement . . . . . . . . . . . . . . 3-29

G

Geared Hub

Input Seal Replacement . . . . . . . . . . . . . . . 9-11
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Side Cover Replacement . . . . . . . . . . . . . . 9-11
Spindle Bearing Adjustment . . . . . . . . . . . 9-19
Spindle Seal Replacement . . . . . . . . . . . . . 9-17
Vent Line Replacement . . . . . . . . . . . . . . . 9-24

General Body Information . . . . . . . . . . . . . . . . 10-2
General Information

Auxiliary Power Point, Interior Fuse Box 12-10
Auxiliary Power Studs, Exterior

Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

Circuit Faults . . . . . . . . . . . . . . . . . . . . . . . 12-4
Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . 12-5
Fuse/Relay Location and Identification . . 12-10
Ground Points . . . . . . . . . . . . . . . . . . . . . 12-13
Preliminary Checks . . . . . . . . . . . . . . . . . . 12-3

Glovebox Replacement . . . . . . . . . . . . . . . . . 10-19
Glow Plug

Glow Plug and Injection Nozzle . . . . . . . . 2-90
Glow Plug Removal . . . . . . . . . . . . . . . . . . 2-54
Glow Plug Test . . . . . . . . . . . . . . . . . . . . . . 2-6
Operation and Testing . . . . . . . . . . . . . . . . . 2-6
Relay/Controller Replacement . . . . . . . . . . 3-40
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Glow Plugs

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 12-40
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 12-43

H

Halfshaft Boot Replacement . . . . . . . . . . . . . . 9-21
Heated Glass

Both Heated Windshields Inoperative . . . 12-92
Heated Windshield Schematic . . . . . . . . . 12-93
Left Heated Windshield Inoperative . . . . 12-90
Rear Window Defroster Inoperative . . . . 12-94

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Index

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Rear Window Defroster Schematic . . . . . 12-95
Right Heated Windshield Inoperative . . . 12-91

Hood

Center Hood Stop Replacement . . . . . . . . 10-49
Front Hood Screen Replacement . . . . . . . 10-50
Grille and Screen Replacement . . . . . . . . 10-49
Guide Bracket Assembly Replacement . . 10-50
Hood and Hinge Replacement . . . . . . . . . 10-47
Hood Latch And Prop Rod . . . . . . . . . . . 10-43
Hood Prop Rod and Bracket Replacement 10-45
Hood Release Cable Replacement . . . . . . 10-44
Hood Retainer Bracket, L . . . . . . . . . . . . 10-50
Hood Retainer Bracket, R . . . . . . . . . . . . 10-50
Latch and Bracket Replacement . . . . . . . 10-43
Outer Hood Seal Replacement . . . . . . . . . 10-48
Right Close-Out Seal and Retainer . . . . . 10-51
Side Hood Stop Replacement . . . . . . . . . 10-49

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-61

Horn Assembly Replacement . . . . . . . . . 10-53
Horn Replacement . . . . . . . . . . . . . . . . . . 12-61
Horn Schematic . . . . . . . . . . . . . . . . . . . . 12-63
Horns Inoperative . . . . . . . . . . . . . . . . . . . 12-62
Mounting Bracket Replacement . . . . . . . 10-53

Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30
Hummer Service Hotline . . . . . . . . . . . . . . . . . . 1-2
HVAC

Ambient Temperature Switch . . . . . . . . . 11-34
Auxiliary HVAC Unit

A/C Drain Tube(s) Replacement . . . . 11-48
Blower Motor Replacement . . . . . . . . 11-49
Blower Switch Replacement . . . . . . . 11-47
Evaporator/Heater Core Replacement 11-49
Expansion Valve Replacement . . . . . 11-50
Heater Hose Replacement . . . . . . . . . 11-47
High-Pressure Hose Replacement . . . 11-48
Low-Pressure Hose Replacement . . . 11-49
Replacement . . . . . . . . . . . . . . . . . . . . 11-46

Blend Door Motor . . . . . . . . . . . . . . . . . . 11-42
Compressor

Description . . . . . . . . . . . . . . . . . . . . . . 11-1

Condenser . . . . . . . . . . . . . . . . . . . . . . . . 11-34
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36
Defrost Duct and Windshield

Nozzles Replacement . . . . . . . . . . . . . . . 11-26

Drain Tube Replacement . . . . . . . . . . . . . 11-24
Essential Tools . . . . . . . . . . . . . . . . . . . . . 11-51
Heater Hose Replacement . . . . . . . . . . . . 11-22
High Pressure Cutoff Switch . . . . . . . . . . 11-35
Low Pressure Cutoff Switch . . . . . . . . . . 11-34
Main HVAC Unit . . . . . . . . . . . . . . . . . . . 11-37

Blower Motor . . . . . . . . . . . . . . . . . . . 11-38
Diverter Doors . . . . . . . . . . . . . . . . . . 11-37
Evaporator . . . . . . . . . . . . . . . . . . . . . 11-38
Expansion Valve . . . . . . . . . . . . . . . . 11-38
Heat Unit Cowl Insulation

Replacement . . . . . . . . . . . . . . . . . . . 11-24

Heater Core . . . . . . . . . . . . . . . . . . . . 11-38
High Pressure Cutoff Switch . . . . . . . 11-38
Replacement . . . . . . . . . . . . . . . . . . . . 11-39
Thermostatic Cycling Switch . . . . . . . 11-38

Rear Console Replacement . . . . . . . . . . . 11-46
Receiver Dryer Replacement . . . . . . . . . . 11-21
Receiver/Dryer . . . . . . . . . . . . . . . . . . . . . 11-34
Receiver/Dryer Pressure Switch

Replacement . . . . . . . . . . . . . . . . . . . . . . 11-21

Special Tools . . . . . . . . . . . . . . . . . . . . . . 11-52
Specifications . . . . . . . . . . . . . . . . . . . . . . 11-13
System Description . . . . . . . . . . . . . . . . . . 11-1
System Diagnosis . . . . . . . . . . . . . . . . . . . . 11-8
System Performance Checks . . . . . . . . . . . 11-2
Unit Service . . . . . . . . . . . . . . . . . . . . . . . 11-37
Vacuum Door Motor . . . . . . . . . . . . . . . . 11-41
Water Control Valve . . . . . . . . . . . . . . . . 11-22
Water Control Valve Replacement . . . . . 11-23

HVAC Systems

HVAC Blower Schematic . . . . . . . . . . . . 12-80
HVAC Compressor Inoperative . . . . . . . . 12-75
HVAC Compressor Schematic . . . . . . . . 12-82
HVAC Main Blower Inoperative

ALL BUT High . . . . . . . . . . . . . . . . . . . 12-75

HVAC Temp Blend Door/Rear Blower . . 12-81
HVAC Temperature Door Inoperative . . 12-77

Hydro-Boost

Bleeding the Hydro-boost System . . . . . . . 7-13
Hydro-Boost Replacement . . . . . . . . . . . . . 7-13

3-1-01