Hummer H1 (1992-1998). Instruction - page 57

Change 1 2-189

2 - 4 3 . ENGINE RUN-IN (Cont’d)

3.

Remove engine load and idle until temperatures drop.

3.1.

Test governor speed with a WOT no-load test for 30 seconds.

4.

Stop engine and inspect for and correct any leaks.

5.

Disconnect engine from dynamometer.

Table 2-1. 6.2 L Engine Run-In Schedule.

Speed (rpm)

Time (Minutes)

Torque

Lb-Ft

N

m

725

5

0

0

2000

30

103

140

3000

30

133

180

3400

30

146

198

Max

30

No Load

3400

30

WOT*

* WOT – Wide OpenThrottle. Final test interval at 3600 rpm will

verify the power level of the engine. Power output should be
approximately 150 hp (112 kW) and 219 lb-ft (297 N

m) of torque.

NOT E

Power output should be 135 hp (100.8 kW) and 197.1 lb-ft
(267.3 N

m) of torque when using JP-8 fuel.

Speed (rpm)

Time (Minutes)

Torque

Lb-Ft

N

m

650

5

0

0

1200

30

80

109

2000

30

94

128

3000

40

140

190

3600

15

WOT*

4000

0.5

WOT*

Table 2-1.1. 6.5 L (NA) and 6.5 L (T) Engine Run-In Schedule.

* WOT – Wide OpenThrottle. Final test interval at 3400 rpm will

verify the power level of the engine. Power output should be
approximately 160 hp (119 kw) at 247 lb-ft (335 N

m) of torque for

naturally aspirated engine. For turbocharged engine, power output
should be 190 hp (142 kw) at 293.5 lb-ft (398 N

m) of torque.

Section VII. REPAIR AND REPLACEMENT STANDARDS

2-44. GENERAL

All parts, components or assemblies which do not meet the standards specified in para. 2-45 will be
replaced with new material. Parts must be closely inspected to ensure there is no damage in areas not
listed, which would make them unfit for further use.

2-45. REPAIR AND REPLACEMENT STANDARDS

Tables 2-2 and 2-3 list general specifications to be utilized while repairing the engine.

Table 2-2. General Repair Standards (6.2L).

Cylinder Bore

Diameter
Out of Round
Taper - Thrust Side

Piston

Piston Clearance – # 1,2, 3,4,5,6
Piston Clearance - #7, 8

Compression Rings

Groove Clearance:

Top
Second

Gap:

Top
Second

Oil Ring

Groove Clearance
Gap

Piston Pin

Diameter
Clearance
Fit in Rod

Camshaft

Lift:

Intake
Exhaust

Journal Diameter – # 1,2,3,4
Journal Diameter - # 5
Journal Clearance

Crankshaft

Main Journal Diameter - # 1,2,3,4
Main Journal Diameter – # 5

Taper
Out of Round

Main Bearing Clearance - # 1,2,3,4,5
End Play

STANDARD

3.976-3.979 in.
0.0008 in.
0.0008 in.

0.0035-0.0045 in.
0.004-0.005 in.

0.003-0.007 in.
0.002-0.003 in.

0.012-0.022 in.
0.030-0.039 in.

0.002-0.004 in.
0.010-0.020 in.

1.2203-1.2206 in.

0.0003-0.0006 in.
0.0003-0.0010 in.

0.281±.002 in.
0.281±.002 in.
2.164-2.166 in.
2.007-2.009 in.
0.001-0.004 in.

2.949-2.950 in.
2.949-2.950 in.
0.0002 in. max.
0.0002 in. max.
0.002-0.004 in.
0.004-0.010 in.

METRIC

100.990-101.066 mm

0.0203 mm max.
0.0203 mm max.

0.0889-0.1143 mm
0.102-0.127 mm

0.076-0.178 mm
0.051-0.076 mm

0.30-0.55 mm
0.76-1.0 mm

0.051-0.102 mm
0.25-0.51 mm

30.9956-31.0032 mm
0.0076-0.0153 mm
0.0076-0.025 mm

7.137±0.05 mm
7.137±0.05 mm
54.965-55.016 mm
50.978-51.029 mm

0.025-0.102 mm

74.905-74.930 mm
74.905-74.930 mm
0.0051 mm max.
0.0051 mm max.
0.051-0.102 mm
0.102-0.254 mm

2-190

2-45. REPAIR AND REPLACEMENT STANDARDS (Cont’d)

Table 2-2. General Repair Standards (6.2L) (Cont’d).

Crankshaft (Cent’d)

Crankpin:

Diameter
Taper
Out of Round
Rod Bearing Clearance
Rod Side Clearance

Valve Train

Rocker Arm Ratio
Face Angle
Seat Angle
Seat Runout
Seat Width:

Intake
Exhaust

Stem Clearance:

Intake
Exhaust

Valve Spring Force

Closed
Open
Installed Height

Timing Chain Deflection

New Chain
Old Chain

STANDARD

2.398-2.399 in.
0.0002 in. max.
0.0002 in. max.

0.002-0.004 in.
0.007-0.025 in.

1.5:1

45°
46°
0.002 in.

0.035-0.060 in.
0.062-0.093 in.

0.001-0.003 in.
0.001-0.003 in.

80 lb @ 1.8 in.
230 lb@ 1.39 in.
1.8 in.

0.5 in. max.
0.81 in. max.

METRIC

60.909-60.935 mm
0.0051 mm max.
0.0051 mm max.
0.051-0.102 mm

0.178-0.635 mm

1.5:1

45°
46°
0.05 mm

0.89-1.52 mm

1.57-2.36 mm

0.025-0.076 mm
0.025-0.076 mm

356 N @ 46.0 mm

1023 N @ 35.3 mm

46.0 mm

12.7 mm max.

20.6 mm max.

Table 2-3. General Repair Standards (6.5L).

Cylinder Bore

Diameter
Out of Round
Taper - Thrust Side

Piston

Piston Clearance - # 1,2,3,4, 5,6
Piston Clearance - # 7,8

Compression Rings

Groove Clearance:

Top
Second

Gap:

Top
Second

Oil Ring

Groove Clearance
Gap

STANDARD

3.978-3.981 in.
0.0008 in.
0.0008 in.

0.0035-0.0045 in.
0.004-0.005 in.

0.003-0.007 in.
0.002-0.003 in.

0.012-0.022 in.
0.030-0.039 in.

0.002-0.004 in.
0.010-0.020 in.

METRIC

101.041-101.12 mm

0.0203 mm max.
0.0203 mm max.

0.0889-0.1143 mm
0.102-0.127 mm

0.076-0.178 mm
0,051-0.076 mm

0.30-0.55 mm
0.76-1.0 mm

0.051-0.102 mm
0.25-0.51 mm

2-45. REPAIR AND REPLACEMENT STANDARDS (Cont’d)

Table 2-3. General Repair Standards (6.5L) (Cont’d).

Piston Pin

Diameter
Clearance
Fit in Rod

Camshaft

Lift:

Intake
Exhaust

Journal Diameter - # 1,2,3,4
Journal Diameter – # 5
Journal Clearance

Crankshaft

Main Journal Diameter - # 1,2, 3,4
Main Journal Diameter – # 5

Taper
Out of Round

Main Bearing Clearance – # 1,2,3,4,5
End Play
Crankpin:

Diameter
Taper
Out of Round
Rod Bearing Clearance
Rod Side Clearance

Valve Train

Rocker Arm Ratio
Face Angle
Seat Angle

Seat Runout
Seat Width:

Intake
Exhaust

Stem Clearance:

Intake

Exhaust

Valve Spring Force

Closed
Open
Installed Height

Timing Chain Deflection

New Chain
Old Chain

STANDARD

1.2203-1.2206 in.

0.0003-0.0006 in.
0.0003-0.0010 in.

0.281±0.002 in.
0.281±.002 in.
2.164-2.166 in.
2.007-2.009 in.
0.001-0.004 in.

2,949-2.950 in.
2.949-2.950 in.
0.0002 in. max.
0.0002 in. max.
0.002-0.004 in.
0.004-0.010 in.

2.398-2.399 in.
0.0002 in. max.
0.0002 in. max.
0.002-0.004 in.
0.007-0.025 in.

1.5:1

45°
46°
0.002 in.

0.035-0.060 in.
0.062-0.093 in.

0.001-0.003 in.
0.001-0.003 in.

80 lb @ 1.8 in.
230 lb@ 1.39 in.

1.8 in.

0.5 in. max.
0.81 in. max.

METRIC

30.9956-31.0032 mm
0.0076-0.0153 mm
0.0076-0.025 mm

7.137±0.05 mm
7.137±0.05 mm

54.965-55.016 mm
50.978-51.029 mm
0.025-0.102 mm

74.905-74.930 mm
74.905-74.930 mm
0.0051 mm max.
0.0051 mm max.
0.051-0.102 mm
0.102-0.254 mm

60.909-60.935 mm
0.0051 mm max.
0.0051 mm max.
0.051-0.102 mm
0.178-0.635 mm

1.5:1

45°
46°
0.05 mm

0.89-1.52 mm

1.57-2.36 mm

0.025-0.076 mm
0.025-0.076 mm

356 N @ 46.0 mm

1023 N @ 35.3 mm

46.0 mm

12.7 mm max.

20.6 mm max.

2-192

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