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