Hummer H1 (2006+). Manual - part 35

2-46

Engine

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OIL PAN REPLACEMENT

Lower Oil Pan

Removal

1.

Remove the driveline protection (See Section 9).

2.

Drain the engine oil.

3.

Remove the 18 bolts retaining the lower oil pan to the upper oil pan (Figure  2-42).

Figure 2-42:   Upper and Lower Oil Pan

4.

Remove the lower oil pan from the engine.

Installation

1.

Clean any residual sealant or gasket material from the upper oil pan and lower oil pan gasket sealing surfaces.

2.

Carefully apply a 2-3mm bead of RTV sealant GM PN 12378521 or equivalent on the lower oil pan sealing surface.

3.

Place the lower oil pan in position on the upper oil pan and secure with the lower oil pan attachment bolts.

4.

Tighten the lower oil pan attachment bolts to 89 in lb. (10 N•m) in a circular sequence starting in the center of the sides and
working out to the ends.

5.

Install the oil drain plug with a new gasket and tighten the oil drain plug to 62 lb ft. (84 N•m).

6.

Refill the engine with fresh oil and replace the oil filter.

7.

Install the driveline protection (See Section 9).

8.

Operate the engine and check for leaks after normal operating temperature is obtained.

Upper Oil Pan

Removal

1.

Remove the driveline protection (See Section 9).

2.

Drain the engine oil.

3.

Remove the 18 bolts retaining the lower oil pan to the upper oil pan.

4.

Remove the lower oil pan from the engine.

5.

Removal of the flywheel from the engine is required to provide access to the two bolts retaining the upper oil pan to the
flywheel housing (See Section 5).

LOWER OIL PAN

BOLT

UPPER OIL PAN

RTV SEALANT

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 Engine  2-47

5745804

6.

Remove the two bolts retaining the upper oil pan to the flywheel housing(Figure  2-43).

Figure 2-43:   Flywheel Housing to Upper Oil Pan Bolt Location

7.

Remove the oil pump pickup tube and bracket from the main bearing cap and the oil pump.

8.

Remove the bolts retaining the upper oil pan to the block taking care to note the location of the longer bolts and the wiring
harness p-clip.

9.

Carefully remove the upper oil pan from the block, disconnect the oil dipstick tube from the upper oil pan as it is lowered.

Installation

1.

Carefully remove all existing sealant from the block, flywheel housing and upper oil pan sealing surfaces.

2.

Replace the o-rings on the engine oil dipstick tube, lubricate the o-rings with clean engine oil.

3.

Clean any gasket residue from the oil pump where the oil pickup tube connects.

4.

Carefully apply a 2-3mm bead of RTV sealant GM PN 12378521 or equivalent on the upper oil pan to block mating surface.
Also apply a similar bead on the flywheel housing to the upper oil pan mating surface.

UPPER OIL PAN

LOWER OIL PAN

BOLTS

BOLT

BOLT

RTV SEALANT

FLYWHEEL HOUSING

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Engine

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5.

Carefully lift the upper oil pan into position while inserting the oil dipstick tube into the upper oil pan.

6.

Place the upper oil pan in position on the block and secure with the bolts previously removed taking care to install the longer
bolts and the wiring harness p-clip in the correct locations. Do not fully tighten the bolts at this time.

7.

Install the two bolts securing the upper oil pan to the flywheel housing.

8.

Tighten the upper oil pan to the block bolts to 15 lb ft. (20 N•m) in a circular clockwise pattern starting at the center of the
river’s side of the pan.

9.

Tighten the two bolts securing the upper oil pan to the flywheel housing to 37 lb ft. (50 N•m).

10. Install the flywheel and other components removed to provide access to the two bolts retaining the upper oil pan to the

flywheel housing (See Section 5).

11. Install the oil pickup tube to the oil pump with a new gasket. 

12. Secure the pickup tube and bracket to the oil pump and the main bearing cap, tighten the fasteners to 18 lb ft. (25 N•m).

13. Install the lower oil pan to the upper oil pan with a new gasket and the previously removed bolts. Torque the bolts to 89 in lb.

(10 N•m) in a circular sequence starting in the center of the sides and working out to the ends.

14. Install the oil drain plug with a new gasket and tighten the oil drain plug to 62 lb ft. (84 N•m).

15. Refill the engine with fresh oil and replace the oil filter.

16. Install the driveline protection (See Section 9).

17. Operate the engine and check for leaks after normal operating temperature is obtained.

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ENGINE REMOVAL

1.

Remove the hood (Refer to section 10).

2.

Shift the transmission into neutral and set the parking brake.

3.

Disconnect and remove the batteries (Refer to section 12).

4.

Remove the right side splash shield and battery tray (Refer to section 10).

5.

Remove the left side splash shield (Refer to section 10).

6.

Remove the rubber and sponge pads from the air lift brackets (Refer to section 10).

7.

Drain the engine oil.

8.

Drain the coolant  (See “Engine Cooling System Service” on page 4-8) .

9.

Recover the A/C refrigerant (Refer to section 11).

10. Remove the CTIS compressor (Refer to section 6).

11. Disconnect the A/C condenser lines, the transmission cooler lines, the fuel cooler lines, the T-case cooler lines, the coolant

hoses and the auxiliary coolant pump thermal switch electrical connector from the cool pack.

12. Remove the charged air hose from the charged air cooler outlet to the intake pipe (Refer to section 3).

13. Remove the charged air hose from turbo outlet and the charged air cooler (Refer to section 3).

14. Remove the coolant hoses from the radiator and lower radiator hose to the surge tank and remove the surge tank form the right

air lift bracket (Refer to section 4).

15. Remove the radiator support bracket bolts and remove the lower radiator mount with the help of an assistant, remove the cool

pack assembly from the vehicle (Figure  2-44).

Figure 2-44:   Cool Pack Assembly

16. Remove the cooling fan, fan drive assembly and the upper portion of the front, rear crossmember as an assembly (Refer to

section 4).

17. Remove the air inlet hose from the air cleaner to the turbo intake tube (Refer to section 4).

18. Remove the engine cover (Refer to section 10).

19. Remove the center driveline protection (Refer to section 9).

CAUTION: Care must be taken to ensure that the front propeller shaft is not separated at the slip yoke spline. The shaft is bal-
anced at the factory and if separated it will need to be replaced. 

20. Remove the front propeller shaft (Refer to section 9).

21. Remove the vane position sensor from the turbocharger using a Snap-on wrench RX32A or equivalent.

22. Remove the serpentine belt and the serpentine belt tensioner (Refer to section 4).

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