Hummer H1 (1992-1998). Instruction - page 3

c. Bearings.

CAUTION

All engine connecting rod and main bearings will be replaced if one
o r m o r e b e a r i n g s f a i l .

C h e c k a l l b e a r i n g s f o r c o n f o r m a n c e t o a p p l i c a b l e r e p a i r s t a n d a r d s .

d. Bushings and Bushing-Type Bearings.

(1) Check all bushings and bushing-type bearings for secure fit, evidence of heating, wear, burrs,

nicks, and out-of-round conditions.

from

e.

f.

g.

h.
i.

j.

(2) Check for dirt in lubrication holes or grooves. Holes and grooves must be clean and free

damage.

Machined Parts.

(1) Check machined parts for cracks, distortion, and damage.
(2) Check all surfaces for nicks, burrs, and raised metal.

Studs, Bolts, and Capscrews. Replace if bent, loose, stretched, or threads are damaged.
Gears.

NOTE

When gear teeth wear limits are not established, good judgment is
required to determine if gear replacement is necessary.

(1) Inspect all gears for cracks and missing teeth. Replace if cracked or teeth are missing.
(2) Inspect gear teeth for wear, sharp fins, burrs, and galled or pitted surfaces.
(3) Inspect splines for wear, burrs, and galled or pitted surfaces.
(4) Check keyway slots for wear and/or damage.
Oil Seals. Oil seals are mandatory replacement items.
Casting Plugs. Inspect for leakage. Replace plugs when leakage is present.
Springs. Inspect for damaged, distorted, and collapsed coils.
Snaprings, Retaining Rings, and Washers. Many of these parts are mandatory replacement

k.

items. Inspect all others for obvious damage.

2 - 1 1 . R E P A I R

a. General Instructions. Repair of most parts and components is limited to general procedures

outlined in applicable maintenance instructions and the following detailed procedures “b” through “h”.

CAUTION

Repaired items must be thoroughly cleaned to remove metal chips
and abrasives to prevent them from entering working parts of

the engine.

b. Castings.

(1) All cracked castings will be replaced.
(2) Only minor repairs to machined surfaces, flanges, and gasket mating surfaces are permitted.

Remove minor nicks, burrs, and/or scratches with:

(a) Fine mill file.

(b) Abrasive crocus cloth dipped in cleaning solvent.
(c) Lapping across a surface plate.
(d) Remachining of machined surfaces to repair damage, warpage, or uneven surfaces is not

permitted. Replace castings.

(3) Repair damaged threaded pipe plug and/or capscrew holes with a thread tap or repair oversize

holes with threaded inserts.

2-5

c. Bearings. See TM 9-214.
d. Studs. Replace all bent and stretched studs. Repair minor thread damage with a thread restorer file.

Replace studs having stripped or damaged threads as outlined below:

(1) Remove, using a stud remover. Back studs out slowly to avoid heat buildup and seizure which

can cause stud to break off.

(2) If studs break off too short to use with a stud remover, use extractor to remove.

(3) Replacement studs have a special coating and must have a small amount of antiseize compound

(Appendix B, Item 3) applied on threads before stud is installed. Install replacement stud slowly to prevent
heat buildup and snapping off.

e. Gears.

(1) Remove gears using pullers, as required.
(2) Use the same methods described in paragraph 2-11.b.(2) for castings t

O

remove minor nicks,

burrs, or scratches on gear teeth.

(3) If keyways are worn or enlarged, replace gear.

f.

Bushings and BushingType Bearings. When bushings and bushing-type bearings seize to a

shaft and spin in the bore, the associated part must also be inspected and replaced, as required.

g. Oil Seals.

(1) Remove oil seals, being careful not to damage casting or adapter bore.
(2) Always install new seal in bore using proper seal replacing tool.

h. Cylinder Block or Cylinder Head. Repair of cylinder block and cylinder head is limited to

procedures outlined in paragraphs 2-16 and 2-21. Cylinder block or cylinder head must be replaced if

measurements are outside tolerance limits listed in table 2-2 or table 2-3.

2-12. ASSEMBLY

a. Cleanliness is essential in all component assembly operations. Dirt and dust, even in minute

quantities, are abrasive. Parts must be cleaned as specified, and kept clean. Wrap or cover parts and
components when assembly procedures are not immediately completed.

b. Coat all bearings and contact surfaces with engine oil (MIL-L-2104) to ensure lubrication of parts

during initial operation after repair.

c. Use new gaskets and preformed packings during assembly of all components.

2-6

Change 1 2-6.1

Section V. ENGINE DISASSEMBLY, REPAIR, AND ASSEMBLY

2 - 1 3 . ENGINE DISASSEMBLY, REPAIR, AND ASSEMBLY TASK SUMMARY

T A S K

P R O C E D U R E S

P A G E

P A R A .

N O .

2-13.1.

Engine Replacement in Shipping/Storage Container

2-6.2

2-14.

Mounting Engine on Repair Stand

2-8

2-15.

Engine Disassembly into Subassemblies

2-10

2-16.

Cylinder Block Repair

2-40

2-17.

Crankshaft Repair

2-52

2-18.

Connecting Rod and Piston Repair

2-54

2-19.

Camshaft, Timing Chain, and Drive Gears Repair

2-58

2-20.

Timing Gear Cover Repair

2-60

2-21.

Cylinder Head and Valve Repair

2-62

2-22.

Valve Train Repair

2-72

2-23.

Torsional Damper Repair

2-74

2-24.

Flywheel Repair

2-75

2-25.

Rocker Arm Cover Repair

2-76

2-26.

Oil Pan Repair

2-77

2-27.

Oil Pump Repair

2-78

2-28.

Oil Filter Adapter and Oil Pressure Sending Unit Repair

2-82

2-29.

Exhaust Manifold Repair

2-83

2-30.

Intake Manifold Repair

2-84

2-31.

Fuel Pump Repair

2-85

2-32.

Fuel Injection Pump Repair (All Models)

2-86

2-33.

Pre-1990 (6.2L) Fuel Injection Pump (DB2829-4523) Calibration

2-126

2-34.

1990 (6.2L) Fuel Injection Pump (DB2829-4879) Calibration

2-131

2-35.

(6.5L) Fuel Injection Pump (DB2831-5149) Calibration

2-136

2-35.1.

(6.5L) Fuel Injection Pump (DB2831-5209) Calibration

2-140.1

2-35.2.

(6.5L) Fuel Injection Pumps (DB2831-5485 or DB2831-5079)
Calibration

2-140.6

2-35.3.

(6.2L or 6.5L) Fuel Injection Pumps (DB2829-4523, DB2829-4879,
or DB2831-5149) Calibration Using Fuel Injection Pump Test
Stand (FTIS) Model A8022

2 - 1 4 0 . 1 2

2-36.

Glow Plug Repair

2-141

2-37.

Fuel Injection Nozzle Repair

2-142

2-38.

Water Pump Repair

2-144

2-39.

Water Crossover Repair

2-146

2-40.

Fan Drive Repair

2-148

2-41.

Engine Assembly from Subassemblies

2-153

2 - 1 3 . 1 . ENGINE REPLACEMENT IN SHIPPING/STORAGE CONT

A I N E R

This task covers:

a. Removal

b.

Installation

INITIAL SETUP:

Tools

General mechanic’s tool kit:

automotive (Appendix E, Item 1)

Special Tools

Engine lifting sling (Appendix E, Item 3)

Materials/Parts

Eight lockwashers (Appendix D, Item 26.1)

Manual References

Personnel Required

One mechanic

One assistant

General Safety Instructions

Direct personnel to stand clear during hoisting
operation.

2 - 6 . 2

Change 1

a. Removal

1.

If engine container (5) is closed and sealed, press air-release button (1) located at center of breather
valve (2) before opening engine container (5).

2.

Remove twenty-six nuts (19), washers (18), capscrews (16), and upper container (4) from lower
container (13).

3.

Position engine lifting sling on engine assembly (6) and install sling on right cylinder head (25) with
two capscrews (24).

4.

Install sling bracket (21) to engine lifting sling with pin (22) and on left cylinder head (20) with two
capscrews (23). Tighten capscrews (23).

5.

Remove four capscrews (14), lockwashers (8), and washers (7) from two engine mounts (12). Discard
lockwashers (8).

6.

Remove four capscrews (9), lockwashers (8), and washers (7) from two rear engine mounts (10).
Discard lockwashers (8).

WARNING

Direct personnel to stand clear during hoisting operation. Failure to do this

may cause injury to personnel.

7.

Attach hoist to engine lifting sling and remove engine assembly (6) from lower container (13).

8.

Position engine on repair stand (para. 2-14).

b. Installation

1.

Install engine assembly (6) in lower container (13).

2.

Install engine assembly (6) on two rear engine mounts (10) with four washers (7),
lockwashers (8), and capscrews (9).

3.

Install engine assembly (6) on two engine mounts (12) with four washers (7), lockwashers (8), and
capscrews (14).

4.

Remove pin (22) from sling bracket (21).

5.

Remove two capscrews (24) and lifting sling from right cylinder head (25).

6.

Remove two capscrews (23) and sling bracket (21) from left cylinder head (20).

7.

Visually check humidity indicator (17) for discolorization. If indicator (17) is dark purple, replace
desiccant (3).

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