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Repair manual

Mechanical Hummer H2 I

Step-by-step instructions on "Mechanical" for Hummer H2 I (2002–2007). Pick an article — removal, installation, adjustment and diagnostics with illustrations.

Fastener Tightening Specifications

Engine Mechanical Specifications

Sealers, Adhesives, and Lubricants

Diagnostic Starting Point - Engine Mechanical

Strategy Based Diagnostics

Visual/physical Inspection

Intermittent

Symptom List

Base Engine Misfire Without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Abnormal Valve Train Noise

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Excessive Oil Consumption

Engine Noise on Start-Up, but Only Lasting a Few Seconds

Upper Engine Noise, Regardless of Engine Speed

Lower Engine Noise, Regardless of Engine Speed

Engine Noise Under Load

Engine Will Not Crank - Crankshaft Will Not Rotate

Coolant in Combustion Chamber

Coolant in Engine Oil

Engine Compression Test

Cylinder Leakage Test

Oil Consumption Diagnosis

Oil Pressure Diagnosis and Testing

Oil Leak Diagnosis

Crankcase Ventilation System Inspection/diagnosis

Diagnostic Aids

Test Description

Removal Procedure

Installation Procedure

Engine Mount Inspection

Valve Stem Oil Seal and Valve Spring Replacement

Cylinder Head Replacement - Left

Cylinder Head Replacement - Right

Tools Required

Crankshaft Balancer Replacement

Timing Chain and Sprockets Replacement

Engine Replacement

Draining Fluids and Oil Filter Removal

Crankshaft Balancer Removal

Engine Flywheel Removal

Oil Level Indicator and Tube Removal

Exhaust Manifold Removal - Left

Exhaust Manifold Removal - Right

Water Pump Removal

Throttle Body Removal

Fuel Rail and Injectors Removal

Intake Manifold Removal

Coolant Air Bleed Pipe Removal

Engine Valley Cover Removal

Valve Rocker Arm Cover Removal - Left

Valve Rocker Arm Cover Removal - Right

Valve Rocker Arm and Push Rod Removal

Cylinder Head Removal - Left

Cylinder Head Removal - Right

Valve Lifter Removal

Oil Filter, Adapter and Pan Cover Removal

Oil Pan Removal

Engine Front Cover Removal

Engine Rear Cover Removal

Oil Pump, Pump Screen and Deflector Removal

Timing Chain and Sprockets Removal

Camshaft Removal

Piston, Connecting Rod, and Bearing Removal

Crankshaft and Bearings Removal

Engine Block Plug Removal

Engine Block Cleaning and Inspection

Measuring the Cylinder for Taper, Out-Of-Round, and Oversize

Boring Procedure

Honing Procedure

Crankshaft and Bearings Cleaning and Inspection

Cleaning Procedure

Inspection Procedure

Measuring Main Bearing Clearance - Gaging Plastic Method

Measuring Connecting Rod Bearing Clearance - Gaging Plastic Method

Measuring Connecting Rod Bearing Clearance - Using J 43690/J 43690-100

Crankshaft Balancer Cleaning and Inspection

Engine Flywheel Cleaning and Inspection

Press-Fit Piston Pin

Full-Floating Piston Pin

Piston, Pin, and Piston Rings

Measuring Piston Ring End Gap

Connecting Rod and Bearings

Tool Usage Information

Camshaft and Bearings Cleaning and Inspection

Measuring Camshaft Lobe Lift

Camshaft Bearing Installation

Timing Chain and Sprockets Cleaning and Inspection

Valve Rocker Arm and Push Rods Cleaning and Inspection

Valve Lifters and Guides Cleaning and Inspection

Cylinder Head Disassemble

Cylinder Head Cleaning and Inspection

Valve Guide Reaming

Valve and Seat Grinding

Cylinder Head Assemble

Oil Pump Disassemble

Oil Pump Cleaning and Inspection

Oil Pump Assemble

Engine Front Cover Cleaning and Inspection

Engine Rear Cover Cleaning and Inspection

Engine Valley Cover Cleaning and Inspection

Valve Rocker Arm Cover Cleaning and Inspection

Oil Pan Cleaning and Inspection

Exhaust Manifold Cleaning and Inspection

Coolant Air Bleed Pipe Cleaning and Inspection

Water Pump Cleaning and Inspection

Thread Repair

Cylinder Head Bolt Hole Thread Repair

Main Cap Bolt Hole Thread Repair

Service Prior to Assembly

Engine Prelubing

Engine Block Plug Installation

Crankshaft and Bearings Installation

Piston, Connecting Rod, and Bearing Installation

Piston Selection

Piston, Pin, and Connecting Rod Installation

Camshaft Installation

Timing Chain and Sprockets Installation

Oil Pump, Pump Screen and Deflector Installation

Engine Rear Cover Installation

Crankshaft Rear Oil Seal Installation

Engine Front Cover Installation

Crankshaft Front Oil Seal Installation

Oil Pan Installation

Oil Filter, Adapter, Pan Cover Installation

Valve Lifter Installation

Cylinder Head Installation - Left

Cylinder Head Installation - Right

Valve Rocker Arm and Push Rod Installation

Valve Rocker Arm Cover Installation - Left

Valve Rocker Arm Cover Installation - Right

Engine Valley Cover Installation

Coolant Air Bleed Pipe Installation

Intake Manifold Installation

Fuel Rail and Injectors Installation

Throttle Body Installation

Water Pump Installation

Exhaust Manifold Installation - Left

Exhaust Manifold Installation - Right

Oil Level Indicator and Tube Installation

Engine Flywheel Installation

Crankshaft Balancer Installation

Crankcase Ventilation System Description

Drive Belt System Description

Camshaft and Drive System

Crankshaft

Cylinder Heads

Engine Block

Exhaust Manifolds

Intake Manifold

Oil Pan

Piston and Connecting Rod Assembly

Valve Rocker Arm Cover Assemblies

Valve Train

New Product Information

Torque Values And/or Fastener Tightening Strategies

Disassembly and Assembly Procedure Revisions

Engine Mechanical Diagnostic Procedure Revisions

New Special Tools Required

A Component Comparison from the Previous Year

Cleanliness and Care

Separating Parts

Gasket Use and Applying Sealants

Separating Components

Cleaning Gasket Surfaces

Assembling Components

Pipe Joint Compound

Rtv Sealer

Anaerobic Sealer

Tools and Equipment

Special Tools