Hummer H1 (2006+). Manual - part 288

10-14 Body

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Fiberglass Repair

General Information

The HUMMER H1 hood and the engine access cover are made of fiberglass (sheet molding compound). Crack, splits or holes may
be repaired with a glass reinforced plastic laminate repair kit.

Inspection

NOTE: The hood surface has a thin layer of gel coat that may appear cracked in a spider web-like pattern due to the hood flexing.
No repair is required.

1.

Examine the cracks to determine if they are on the surface only or are deep breaks into the material thickness.

2.

If the filler material chips off at the bonding flanges and appears as cracked but not broken through, the area need not
be repaired.

3.

If the total penetration crack is greater than 1 in. (25.4 mm)  in a critical areas: hinges, latches or hood stop areas, repair it
immediately (Figure  10-11).

4.

If the total penetration cracks exist in noncritical areas, do not repair until the size is greater than 3 in. (76 mm).

5.

If severe breaks develop in one area, remove the fragmented material and use the repair procedure for holes.

Figure 10-11:   Hood Stop and Hinge

Repair

1.

Repairing cracks or splits.

WARNING:  When sanding fiberglass, personal protective equipment (respirator, goggles/shield, gloves, coveralls,
etc.) must be used. Failure to do this may result in injury.

a.

Using sandpaper, remove the dirt and the paint 3-4 in. (8-10 cm) around the area of the crack.

b.

Rough-sand the surface to which the mat will be added and the underside of the surface, if possible. The surface must be
dry.

c.

Bevel the edges of the crack in a broad “V”.

d.

Cut a piece of mat and apply to the underside of the surface with a resin mixture. Extend the patch beyond the break
about  2 in. (5 cm). Press the patch firmly into place. Saturate the patch with additional layer of resin and then allow 1-3
hours to cure.

e.

At the same time, cover the top exposed surface with resin, allowing 1 to 3 hours to cure.

HOOD STOP

LATCH

HINGE

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 Body  10-15

f.

For stressed areas, lightly sand the first patch and add another patch layer, repeating steps a through c.

g.

Finish-sand the exposed surface.

h.

Prime and paint.

2.

Repairing the holes.

a.

Remove the damaged material.

b.

Using sandpaper, remove the dirt and the paint in the area of the hole extending away 3-4 in. (8-10 cm).

c.

Rough-sand the top and the underside of the surface to which the mats will be added.

d.

Cut two of the same size pieces of fiberglass mat that will extend about 2 in. (5 cm) past the edge of the hole.

e.

Coat both the top and the underside of the surface, and saturate both pieces of mat with the resin mixture.

f.

When tacky, apply one mat to the inner surface and one to the outer surface. Press the two patches together.

g.

Allow 1-3 hours to cure. Additional coats of resin may be added if necessary for appearance purposes. Sand lightly
between coats.

h.

Finish-sand the exposed surface.

i.

Prime and paint.

WATER LEAK DETECTION AND REPAIR

If water has leaked into the vehicle, inspect for leakage points. Spray water, under pressure, against the vehicle in the general area
where the leak is believed to be located. Have an assistant inside the vehicle locate and mark the point(s) where any water appears.

Water that appears at a certain place inside the vehicle may actually be entering the vehicle from another point. It may be necessary
to remove the floor mat, interior trim panels, insulation, dash pad, instrument panel, etc. to gain access and diagnose the leak. Back
track the path of water to the point of entry. If it is still not possible to locate the point of entry, try the following:

1.

Close all the windows and doors.

2.

Run a small stream of water over the suspected area(s) of leakage.

3.

Using a leak detector-type solution (commercially available), spray a film over the suspect area on the exterior surface.

4.

From inside the vehicle, use an air wand and force air onto the suspect leak area and check for pressure bubbles that indicate
air is escaping from the vehicle.

5.

Repair the leak.

If the leak is between body panels or around rivet heads, use Silaprene sealant (P/N 05593929) and wipe the sealant into and/or
around the leak area. Be sure to remove any excess sealant while it is still pliable.

If the leak is around a door, it may be because the door is not properly aligned. Refer to Door Replacement in this section for in-
structions on door adjustment. If the door is contacting the weather seal correctly, make sure the weather seal is not damaged and is
properly sealed on the door. If the weather seal is not properly sealed, rubber cement can be used to hold it in place. If the weather
seal is damaged, replace it.

If the leak is around a window held by a weather seal (i.e., door glass), completely dry the area and apply a new window glass seal.
If the new seal still does not close out against the glass, the window opening flange may need to be adjusted inward. If the weather
seal is damaged, it should be replaced. Check the flange that holds the weather seal for any nicks or burrs that may have caused the
damage.

Windshield leaks should be repaired by removing the glass and the weather seal that is leaking. Clean off any remaining sealer on the
windshield frame and the weather seal, and lay a new bead of sealer evenly around the windshield frame and between the glass and the
weather seal. Install the glass and weather seal as an assembly into the frame. Attach the retainers, and allow sealer to harden.

6.

Retest the entire vehicle for leaks.

CENTER CONSOLE REPLACEMENT

Removal

1.

Remove the five screws securing the glove box. Remove the glove box (Figure  10-13).

2.

Remove the four screws securing the drivers side power window switch assembly and the assembly. 

3.

Remove the four screws securing the passenger side power window switch assembly and the assembly. 

4.

Remove the seven screws securing the rear passenger power window switch assembly and the assembly.

10-16 Body

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5.

Remove the two screws securing the center console to the cargo floor (Figure  10-12).

6.

Slide the center console toward the rear of the vehicle.

7.

Remove the cigarette lighter heater from the console. 

Figure 10-12:   Center Console Replacement

Installation

1.

Install the cigarette lighter heater in the center console.

2.

Position the center console into place and install the drivers side power window switch assembly.

3.

Install the two screws that secure the center console to the cargo floor.

4.

Install the rear passenger power window switch assembly.

5.

Install the passenger side power window switch assembly.

6.

Install the glove box.

Figure 10-13:   Glove box Mounting

INSTRUMENT PANEL/ GAUGES

Instrument Panel (I.P.) Replacement

Removal

1.

Disconnect the negative battery cables (Refer to section 12).

2.

Remove the upper crash pad.

3.

Remove the left instrument panel closeout.

PASSENGER

POWER WINDOW

SWITCH ASSEMBLY

DRIVERS

POWER WINDOW

SWITCH ASSEMBLY

CENTER

CONSOLE

SCREW

REAR CONTROL

PANEL ASSEMBLY

GLOVE BOX

CENTER CONSOLE

NUT INSERT

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 Body  10-17

4.

Unbolt the 56 way I.P. harness connector from the body harness.

5.

Remove the ground strap from the I.P. wiring harness to the ground bar behind the I.P.

6.

Remove the center dash assembly (Refer to section 10).

7.

Remove the right side I.P. mounting bolt.

8.

Remove the two left side I.P. mounting screws securing the I.P. to the A-pillar.

9.

Remove the two screws on top of the I.P. and remove the I.P.

Installation

1.

Maneuver the I.P. into position between the steering wheel and the A beam.

2.

Loosely install the left side I.P. mounting bolts.

3.

Loosely install the right side I.P. mounting bolts.

4.

Install the two screws in the top of the I.P.

5.

Tighten the previous loosely installed bolts.

6.

Install the center dash assembly

7.

Install the ground strap.

8.

Install the 56 way I.P. harness connector.

9.

Install the upper crash pad.

10. Install the left instrument panel closeout.

11. Connect the negative battery cables (Refer to section 12).

Crash Pad Replacement (Upper)

Removal

1.

Remove the six screws securing the left and right defrost vents to the upper crash pad (Figure  10-14).

2.

Remove the four screws securing the crash pad.

3.

Slide the crash pad away from the windshield.

4.

Disconnect the hoses from the left and right demisters and remove the pad.

Installation

1.

Connect the hoses to the left and right demisters.

2.

Engage the securing tabs and slide the crash pad forward to the windshield.

3.

Secure the crash pad to the dashboard with the four screws.

4.

Install the defroster vents and screws. 

Figure 10-14:   Crash pad Replacement

CRASH PAD

(RIGHT SIDE)

CLOSE-OUT

PANEL

CENTER DASH

ASSEMBLY