Hummer H1 (1992-1998). Manual - part 49

2-41. ENGINE ASSEMBLY FROM SUBASSEMBLIES (Cont’d)

 c. Pistons and Connecting Rods 

1.

2.

3.
4.

5.

6.

7.

8.

Rotate cylinder block (6) approximately 90°.

NOTE

Measure outside diameter of crankshaft rod bearing journals to
determine what thickness connecting rod bearings to install.

Check identification number on side of connecting rod (9) and install upper rod bearing half (7)
in connecting rod (9) and lower rod bearing half (12) in corresponding rod cap (5).

Rotate crankshaft (4) so rod journal (13) faces outward.
Cover connecting rod bolts (8) with 3/8-in. inside diameter rubber hose.
Apply OE/HDO to piston rings (11) and piston (10).

NOTE

Make sure all ring gaps are staggered so they are not in line with
each other or piston pin.

Compress piston rings (11) with ring compressor.

NOTE

● 

Depression on top of piston must be assembled toward outside

of engine.

● 

Starting from front of cylinder block, cylinders 1, 3, 5, and 7 are

on left side and cylinders 2, 4, 6, and 8 are on right side.

● 

For remaining pistons, rotate crankshaft so rod journal faces

outward.

Check identification number on side of connecting rod (9) and install piston (10) and connecting
rod (9) into corresponding cylinder.
Tap piston (10) into cylinder until connecting rod (9) seats on crankshaft (4) and remove
rubber hoses.

 2-41. ENGINE ASSEMBLY FROM SUBASSEMBLIES (Cont’d)

9.

10.
11.
12.
13.
14.

15.

16.
17.

18.
19.

20.

NOTE

The gauging plastic shall be positioned the full width of the bear-
ing and centered on the bearing journal when the bearing cap
is installed.

Position gauging plastic on bearing journal (3) the fill width of the bearing (4) and parallel to the
center line of the crankshaft.

NOTE

Identification numbers on connecting rods and rod caps must be
installed on the same side.

Check identification number on side of connecting rod (6) and install corresponding rod cap (2).
Secure rod cap (2) to connecting rod (6) with two nuts (1) and tighten to 44-52 lb-ft (60-71 N•m).
Remove two nuts (1) and rod cap (2) from connecting rod (6).
Measure gauging plastic at its widest point.
If the gauging plastic tapers toward the middle or ends, there is a difference in clearance indicating
taper, low spot, or irregularity of bearing or crankshaft journal. If gauging plastic indicates more
than 0.001 in. (0.025 mm) taper, measure crankshaft journal with micrometer (para. 2-17).

NOTE

It is acceptable to use a standard bearing with a 0.001 in.
(0.025 mm) undersize bearing to obtain the proper rod bearing
clearance. If unable to produce proper clearance, replace
crankshaft.

If the measurement is within specification, 0.002-0.004 in. (0.051-0.102 mm) bearing is satisfactory.
If measurement is not within specifications, a 0.001 in. (0.025 mm) undersize bearing may produce
proper bearing clearance. Replace bearings and repeat steps 9 through 15.
Remove gauging plastic.

Apply OE/HDO to rod bearings. Check identification number on side of connecting rod (6) and

install corresponding rod cap (2).
Secure rod cap (2) to connecting rod (6) with two nuts (1) and tighten to 44-52 lb-ft (60-71 N•m).
Rotate crankshaft (5) to ensure crankshaft (5) rotates.
Repeat steps 2 through 19 for remaining pistons and connecting rods.

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2-41. ENGINE ASSEMBLY FROM SUBASSEMBLIES (Cont’d)

2-161

2-41. ENGINE ASSEMBLY FROM SUBASSEMBLIES (Cont’d)

1. Rotate cylinder block (7) so crankshaft faces upward.

2. Install oil pump (8) on rear main bearing cap (6).

3. Install stud (1) and oil pump (8) on rear main bearing cap (6) and tighten stud (1) to

59-74 lb-ft (80-100 N•m).

4. Install pickup tube bracket (4) on stud (1) with nut (2). Tighten nut (2) to 35 lb-ft (48 N•m).

5. Tighten capscrew (5) securing pickup tube bracket (4) to pickup tube (3) to 12 lb-ft (16 N•m).

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