Hummer H1 (2006+). Manual — part 30

2-26

Engine

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ROCKER ARM COVER SERVICE

Right Side Upper & Lower Cover Removal

Upper Cover

1.

Disconnect and isolate the negative battery cable.

2.

Remove the engine cover.

3.

Remove the air horn and the inlet hose.

4.

Remove the air cleaner assembly.

5.

Remove the charged air cooler outlet duct from the intake.

6.

Remove the exhaust gas recirculation (EGR) cooler tube (Refer to section 3).

7.

Remove the fuel injection control module (Refer to section 3).

8.

Remove the fuel injection control module bracket.

Figure 2-16: Rocker Arm Cover Upper Removal/Installation (Right Side)

9.

Remove the transmission dip stick.

10. Remove the transmission harness bracket.

11. Remove the clips securing the injector/glow plug harness to the cover.

12. Remove the fuel injector high pressure lines (Refer to section 3).

13. Remove the right upper valve rocker arm cover bolts and remove the cover (Figure 2-16).

Lower Cover

14. Remove the fuel injectors (Refer to section 3).

15. Remove the bolts securing the lower valve rocker arm cover to the head and remove the cover.

Right Side Cover Upper & Lower Installation

Lower Cover

1.

Inspect the lower valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.

2.

Install the lower valve rocker arm cover and torque the bolts in the sequence shown (Figure 2-18) to 89þlb-in. (10þN·m).

3.

Install the fuel injectors.

Upper Cover

4.

Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.

5.

Install the upper valve rocker arm cover and torque the bolts in the sequence shown (Figure 2-17) to 71þlb-in. (8þN·m).

UPPER ROCKER

ARM COVER

GASKET

LOWER

COVER

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Engine 2-27

5745804

6.

Install the fuel injector pipes (Refer to section 3).

7.

Install the clips securing the injector/glow plug harness to the cover.

8.

Install the transmission harness bracket.

9.

Install the transmission dip stick.

10. Install the fuel injection control module bracket.

11. Install the fuel injection control module (Refer to section 3).

12. Install the exhaust gas recirculation (EGR) cooler tube (Refer to section 3).

13. Install the charged air cooler inlet duct connector to the turbocharger and torque the clamp to 53þlb-in. (6þN·m).

14. Install the air cleaner assembly.

15. Install the air horn and the inlet hose.

16. Install the engine cover.

17. Connect the negative battery cable.

Figure 2-17: Rocker Arm Cover Right Upper Torque Sequence

Figure 2-18: Rocker Arm Cover Right Lower Torque Sequence

Left Side Upper & lower Cover Removal

Upper Cover

1.

Disconnect and isolate the negative battery cable.

2.

Remove the engine cover (Refer to section 10).

3.

Remove the charged air cooler inlet duct connector from the turbocharger.

2

8

4

1

14

12

10

6

3

7

11

13

5

9

05-S02-102

6

15

10

13

3

16

7

14

11

2

9

5

4

8

12

1

05-S02-100

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2-28

Engine

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4.

Drain the engine coolant.

5.

Disconnect the main engine electrical harness connectors.

6.

Remove the main engine electrical harness connector hold down bolts.

7.

Remove the main electrical connector harness bracket bolts and remove the bracket.

8.

Remove the water outlet tube.

9.

Remove the positive crankcase ventilation (PCV) hose/pipe.

10. Remove the left fuel injector pipes (Refer to section 3).

11. Remove the upper valve rocker arm cover bolts and remove the cover (Figure 2-19).

Lower Cover

12. Remove the fuel injectors (Refer to section 3).

13. Remove the lower valve rocker arm cover bolts and remove the cover (Figure 2-20).

Figure 2-19: Upper Rocker Arm Cover (Left Side)

Figure 2-20: Lower Rocker Arm Cover (Left Side)

UPPER ROCKER

ARM COVER

GASKET

LOWER ROCKER

ARM COVER

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Engine 2-29

5745804

Left Side Upper & lower Cover Installation

Lower Cover

1.

Inspect the lower valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.

2.

Install the lower valve rocker arm cover and torque the bolts in the sequence shown (Figure 2-21) to 89þlb-in. (10þN·m).

3.

Install the fuel injectors (Refer to section 3).

Figure 2-21: Rocker Arm Cover Left Lower Torque Sequence

Upper Cover

4.

Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.

5.

Install the upper valve rocker arm cover and torque the bolts in the sequence shown (Figure 2-22) to 71þlb-in. (8þN·m)

6.

Install the fuel injector pipes (Refer to section 3).

7.

Install the water outlet tube.

8.

Install the PCV hose/pipe.

9.

Install the main electrical connector harness bracket and torque the bolts to 15þlb-ft. (21þN·m).

10. Install the main engine electrical harness connector hold down bolts and torque to 89þlb-in. (10þN·m).

11. Connect the main engine electrical harness connectors.

12. Install the charged air cooler inlet duct connector to the turbocharger and torque the clamp to 53þlb-in. (6þN·m).

13. Install the engine cover (Refer to section 10).

14. Fill and bleed the cooling system.

15. Connect the negative battery cable.

Figure 2-22: Rocker Arm Cover Left Upper Torque Sequence

6

15

10

13

3

16

7

14

11

2

9

5

4

8

12

1

05-S02-100

2

8

4

5

9

1

14

12

10

6

3

7

11

13

05-S02-102

11-1-05