Hummer H1 User manual

H1 HUMMER
SERVICE
MANUAL
COMMERCIAL
HUMMER
®
AM GENERAL CORPORATION
408 South Byrkit Avenue
P. O . B o x 7 2 8
Mishawaka, Indiana 46546-0728
AM General Number 05745159
Copyright
©2002
All Rights Reserved. Printed in U.S.A.
TABLE OF CONTENTS
General Information 1
Engine 2
Fuel, Emissions and Exhaust 3
Cooling System 4
Transmission/Transfer Case 5
Wheels and Tires/
Central Tire Inflation System 6
Brake System 7
Steering System 8
Axles/Suspension and Frame 9
Body 10
Heating/Ventilation/
Air Conditioning (HVAC) 11
Electrical 12
Accessories 13
Index 14

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1-1
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05745159
Section 1
General Information, Lubrication and Maintenance
TABLE OF CONTENTS
Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
About This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Bolt Identification and Torque Limits (Dry*) . . . . . . . . . . . . . . .1-13
Bolt Identification and Torque Limits (Wet*). . . . . . . . . . . . . . .1-14
Carbon Monoxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Emission Control information Label . . . . . . . . . . . . . . . . . . . . . .1-3
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
EPA Noise Emission Control Information Label. . . . . . . . . . . . .1-5
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-31
Fluid Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Hummer Service Hotline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Lubrication and Maintenance Items. . . . . . . . . . . . . . . . . . . . . .1-25
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21
Miscellaneous essential Tools. . . . . . . . . . . . . . . . . . . . . . . . . .1-33
Paint and Trim Colors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Recommended Fuel/Fluids/Lubricants/Capacities . . . . . . . . .1-24
Replacement Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
Safety Certification Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Scheduled Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Service Manual Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
Towing, Lifting, Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Transfer Case Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
U.S./Metric Conversions and Equivalents . . . . . . . . . . . . . . . .1-15
Vehicle Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Vehicle Identification Number (VIN) . . . . . . . . . . . . . . . . . . . . . .1-5
Vehicle Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
SAFETY SUMMARY
Individuals who decide to perform their own repairs should
have proper training and limit repairs to components which
will not affect the safety of the vehicle or its occupants.
When replacement parts are required, it is strongly recom-
mended that they are purchased through an authorized HUM-
MER dealer. It is essential that replacement parts meet or
exceed manufacturerÕs specifications. Vehicle performance
and personal safety may be impaired if other than original fac-
tory components are installed.
The installation of nonapproved accessories or conversions is
not recommended as they could affect the vehicleÕs driving
characteristics and personal safety. AM General Corporation
will not be liable for personal injury or damage to property re-
sulting from the installation of nonapproved accessories or
conversions to the HUMMER.
Following the safety precautions as prescribed throughout this
manual may greatly reduce the risks of personal injury and
damage to the vehicle. However, it is unlikely that AM General
Corporation will account for all possibilities.
Warnings, cautions, and notes are used throughout this service
manual to assist service personnel in the performance of main-
tenance actions. These statements are designed as reminders
for trained and experienced service personnel.
WARNINGS Ñ Indicate potential safety hazards and must be
followed to avoid personal injury. Warnings appear as follows:
CAUTIONS Ñ Indicate potential equipment damage, and
must be followed to avoid damage to components or systems.
An example of a caution is shown below:
NOTES Ñ Indicate methods or actions that may simplify ve-
hicle maintenance or help maintain vehicle performance. An
example of a note is shown below:
WARNING: To avoid injury, do not remove surge
tank filler cap before depressurizing cooling system
when engine temperature is above 190° F (88° C).
CAUTION: To avoid starter damage, do not operate
starter continuously for more than 15 seconds. Wait 10
to 15 seconds between periods of operation.
NOTE: Clean all components, examine for wear or dam-
age, and replace if necessary.

1-2 General Information, Lubrication and Maintenance
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CARBON MONOXIDE
WARNING: Carbon monoxide (exhaust gases) can be
fatal.
WARNING: Brain damage or death can result from
heavy exposure to carbon monoxide. The following pre-
cautions must be followed to ensure personal safety.
1. Do not operate vehicle engine in enclosed areas. Do not
idle the vehicle engine with vehicle windows closed. Be
alert at all times for exhaust odors. Be alert for exhaust
poisoning symptoms. They are:
¥ Headache
¥ Dizziness
¥ Sleepiness
¥ Loss of muscular control
2. If you see another person with exhaust poisoning
symptoms:
¥ Remove person from area
¥ Expose to open air
¥ Keep person warm
¥ Do not permit physical exercise
¥ Administer artificial respiration, if necessary
¥ Notify medical personnel
The best defense against exhaust poisoning is adequate ventila-
tion.
ABOUT THIS MANUAL
This service manual contains instructions for maintaining the
commercial HUMMER. Spend some time looking through this
manual. Features to improve the usefulness of this manual and
increase your efficiency are:
Accessing Information - These include: tabulated sections for
quick reference, extensive troubleshooting guides for specific
systems, and step-by-step directions for service repairs.
Illustrations - A variety of methods are used to make locating
and repairing components easy. Locator illustrations, exploded
views, and cut-away diagrams make the information in this
manual easy to understand.
The service manual is the best source available for providing
information and data critical to vehicle operation and mainte-
nance. In this manual you will find the following information:
¥ Safety Summary
¥ General Information
¥ General Service Procedures
¥ Detailed Service Procedures
¥ Torque Ranges
¥ Wiring Diagrams and Schematics
HUMMER owners and dealership service personnel can sub-
mit service manual suggestions and comments in writing to:
AM General Corporation
Commercial Publications Department
408 S. Byrkit St.
P.O. Box 728
Mishawaka, IN 46546-0728
Forms are furnished at the end of this manual.
Service Manual Revisions
In order to receive future revisions to this service manual,
please write to:
AM General Corporation
Service Parts Logistics Operations
Commercial Publications/Customer Service
408 South Byrkit Avenue
P.O. Box 728
Mishawaka, Indiana 46546-0728
Be sure to specify publication number.
HUMMER SERVICE HOTLINE
On occasion, an unusual service problem can arise that is not
covered in the manual. For this reason, AM General Corpora-
tion has established a service hotline for dealership assistance.
The hotline number is: 1-800-638-8303
Transfer Case Hotline
If you have questions that are not answered in Section 5 of this
Service Manual, you can call the Transfer Case Hotline at
1-800-945-4327 (in the U.S.) for more information. Interna-
tional and Canadian customers and dealers should call
1-315-432-4110 .

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General Information, Lubrication and Maintenance 1-3
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05745159
EMISSION CONTROL INFORMATION LABEL
The vehicle emission control label contains engine information
such as curb idle rpm, engine displacement, catalytic converter
type, fuel rate, and vacuum hose routing.
This label is affixed to the air cleaner housing (Figure 1-1).
Figure 1-1: Emission Control Information Label Information

1-4 General Information, Lubrication and Maintenance
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SAFETY CERTIFICATION LABEL
The safety certification label is located on the driver side B-
pillar (door latch post) (Figures 1-2, 1-3, and 1-4). The label is
required by the National Highway Traffic Safety Administra-
tion and includes a tamper-proof feature. If the label is tam-
pered with, a void pattern will appear across the label.
The label contains the name of the manufacturer, the month
and year the vehicle was manufactured, the certification state-
ment, the vehicle identification number (VIN), and the vehicle
model type. It also contains the Gross Vehicle Weight Rating
(GVWR), Gross Axle Weight Ratings (GAWR), and wheel
and tire information. For more information on the GVWR and
GAWR, refer to ÒVEHICLE LOADING INFORMATIONÓ in
the Hummer OwnerÕs Manual.
Figure 1-2: Safety Certification Label
for Fleet Vehicles (12,100 lb. GVW vehicles)
Figure 1-3: Safety Certification Label for
10,300 lb GVWR Vehicles
Figure 1-4: Safety Certification Label for
10,800 lb GVWR Vehicles
TRANSMISSION IDENTIFICATION
The 4L80-E automatic transmission serial number is located on
a plate at the right side of the transmission (Figure 1-5).
Figure 1-5: Transmission I.D. Plate Location
TRANSMISSION
I.D. PLATE

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General Information, Lubrication and Maintenance 1-5
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05745159
EPA NOISE EMISSION CONTROL INFORMA-
TION LABEL
The EPA noise emission control information label is located on
the passenger side B-pillar (door latch post). The label is re-
quired by the EPA and includes a tamper-proof feature. If the
label is tampered with, a void pattern will appear across the la-
bel. Notify the dealer or the manufacturer if the label is missing
or displays a void pattern (Figure 1-6).
The label contains the name of the manufacturer, the month
and year the vehicle was manufactured, a statement regarding
vehicle conformance to applicable U.S. EPA regulations, and a
description of acts prohibited by the Noise Control Act of
1972.
Figure 1-6: EPA Noise Emission Control
Information Label Location
TRANSFER CASE IDENTIFICATION
The transfer case serial and assembly numbers are located on a
tag attached to the rear case (Figure 1-7).
Figure 1-7: Transfer Case I.D. Plate Location
ENGINE IDENTIFICATION
The engine serial number label is located at the rear of the left
cylinder head (Figure 1-8).
Figure 1-8: Engine I.D. Label Location
VEHICLE IDENTIFICATION NUMBER (VIN)
The VIN plate is located at the upper left front corner of the
dashpad (Figure 1-9).
Figure 1-9: VIN Plate Location
The first twelve digits of the seventeen digit VIN are explained
in the chart on the following page.
TRANSFER CASE SERIAL NUMBER
(ON ID PLATE)
ENGINE SERIAL
NUMBER LABEL
VIN PLATE

1-6 General Information, Lubrication and Maintenance
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1 3 7 Y A 89 3 4 Y E 000001
Digit 1
Manufacturing
Country
Digit 2
Company/Make
Digit 3
Vehicle Type
Digit 4
Engine Type
Digit 5
Transmission/Drive
Digit 6 and 7
Truck Line Series
Model, Body Type
Digit 12
Sequential,
Assigned
Serial Number
Digit 11
Plant Code
Digit 10
Model Year
Digit 9
Check Digit
Digit 8
GVWR
through 17
Vehicle Identification Number Decoding Chart
Digit Code Code Definition
1 1 United States
2 3 AM General Corporation
3 7 Commercial Vehicles
Z 6.5L (395 in.
3
),Turbocharged Diesel, GM, 8 cyl., 195 hp
5 A 4-Speed, Automatic/LHD
6 & 7 83 1-1/4 ton 4-door Truck, utility – HMC4
84 1-1/4 ton Station wagon Truck, utility – HMCS
89 1-1/4 ton 2-door enlarged cab Truck, utility – XLC2
90 1-1/4 ton Open body w/full hard doors Truck, utility – HMCO
8 3 Class 3, 10,001 lb - 14,000 lb (4,541 kg - 6,356 kg)
9 — Check Digit
10 Y 2000
11 E Mishawaka, Indiana
12-17 — Sequential Serial Number
3-1-01

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General Information, Lubrication and Maintenance 1-7
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05745159
COMPONENT DATA
Engine:
Manufacturer .................................................................................................................................................................GM Powertrain
Model ........................................................................................................................................................................... 6.5 L (395 in.
3
)
Type.........................................................................................................................Four Cycle, Turbocharged Diesel, Liquid-Cooled
Power Output: ..................................................................................................... 195 HP @ 3400 rpm/430 ft lb. Torque @ 1800 rpm
Engine Dimensions:
Length.............................................................................................................................................................................. 35 in. (89 cm)
Width............................................................................................................................................................................... 28 in. (71 cm)
Height .............................................................................................................................................................................. 28 in. (71 cm)
Net Weight, Dry ............................................................................................................................................................701 lb (318 kg)
Governed Speed:
Full Load ............................................................................................................................................................................ 3,400 RPM
No Load.............................................................................................................................................................................. 3,650 RPM
Idle Speed............................................................................................................................................................................... 700 RPM
Operating Speed ........................................................................................................................................................1,500-2,600 RPM
Cylinders:
Number.................................................................................................................................................................................................8
Arrangement................................................................................................................................................................................. 90¡ V
Firing Order..............................................................................................................................................1-8-7-2-6-5-4-3 (Clockwise)
Bore ......................................................................................................................................................................4.06 in. (103.12 mm)
Stroke ......................................................................................................................................................................... 3.82 in. (9.7 cm)
Displacement.................................................................................................................................................................6.5 L (395 in.
3
)
Compression Ratio: ......................................................................................................................................................................20.2:1
Lubricating System:
Type................................................................................................................................................................................. Pressure Feed
Operating Pressure:
(Minimum)................................................................................................................................. 30 psi (206.8 kPa) @ 2000 RPM
(Idle Minimum)..................................................................................................................................................... 6 psi (41.3 kPa)
System Capacity (Filter Included)...................................................................................................................................... 8 qt (7.6 L)
Operating Temperature (Normal)................................................................................................................. 180¡-275¡ F (82¡-135¡ C)
Oil Pump ............................................................................................................................................................................High Output
Filter ................................................................................................................................................................ Paper Element, Spin On
Fuel/Air System:
Fuel Supply Pump Type....................................................................................................................................................... Electronic
Fuel Filter Type...................................................................................................................... Two Stage Fuel Filter /Water Separator
Glow Plug Type ...........................................................................................................................................................(11G) Fast Start
Starter:
Manufacturer ...........................................................................................................................................................................Prestolite
Model ...........................................................................................................................................................................................MMO
Capacity (Peak) ........................................................................................................................................................................... 6.0 hp
Voltage ...........................................................................................................................................................................................12 V
Cooling System:
Type........................................................................................................................................................... Liquid w/Fan and Radiator
Operating Temperature. ............................................................................................................................... 190¡-235¡ F (88¡-113¡ C)
Filler Cap Pressure ...................................................................................................................................................... 15 psi (103 kPa)
Radiator Type.................................................................................................................................................. 4 Row Core Downflow
Fan Type..............................................................................................................................................8 Blade,suction w/viscous drive
Fan Diameter ............................................................................................................................................................ 19.5 in. (49.5 cm)

1-8 General Information, Lubrication and Maintenance
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Thermostat:
Starts to Open ..........................................................................................................................................................190¡ F (88¡ C)
Fully Open.............................................................................................................................................................212¡ F (100¡ C)
Generator:
Manufacturer ................................................................................................................................................................................Delco
Output ................................................................................................................................................. 124 AMP @ 1842 Engine RPM
Rated Voltage .................................................................................................................................................................. 13.35 -15.9 V
Batteries:
Manufacturer ..............................................................................................................................................................Johnson Controls
Type.......................................................................................................................................................................... Low Maintenance
Number ............................................................................................................................................................................................... 2
Voltage ...........................................................................................................................................................................................12 V
Amperage
@ 0¡ F ...............................................................................................................................800 Cold Cranking amps Each Battery
32¡ F ...............................................................................................................................1000 Cold Cranking amps Each Battery
80¡ F ............................................................................................................................................110 Reserve Capacity (Minutes)
Transmission:
Manufacturer ................................................................................................................................................................ GM Powertrain
Model......................................................................................................................................................................................... 4L80-E
Type...................................................................................................................................................................... 4-Speed, Automatic
Converter Torque Ratio................................................................................................................................................................ 2.2:1
Gear Ratios:
First...................................................................................................................................................................................... 2.48:1
Second ................................................................................................................................................................................. 1.48:1
Third .................................................................................................................................................................................... 1.00:1
Fourth .................................................................................................................................................................................. 0.75:1
Reverse ....................................................................................................................................................................................... 2.08:1
Oil Type.............................................................................................................................................................................. Dexron
¨
III
Oil Pressure .............................................................................................................................................. 35-324 psi (241-2,234 kPa)
Transfer Case:
Manufacturer ........................................................................................................................................................... New Venture Gear
Model................................................................................................................................................................................................242
Type......................................................................................................................................................... Full Time Four-Wheel Drive
Gear Ratios
High and High Lock ..........................................................................................................................................................................1:1
Low Range................................................................................................................................................................................... 2.72:1
Oil Type.............................................................................................................................................................................. Dexron
¨
III
Geared Hub:
Manufacturer ......................................................................................................... AM General Corporation design, made by Tremec
Type......................................................................................................................................................................................Spur Gears
Gear Ratio.....................................................................................................................................................................................1.92:1
Oil Type................................................................................................................................................................................SAE 80-90
Axle/Differential:
Manufacturer .............................................................................................................AM General Corporation design, made by Dana
Type:
Axle ......................................................................................................Fixed Mounted Differential W/ Independent Half Shafts
Differential .............................................................................................................Hypoid Torque Biasing (Paired Worm Gears)
Gear Ratio:
10,300 and 10,800:................................................................................................................................................................2.56:1
12,100:...................................................................................................................................................................................3.08:1

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General Information, Lubrication and Maintenance 1-9
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05745159
Service Brake Caliper (Front):
Manufacturer ................................................................................................................................................................... Kelsey-Hayes
Piston Diameter ............................................................................................................................................................ 2.6 in. (6.6 cm)
Service/Parking Brake Caliper (Rear):
Manufacturer ................................................................................................................................................................... Kelsey-Hayes
Piston Diameter ............................................................................................................................................................ 2.6 in. (6.6 cm)
Service/Parking Brake Rotor:
Manufacturer ................................................................................................................................................................... Kelsey-Hayes
Diameter ................................................................................................................................................................ 10.5 in. (266.7 mm)
Thickness.................................................................................................................................................................... 0.87 in. (22 mm)
Minimum Thickness.................................................................................................................................................0.81 in. (20.7 mm)
Steering System:
Steering Gear:
Manufacturer..................................................................................................................................................................... Saginaw
Type .........................................................................................................................................Recirculating Ball, Worm and Nut
Ratio ................................................................................................................................................................................... 13/16:1
Power Steering Pump:
Manufacturer..................................................................................................................................................................... Saginaw
Output Pressure (Max) .................................................................................................... 1,465 - 1,515 psi (10,101 - 10,446 kPa)
Flow Rate (Max)........................................................................................................................................... 2.6 gpm (9.8 Lpm)
Capacity (@ 1500 RPM) .............................................................................................................................. 2.6 gpm (9.8 Lpm)
Reservoir ............................................................................................................................................................................ Remote
Frame:
Manufacturer .............................................................................................................AM General Corporation design, made by Dana
Type........................................................................................................................................................................................ Steel Box
No. of Crossmembers........................................................................................................................................................................... 5
Air Conditioner:
Manufacturer (Compressor) ............................................................................................................................................. GM-Harrison
Model ............................................................................................................................................................................................HD-6
Field (Coil) ..................................................................................................................................................................................... 12 V
Oil Capacity.................................................................................................................................................................. 8 fl oz (237 ml)
Refrigerant.................................................................................................................................................................................. R-134a
Capacity (system + 2 oz. of oil) .................................................................................................................................. 3.2 lb. (1.45 kg)
Winch:
Manufacturer ................................................................................................................................................................................. Warn
Model ................................................................................................................................................... 12,000 lb., 12VDC HUMMER
Type.......................................................................................................................................... Electric Drive, Thermal Cutoff Switch
Capacity................................................................................................................................................................. 12,000 lb (5,448 kg)
Wheels and Tires:
Manufacturer ..........................................................................................................................Goodyear Tire Size 37 in. X 12.5R-16.5
Wheel Type:
Standard ......................................................................................................................................................................... One-Piece
Size...........................................................................................................................................................................16.5 x 8.25 in.

1-10 General Information, Lubrication and Maintenance
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FLUID CAPACITIES
Cooling System .................................................................................................................................................................. 26 qt (25 L)
Engine:
Crankcase (oil pan) only .............................................................................................................................................. 7 qt (6.6 L)
Crankcase and Filter..................................................................................................................................................... 8 qt (7.6 L)
Fuel Tank...................................................................................................................................................................25 gal. (95 L)
Auxiliary Fuel Tank ...............................................................................................................................................17 gal. (64.3 L)
Axle (front/rear) ........................................................................................................................................................... 2 qt (1.9 L)
Transmission:
Drain and Refill (with Pan Removed) ....................................................................................................................... 7.7 qt (7.3 L)
W/Dry Converter ................................................................................................................................................... 13.5 qt (12.8 L)
Transfer Case.................................................................................................................................................................... 3.5 qt (3.3 L)
Geared Hub........................................................................................................................................................................ 1 pt (0.47 L)
Steering System ................................................................................................................................................................ 1 qt (0.95 L)
Brake Hydraulic System (DOT 3)
Master Cylinder ................................................................................................................................................. 1.64 pt (0.78 L)
Total System....................................................................................................................................................... 3.12 pt. (1.5 L)
Windshield Washer Reservoir........................................................................................................................................2.5 gal. (9.5 L)
VEHICLE WEIGHTS
Curb Weight (10,300/10,800 GVWR):
Two-Door Enlarged Cab (Hard Top) (XLC2) ................................................................................................. 6,460 lb (2,930 kg)
Four Door Open Top (w/ full doors) (HMCO) ................................................................................................ 6,710 lb (3,044 kg)
Four Door Hard Top (HMC4).......................................................................................................................... 6,860 lb (3,112 kg)
Four-Door Station Wagon (HMCS)................................................................................................................. 7,050 lb (3,198 kg)
Payload (10,300 GVWR):
Two-Door Enlarged Cab (Hard Top) (XLC2) ................................................................................................. 3,840 lb (1,742 kg)
Four-Door Open Top (w/ full doors) (HMCO)................................................................................................3,590 lb (1,628 kg)
Four Door Hard Top (HMC4).......................................................................................................................... 3,440 lb (1,560 kg)
Four-Door Station Wagon (HMCS)................................................................................................................. 3,250 lb (1,474 kg)
Payload (10,800 GVWR):
Two-Door Enlarged Cab (Hard Top) (XLC2) ................................................................................................. 4,340 lb (1,968 kg)
Four-Door Open Top (w/ full doors) (HMCO)................................................................................................4,090 lb (1,855 kg)
Four Door Hard Top (HMC4).......................................................................................................................... 3,940 lb (1,768 kg)
Four-Door Station Wagon (HMCS)................................................................................................................. 3,750 lb (1,700 kg)
Gross Vehicle Weight (GVW) ............................................................................................ 10,300 lb (4,676 kg)/10,800 lb (4,899 kg)
Gross Axle Weight Rating (GAWR):
Front..............................................................................................................................................................4,100 lb (1,860 kg)
Rear...............................................................................................................................................................6,800 lb (3,084 kg)
Gross Combination Weight (GCW) ...................................................................................................................... 14,800 lb (6,719 kg)
Maximum Towed Load:
Two-Door Enlarged Cab (Hard Top) (XLC2) ................................................................................................. 8,340 lb (3,783 kg)
Four-Door Open Top (w/ full doors) (HMCO)................................................................................................8,090 lb (3,670 kg)
Four-Door Hard Top (HMC4).......................................................................................................................... 7,940 lb (3,602 kg)
Four-Door Station Wagon (HMCS)................................................................................................................. 7,750 lb (3,515 kg)

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General Information, Lubrication and Maintenance 1-11
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05745159
Turbo Diesel Engine -- (12,100 lb. (5,489 kg) GVWR Vehicles -- Fleet Vehicles Only
Curb Weight (12,100 GVWR):
Two-Door Enlarged Cab (Hard Top) (XLC2) ................................................................................................. 6,720 lb (3,048 kg)
Four Door Hard Top (HMC4).......................................................................................................................... 7,120 lb (3,230 kg)
Four-Door Station Wagon (HMCS)................................................................................................................. 7,310 lb (3,316 kg)
Payload (12,100 GVWR):
Two-Door Enlarged Cab (Hard Top) (XLC2) ................................................................................................. 5,380 lb (2,440 kg)
Four Door Hard Top (HMC4).......................................................................................................................... 4,980 lb (2,258 kg)
Four-Door Station Wagon (HMCS)................................................................................................................. 4,790 lb (2,172 kg)
Gross Vehicle Weight (GVW) .............................................................................................................................. 12,100 lb (5,488 kg)
Gross Axle Weight Rating (GAWR):
Front ............................................................................................................................................................. 4,400 lb (1,995 kg)
Rear .............................................................................................................................................................. 7,700 lb (3,492 kg)
Gross Combination Weight (GCW)...................................................................................................................... 16,500 lb (6,719 kg)
Maximum Towed Load:
Two-Door Enlarged Cab (Hard Top) (XLC2) ................................................................................................. 9,780 lb (4,436 kg)
Four-Door Hard Top (HMC4) ......................................................................................................................... 9,380 lb (4,254 kg)
Four-Door Station Wagon (HMCS)................................................................................................................. 9,190 lb (4,168 kg)
VEHICLE DIMENSIONS
Length (see Note)184.5 in. (4,68.6 mm):
Height ................................................................................................................................................................75 in. (190.5 mm)
Width (without mirrors) ................................................................................................................................86.50 in. (219.7 mm)
Ground Clearance ................................................................................................................................... 16 in. (41 cm) (at GVW)
Wheelbase ............................................................................................................................................................. 130 in (330 cm)
Track Width ............................................................................................................................................................. 72 in. (183 m)
NOTE: The vehicle weight and dimensions data applies to models without a winch.

1-12 General Information, Lubrication and Maintenance
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ABBREVIATIONS
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . Antilock Brake System
A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning
a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternating Current
AMPÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ampere
COÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carbon Monoxide
CÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Celsius (centigrade)
cmÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Centimeter
CTIS . . . . . . . . . . . . . . . . . . . . . . Central Tire Inflation System
CDRÊ. . . . . . . . . . . . . . . . . . . Crankcase Depression Regulator
cm
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cubic Centimeter
in.
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cubic Inch
cyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder
¡. . . . . . . . . . . . . . . . . . . . . . . . . Degree (angle or temperature)
DTC . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Trouble Code
dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter
d.c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Current
EPA. . . . . . . . . . . . . . . . . . . Environmental Protection Agency
F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fahrenheit
ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feet
ft/minÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feet Per Minute
fl ozÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fluid Ounce
gal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gallon
g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gram
GAWR . . . . . . . . . . . . . . . . . . . . . . Gross Axle Weight Rating
GVW. . . . . . . . . . . . . . . . . . . . . . . . . . . . Gross Vehicle Weight
GVWR . . . . . . . . . . . . . . . . . . . . Gross Vehicle Weight Rating
hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horsepower
HVAC. . . . . . . . . . . . .Heat, Ventilation, and Air Conditioning
in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inch
INC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Include
ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification
I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Diameter
kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilograms
kmÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometer
km/hÊ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers Per Hour
kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilopascals
lhÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Hand
LÊ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liter
max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum
m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter
mpgÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Miles Per Gallon
mphÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Miles Per Hour
mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Millimeter
min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Minimum
ÐÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minus
ÐÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative
No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number
Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ohms
oz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ounce
O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside Diameter
P/N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part Number
%. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Percentage
ptÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pint
+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plus
+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Positive
lbÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound
lb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound-feet
lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound-inch
psiÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . Pounds Per Square Inch
qt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quart
:Ê . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ratio
ref.Ê . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference
RPMÊ. . . . . . . . . . . . . . . . . . . . . . . . . . Revolutions Per Minute
rhÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right-Hand
cm
2
Ê. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Square Centimeters
in
2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Square Inches
TT4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Trac 4
VINÊ . . . . . . . . . . . . . . . . . . . . . Vehicle Identification Number
VÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volts
WÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Watts
UNCÊ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unified Coarse
UNFÊ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unified Fine

_______________
General Information, Lubrication and Maintenance 1-13
¨
05745159
BOLT IDENTIFICATION AND TORQUE LIMITS (DRY*)
* A phosphate and oil bolt is
considered dry
Bolt Head ID Marks and SAE GRADE
BOLT
SIZE
SAE GRADE
NO. 1 OR 2
SAE GRADE
NO. 5
SAE GRADE
NO. 6 OR 7
SAE GRADE
NO. 8
DIA.
INCHES
MILLI-
METERS
THREADS
PER INCH
POUND FEET
(NEWTON-
METERS)
POUND FEET
(NEWTON-
METERS)
POUND FEET
(NEWTON-
METERS)
POUND FEET
(NEWTON-
METERS)
1/4 6 20 5(7) 8(11) 10(14) 12(16)
1/4 6 28 6(8) 10(14) ÑÑ 14(19)
5/16 8 18 11(15) 17(23) 19(26) 24(33)
5/16 8 24 13(18) 19(26) ÑÑ 27(37)
3/8 10 16 18(24) 31(42) 34(46) 44(60)
3/8 10 24 20(27) 35(47) ÑÑ 49(66)
7/16 11 14 28(38) 49(66) 55(75) 70(95)
7/16 11 20 30(41) 55(75) ÑÑ 78(106)
1/2 13 13 39(53) 75(102) 85(115) 105(142)
1/2 13 20 41(56) 85(115) ÑÑ 120(163)
9/16 14 12 51(69) 110(149) 120(163) 155(210)
9/16 14 18 55(75) 120(163) ÑÑ 170(231)
5/8 16 11 63(85) 150(203) 167(226) 210(285)
5/8 16 18 95(129) 170(231) ÑÑ 240(325)
3/4 19 10 105(142) 270(366) 280(380) 375(509)
3/4 19 16 115(156) 295(400) ÑÑ 420(570)
7/8 22 9 160(217) 395(536) 440(597) 605(820)
7/8 22 14 175(237) 435(590) ÑÑ 675(915)
1 25 8 235(319) 590(800) 660(895) 910(1234)
1 25 14 250(339) 660(895) ÑÑ 990(1342)
1-1/8 29 Ñ ÑÑ 800 - 880
(1085 - 1193)
ÑÑ 1280 - 1440
(1736 - 1953)
1-1/4 32 Ñ ÑÑ Ñ ÑÑ 1820 - 2000
(2468 - 2712)
1-3/8 35 Ñ ÑÑ 1460 - 1680
(1980 - 2278)
ÑÑ 2380 - 2720
(3227 - 3688)
1-1/2 38 Ñ ÑÑ 1940 - 2200
(2631 - 2983)
ÑÑ 3160 - 3560
(4285 - 4827)

1-14 General Information, Lubrication and Maintenance ________________
¨
BOLT IDENTIFICATION AND TORQUE LIMITS (WET*)
*A cadmium plated bolt is considered wet. Bolt Head ID Marks and SAE Grade
BOLT
SIZE
SAE GRADE
NO. 1 OR 2
SAE GRADE
NO. 5
SAE GRADE
NO. 6 OR 7
SAE GRADE
NO. 8
DIA.
INCHES
MILLI-
METERS
THREADS
PER INCH
POUND FEET
(NEWTON-
METERS)
POUND FEET
(NEWTON-
METERS)
POUND FEET
(NEWTON-
METERS)
POUND FEET
(NEWTON-
METERS)
1/4 6 20 4(5) 7(10) 9(12) 11(15)
1/4 6 28 5(7) 9(12) ÑÑ 13(17)
5/16 8 18 10(14) 15(20) 17(23) 22(30)
5/16 8 24 12(16) 17(23) ÑÑ 24(33)
3/8 10 16 16(22) 28(38) 31(42) 40(54)
3/8 10 24 18(24) 32(43) ÑÑ 44(60)
7/16 11 14 25(34) 44(60) 50(68) 63(85)
7/16 11 20 27(37) 50(68) ÑÑ 70(95)
1/2 13 13 35(48) 68(92) 77(104) 95(129)
1/2 13 20 37(50) 77(104) ÑÑ 108(146)
9/16 14 12 46(62) 99(134) 108(146) 140(190)
9/16 14 18 50(67) 108(146) ÑÑ 153(207)
5/8 16 11 57(77) 135(183) 150(203) 189(256)
5/8 16 18 85(115) 153(207) ÑÑ 216(293)
3/4 19 10 95(129) 243(330) 252(342) 338(458)
3/4 19 16 104(141) 266(361) ÑÑ 378(513)
7/8 22 9 144(195) 356(483) 396(537) 545(739)
7/8 22 14 158(214) 392(532) ÑÑ 608(824)
1 25 8 212(287) 531(720) 594(805) 819(1111)
1 25 14 225(305) 594(805) ÑÑ 891(1208)
1-1/8 29 Ñ ÑÑ 720 - 792
(976 - 1074)
ÑÑ 1152 - 1296
(1562 - 1757)
1-1/4 32 Ñ ÑÑ ÑÑ ÑÑ 1638 - 1800
(2221 - 2441)
1-3/8 35 Ñ ÑÑ 1314 - 1512
(1782 - 2050)
ÑÑ ÑÑ
1-1/2 39 Ñ ÑÑ 1746 - 1980
(2368 - 2685)
ÑÑ 2844 - 3204
(3857 - 4345)

_______________ General Information, Lubrication and Maintenance 1-15
¨
05745159
U.S./METRIC CONVERSIONS AND EQUIVALENTS
Metric Conversions
MULTIPLY BY TO GET
INCHES 2.54 CENTIMETERS
FEET 0.305 METERS
MILES 1.609 KILOMETERS
SQUARE INCHES 6.451 SQUARE CENTIMETERS
CUBIC INCHES 16.39 CUBIC CENTIMETERS
FLUID OUNCES 29.573 MILLILITERS
PINTS 0.473 LITERS
QUARTS 0.946 LITERS
GALLON 3.785 LITERS
POUNDS 0.454 KILOGRAMS
SHORT TONS 0.907 METRIC TONS
POUND-INCHES 0.113 NEWTON-METERS
POUND-FEET 1.356 NEWTON-METERS
POUNDS PER SQUARE INCH 6.895 KILOPASCALS
MILES PER GALLON 0.425 KILOMETERS PER LITER
MILES PER HOUR 1.609 KILOMETERS PER HOUR
U.S. Standard Conversions
MULTIPLY BY TO GET
CENTIMETERS/MILLIMETERS 0.3937 INCHES
METERS 3.280 FEET
KILOMETERS 0.621 MILES
SQUARE CENTIMETERS 0.155 SQUARE INCHES
CUBIC CENTIMETERS 0.061 CUBIC INCHES
MILLILITERS 0.034 FLUID OUNCES
LITERS 2.113 PINTS
LITERS 1.057 QUARTS
LITERS 0.264 GALLONS
KILOGRAMS 2.205 POUNDS
METRIC TONS 1.102 SHORT TONS
NEWTON-METERS 0.738 POUND-FEET
NEWTON-METERS 8.851 POUND-INCHES
KILOPASCALS 0.145 POUNDS PER SQUARE INCH
KILOMETERS PER LITER 2.354MILES PER GALLON
KILOMETERS PER HOUR 0.621MILES PER HOUR
Temperature
32¡ FAHRENHEIT = 0¡ CELSIUS 212¡ FAHRENHEIT = 100¡ CELSIUS
CELSIUS = 0.556 X (F¡ -32) FAHRENHEIT = (1.8 X C¡) +32

1-16 General Information, Lubrication and Maintenance ________________
¨
PAINT AND TRIM COLORS
Interior trim colors are tan and gray. Seating materials are
available in cloth and vinyl.
Soft top colors and codes are: Tan (T) and Black (B).
Exterior paint colors and codes are outlined in the following
chart.
REPLACEMENT KEYS
Replacement keys can be cut using Briggs and Stratton or Cur-
tis key cutting tools. Key codes are provided on an identific-
aion tag included with each key set (Figure 1-10).
Figure 1-10: Key Code Location
Top Coat Description AM General Code
Candy Apple Red R19
White Gloss W8
Black Gloss B9
Competition Yellow Y20
Burgundy Metallic P17
Bright White W14
Silver Metallic S15
Mesa Dusk Carmel C22
Metallic Pewter P33
Woodland Green G23

_______________ General Information, Lubrication and Maintenance 1-17
¨
05745159
TOWING, LIFTING, JUMP STARTING
Vehicle Lifting/Jacking Points
Vehicle jacking points are shown in Figure 1-11. The vehicle
can be raised with a floor jack at any of the indicated positions.
Jacking can be performed at the front, rear, or at any one
wheel.
In cases where the entire vehicle must be raised, use jack
stands at equidistant points on the frame rails. Use a minimum
of four stands to support the vehicle. Suggested capacity for in-
dividual jack stands is 3 ton, with a vertical reach of 19 in.
(49 cm).
Typical jack stand placement for raising one side of the vehicle
is shown in Figure 1-12. Always be sure the jack stand saddle
is securely engaged and the stand is level.
Vehicle Hoisting
Hummer vehicles can be raised on a hoist for service access.
Drive-on and swivel arm hoists are both acceptable. Hoist ca-
pacity and width are important. The greater width and weight
of Hummer vehicles require a larger hoisting platform. Do not
use an under capacity hoist, or modify an existing hoist for use;
this practice is neither safe nor recommended.
Figure 1-11: Vehicle Jacking Points
Figure 1-12: Typical Jack Stand Placement
REAR
CROSSMEMBER
REAR
LOWER
CONTROL
ARMS
FRAME RAIL
FRONT
CROSSMEMBER
FRONT LOWER
CONTROL ARMS
FRAME RAIL
REAR
BUMPER
JACK STANDS POSITIONED
UNDER FRAME RAIL

1-18 General Information, Lubrication and Maintenance ________________
¨
Towing Recommendations
Hummer vehicles can be towed with wheel lift, sling-type, or
flat bed tow equipment.
Flat bed and wheel lift equipment is recommended over sling
type or A-frame equipment.
Towing Cautions:
¥ Remove or secure loads in the towed vehicle
¥ Never use the shackles on the front bumpers as tie down
points
¥ Always use safety chains on sling towed vehicles
¥ Always follow the transmission/transfer case shift posi-
tion recommendations (Transfer Case in N (Neutral);
Transmission in P (Park).
¥ Use a low vehicle trailer for recreational towing (behind
an RV or other vehicle) when possible.
¥ Never put chains, cables or straps on any steering com-
ponents.
Flat Bed/Wheel Lift Towing Procedures
Flat bed/wheel lift tow vehicles are highly recommended. They
keep all of the towed vehicle wheels off the pavement. This is
important with full time four wheel drive vehicles.
Loading only requires that the towed vehicle be raised or
winched onto the towing platform. A further advantage of this
type equipment is that tow speed and distance are not limited.
Once the towed vehicle is loaded, set the parking brake, shift
the transmission into Park and install the vehicle tie downs. Tie
down attachment points are shown in Figure 1-13.
Figure 1-13: Vehicle Tie-Down Points
FRAME RAIL/
CROSSMEMBER LOOP
LOOPS

_______________ General Information, Lubrication and Maintenance 1-19
¨
05745159
Conventional Towing Procedures
Front Towing
1. Loop chains around lower control arms and secure to tow
sling (Figure 1-14).
2. Insert 4Ó x 4Ó x 48Ó length of wood between bumper and
sling chains (Figure 1-14).
3. Raise front end and verify that sling is firmly positioned
against front bumper.
4. Release parking brakes.
5. Shift transmission into Park and transfer case into Neutral.
6. Position tow dollies under rear wheels. Proceed with
towing operations.
Figure 1-14: Front Towing With Conventional
Equipment
Rear Towing
1. Loop sling chain around frame rails adjacent to rear cross-
member and secure to tow sling (Figure 1-15).
2. Insert 4Ó x 4Ó x 48Ó length of wood between bumper and
sling chains (Figure 1-15).
3. Raise rear end and verify that sling is firmly positioned
against rear bumper.
4. Release parking brakes.
5. Shift transmission into Park and transfer case into Neutral.
6. Position tow dollies under front wheels. Proceed with
towing operations.
Figure 1-15: Rear Towing with Conventional
Equipment
Conventional Towing When Keys are not
Available
If the vehicle doors are locked and the keys are not available
you cannot determine that the transmission is in Park and the
transfer case is in ÒNÓ (Neutral). In these situations, you must
use one of the following towing methods:
a. Use tow dollies at all wheels and flat tow,
or
b. Raise the vehicle front or rear and use tow dollies un-
der the wheels not raised.
Recreational Towing
Hummer vehicles can be towed behind an RV if desired. A
low-boy style vehicle trailer is best for this purpose. Flat tow-
ing is not recommended.
CHAIN
ASSEMBLY
WOOD
CROSSBEAM
LOWER
CONTROL ARM
SLING
ASSEMBLY
SLING
ASSEMBLY
SLING
CHAINS
WOOD
BLOCK
CROSSMEMBER
FRAME
RAIL