Hummer H1 2000 Factory Service Repair Manual + Parts Catalog

Hummer H1 2000 Factory Service Repair Manual + Parts Catalog

Loaded with Hi Resolution illustrations, instructions, photos, and diagrams, complete to service and repair your vehicle. 

2122 PAGES

 

MANUALS COVER

 

Section 1

General Information, Lubrication and Maintenance: 

Abbreviations

About This Manual

Bolt Identification and Torque Limits (Dry*)  

Bolt Identification and Torque Limits (Wet*)

Carbon Monoxide  

Component Data  

Emission Control information Label  

Engine Identification  

EPA Noise Emission Control Information Label

Essential Tools  

Fluid Capacities  

Hummer Service Hotline

Lubrication and Maintenance Items

Maintenance Schedule  

Miscellaneous essential Tools

Paint and Trim Colors

Recommended Fuel/Fluids/Lubricants/Capacities  

Replacement Keys  

Safety Certification Label  

Safety Summary  

Scheduled Maintenance Chart

Service Manual Comments  

Special Tools  

Towing, Lifting, Jump Starting  

Transfer Case Identification

Transmission Identification  

U.S./Metric Conversions and Equivalents  

Vehicle Dimensions  

Vehicle Identification Number (VIN)

Vehicle Weights

 

Section 2

Engine:

A/C Compressor Removal  

Boost Pressure Test  

Camshaft

Bearing Replacement  

Installation  

Removal  

Timing Chain, Sprocket and Drive Gears  

Crankshaft

Bearing Replacement  

Connecting Rod Journal Diameter

Crankshaft and Main Bearings Removal  

End Play Check  

Main Journal Diameter  

Pulley Replacement  

Cylinder Block

Cylinder Bore and Piston Measurement  

Service  

Cylinder Head

Cylinder Head And Gasket Service  

Installation   

Overhaul  

Removal  

Damper and Flywheel Service  

Engine

Assembly and Adjustment  

Block, Camshaft and Bearing Sizes

Cleaning Materials  

Compression Test  

Description  

Disassembly

Engine Diagnosis

Essential Tools

Identification

Installation  

Mounting Bracket/Insulator  

Noise Diagnosis

Removal  

Scan Tool Use  

Service Piston and Cylinder Bore  

Special Service Tools  

Specifications

Oil Pump

Oil Pump and Drive Removal  

Oil Pump and Pump Drive Service

Oil Pump Drive  

Oil Pump Pressure

Service    

Oil Pump, Oil Pan, Flywheel Installation  

Piston/Connecting Rod

Installation and Bearing Fit

Removal  

Piston/Connecting Rod Overhaul  

Piston and Connecting Rod Assembly  

Piston Ring Installation

Piston Selection and Fit  

Power Steering Pump and Bracket  

Pushrod, Rocker Arm and Shaft Installation  

Rear Main Oil Seal Replacement  

Rear Main Seal Installation  

Road Testing  

Rocker Arm

Cover Removal

Cover Service

Shaft and Pushrod Removal

Shaft and Pushrod Service  

Rocker Cover Installation  

Engine Assembly and Adjustment

Crankshaft and Main Bearing Installation

Crankshaft Main Bearing Selection  

Exhaust Manifold

Installation  

Removal  

Service  

Fan-Pulley-Damper Removal  

Flushing Engine Cooler  

Flywheel Removal  

Front Cover and Baffle Installation  

Front Cover and Oil Filler Tube  

Front Cover And Timing Chain  

Front Cover Oil Seal Replacement  

Front Cover Removal  

Fuel Filter Warning Lamp  

Fuel Injection Line

Installation  

Removal  

Fuel Injection Pump

Fuel Supply and Return Line Removal  

Installation  

Removal  

Glow Plug

Glow Plug Removal

Glow Plug Test  

Glow Plug and Injection Nozzle  

Operation and Testing  

Intake and Exhaust Manifolds  

Intake Manifold  

Removal  

Introduction  

In-Vehicle Service, Diesel Engine  

Lifter, Pushrod, Rocker Arm Service  

Lubricants/Sealants/Coolant  

Oil Filter

Adapter Service  

Filter, Adapter, Fittings  

Oil Filter/Adapter/Oil Pressure Sending Unit  

Oil Pan Removal  

Serpentine Belt Removal  

Timing Chain/Drive Sprockets/Drive Gear  

Timing Chain-Sprocket-Gear Installation  

Torsional Damper  

Torsional Damper/Crankshaft Pulley  

Turbocharger

Diagnosis  

Installation  

Operation  

Removal  

Service  

Service and Diagnosis  

Turbocharger and Center Manifold Removal  

Turbocharger and Intake Manifold  

Vacuum Pump Service  

Valve Lifter

Installation  

Removal  

Replacement  

Water Crossover

Installation  

Removal  

Water Pump and Adapter Plate Installation  

Water Pump and Adapter Plate Removal  

 

Section 3

Fuel, Emissions, and Exhaust:

Air Cleaner Assembly

Air Cleaner Filter Element Service  

Air Cleaner Service  

Air Horn  

Air Induction Hose Replacement  

Air Intake Vent Line Replacement  

Diesel Fuel Injection System  

Drainage Bracket Replacement  

Engine Temperature Sender Replacement  

Exhaust System

Catalytic Converter Replacement

Crossover Pipe Replacement  

Muffler Replacement  

Fuel Filter

Drain Hose and Valve Replacement

Service  

Fuel Injection Pump Boot Replacement  

Fuel Injection System

Injection Line Bracket and Clamp  

Fuel Lift Pump Service  

Fuel System

Contamination  

Diagnosis  

Electronic Accelerator Pedal  

Electronic Injection Pump

Essential Tools

Fuel Filter-Water Separator  

Fuel Injectors  

Fuel Lift Pump  

Fuel Selector Valve  

Fuel Tanks, Lines, and Valves  

Glow Plugs

Fuel Tank

Auxiliary Fuel Tank  

Draining  

Fuel Level Transmitter and Tank Access

Plate Service  

Fuel Tank Vent Line Service

Main Fuel Tank  

Main/Auxiliary Tank Fuel Line  

Vent Filter Replacement  

Glow Plug

Relay/Controller Replacement  

Service  

Main Fuel Tank

Fuel Level Transmitter  

Tank Cleaning  

Powertrain Control Module  

Scan Tool Diagnosis

Sensor and Switch Service  

Sensor, Oil Pressure Switch, and Transmitter  

Weathercap Replacement  

 

Section 4

Cooling System:

Engine Cooling System

Description  

Diagnosis and Troubleshooting

Service  

Fan and Clutch Assembly Service  

Low Coolant Sensor  

Radiator

Lower Hose Replacement  

Lower Tube Assembly Replacement  

Rear Support Bracket  

Shroud Shield Assembly Replacement  

Upper Hose Replacement  

Radiator and Fan Shroud Assembly  

Serpentine Belt Replacement  

Surge Tank

Overflow Hose Replacement  

Replacement  

Tank-to-Lower Radiator Tube Hose

Tank-to-Radiator Vent Hose  

Thermostat Bypass Hose Replacement  

Thermostat Replacement  

Water Crossover Service  

Water Pump

Inlet Hose Replacement  

Water Pump and Adapter Plate  

 

Section 5

Transmission/Transfer Case:

Bulkhead, 76 Way  

Converter Housing

Lower Cover Replacement  

Upper Cover Replacement  

Extension Housing Bushing and Seal  

Flexplate Replacement  

Front Output Shaft

Bearing and Seal Replacement  

Seal Replacement  

Input Gear Bearing Replacement  

Instrument Panel, 56 way    

Mainshaft Pilot Bearing Replacement  

PCM, 24 Way, Brown  

PCM, 32 Way, Blue  

PCM, 32 Way, Brown  

Propeller Shaft

Torque Specifications  

Shift Control Assembly

Installation  

Removal  

Service  

Shift Linkage Adjustment  

Torque Converter/Oil Pump Seal  

Transfer Case

Assembly  

Cleaning and Inspection  

Description  

Diagnosis  

Disassembly and Overhaul  

Fluid Change  

Fluid Level  

Guide Cable Replacement  

Identification  

Installation  

Oil Cooler  

Operating Ranges  

Recommended Lubricant  

Removal  

Shift Rod Service  

Shifting  

Speed Sensor and Switch Replacement  

Torque Specifications  

Vent Line Replacement  

Transmission

Cooler Line and Bypass Valve Service  

Diagnosis  

Line Pressure Test  

Pressure Control Solenoid Test  

Road Test  

Electronic Shift Control Components  

Engine Sensor Inputs  

Essential Tools  

Fill Tube Replacement  

Fluid And Filter Replacement  

Fluid Temperature Sensor  

Gear Ranges  

Gear Ratios  

Identification  

Input and Output Speed Sensors   

Input Speed Sensor Replacement  

Installation  

Park Lock Component Service  

Park/Neutral Position Switch Replacement  

Pressure Control Solenoid  

Rear Mount Replacement  

Recommended Fluid  

Removal  

Scan Tool Diagnosis  

Serviceability  

Shift Rod Replacement  

Shift Solenoids  

Shifter Boot Cover Replacement  

Special Tools  

Torque Converter  

Torque Converter Clutch Solenoid  

Torque Specifications  

Valve Body Switch and Solenoid Service  

Vent Line Service  

Warning Lamps  

Transmission Passthrough, 20 way  

Transmission, 10 Way, Black  

 

Section 6

Wheels and Tires/Central Tire

Inflation System (CTIS):

Central Tire Inflation System

Air Intake Line and Assembly

Air Leak Troubleshooting  

Air Pressure Gauge  

Air Pressure Gauge Lamp

Air Pressure Indicator Lines  

Air Pressure Switch

Auxiliary Air Hose  

Compressor Fuse  

Compressor Relay  

Compressor Service  

Deflate Valve Assembly

Description  

Dust Excluder Replacement  

Front CTI Line Replacement  

Front Supply Tube and Hose  

Geared Hub Replacement  

Inflate/Deflate and Tire Selector Switches

Instrument Cluster  

Interior Harness  

Low Pressure Alarm  

Quick-Disconnect Valve and Tube

Rear CTI Line Replacement  

Rear Tube Connection Shield  

Spindle Extension and Seal    

Supply Line  

Troubleshooting  

Tube Shield Replacement  

Indicator Lights

Compressor/Low Pressure

Runflat

Compressor Belt Replacement  

Steering Stop Adjustment  

Wheels and Tires

Balancing  

Checking Wheel Alignment  

One-Piece Aluminum Wheel and Two-Piece

Runflat Service  

Special Tools  

Tire, Two-Piece Wheel, and Runflat Replacement  

Troubleshooting  

Wheel Alignment  

Wheel Alignment Correction  

Wheel and Tire Assembly Replacement  

Wheel Half Stud Replacement  

Wheel Runout Inspection  

 

Section 7

Brake System:

Anti-lock Brake System (ABS) and Automatic Traction Control,

TorqTrac 4™ (TT4™)  

ABS ECU Replacement  

ABS Modulator Replacement  

ABS/TT4 Diagnostics  

Fault Diagnostic Procedure  

Fuse and Relay Replacement  

System Description  

System Operation  

Brake Master Cylinder

Bench Bleeding  

Bleeding  

Replacement  

Brake System

Bleeding Instructions  

Brake Line Replacement  

Brake Rotor  

Burnishing Linings and Rotors  

Caliper Overhaul, Rear  

Description  

Diagnosis  

Disc Brake Caliper Repair, Front  

Front Service Brake Caliper  

Hydro-Boost System Diagnosis

Left Parking Brake Cable Replacement  

Pad Replacement, Service Brake

Parking Brake Cable Replacement, L  

Parking Brake Cable Replacement, R  

Parking Brake Lever Adjustment  

Parking Brake Lever Replacement  

Parking Brake Switch Replacement  

Pedal Replacement, Service Brake  

Proportioning Valve Replacement

Rotor Replacement, Service Brake  

Troubleshooting  

Hydro-Boost

Bleeding the Hydro-boost System

Hydro-Boost Replacement  

Rear Dual Service/Parking Brake

Adjustment

Caliper Replacement

Pad Replacement  

Rod Replacement  

Speed Sensor Replacement

Tone Wheel Replacement

 

Section 8

Steering System:

Intermediate Steering Shaft

Dust Boot Replacement  

Installation  

Removal  

Replacement  

Power Steering Pump

Assembly  

Cleaning and Inspection  

Disassembly

Repair  

Steering Specifications  

Steering Gear Adjustment Preload Torques  

Steering Pump Flow Rates and Operating Pressures  

Torque Specifications  

Steering System

Center Link Replacement  

Description  

Essential Tools

Idler Arm Replacement  

Pitman Arm Replacement  

Power Steering

Cooler and Hose Replacement

Fluid Reservoir Replacement  

Gear Adjustments  

Gear Assembly and Adjustment  

Gear Cleaning and Inspection  

Gear Disassembly and Overhaul  

Hydraulic System Pressure  

Power Steering Gear Service  

Pressure Test

Pump and Pulley Replacement  

Purging Air from the System  

System Diagnosis Charts  

System Flushing  

Special Tools  

Steering Column

Ignition Interlock Cable Replacement  

Ignition Switch Lock Cylinder  

Lock and Switch Housing

Multi-Switch Replacement  

Steering Column Repair  

Steering Column Replacement  

Steering Gear Replacement  

Steering Wheel Hub/ Column Shroud  

Steering Wheel Replacement  

Tie Rod End Replacement  

Tie Rod Replacement  

 

Section 9

Axles, Suspension, and Frame:

Airlift Brackets  

Axle

Output Shaft Seal Replacement  

Pinion Seal Replacement  

Support and Side Mounting Brackets  

Vent Line Replacement  

Axle Assembly

Cover Service

Repair  

Replacement  

Bumpers

Front Bumper and Towing Brackets  

Rear Bumper Outer Mounting and Tiedown Brackets  

Rear Bumper Replacement  

Frame

Front Suspension Brace Replacement  

Front Suspension Front Crossmember

Front Suspension Rear Crossmember  

Inspection

Left Engine Mount Bracket  

Left Intermediate Body Mount Bracket  

Lifting Shackle Replacement  

Radiator Front Mount Bracket  

Rear Suspension Front Crossmember  

Rear Suspension Rear Crossmember  

Rear-Front Tiedown Bracket

Rear-Rear Tiedown Bracket  

Repairs  

Right Engine Mount Bracket  

Right Front Body Mount Bracket  

Right Intermediate Body Mount Bracket  

Transmission Crossmember Support  

Transmission Mount Crossmember  

Transmission Mount Replacement  

Geared Hub

Input Seal Replacement  

Repair  

Replacement  

Side Cover Replacement  

Spindle Bearing Adjustment  

Spindle Seal Replacement  

Vent Line Replacement

Halfshaft Boot Replacement  

Splash Shield Support Bracket Replacement  

Spring Seat Replacement

Suspension System

Control Arm Bushing Replacement  

Frame Extension Replacement  

Front Bumper and Towing Brackets  

Front Bumper Mounting Bracket  

Lower Ball Joint Replacement  

Lower Control Arm Replacement  

Radius Rod Replacement  

Rear Upper Control Arm Bracket

Stabilizer Bar Link Replacement  

Stabilizer Bar Replacement  

Upper Ball Joint Replacement  

Upper Control Arm Replacement  

Winch

Assembly Repair  

Cable Replacement  

Electric Thermal Switch/Brush Assembly  

Replacement  

Troubleshooting  

 

Section 10

Body:

 

Airlift to Hood Seal Replacement  

Armrest Replacement  

Ashtray Replacement  

Body Inspection and Repair  

Aluminum Repair  

Fiberglass Repair  

Lockbolt Failure  

Rivet Failure  

Rivet Replacement  

Body Mount Replacement

Cargo Tiedown Replacement  

Center Console Replacement  

Cigarette Lighter Replacement  

Dimmer Control Switch Replacement  

Door Glass

“Wind Noise”  

Replacement  

Door Stop Strap Assembly Replacement  

Doors

Disassembly, Replacement and Repair  

Door Glass  

Door Seals Replacement  

Rear Vertical Door Replacement  

Engine Access Cover  

Hold-Down Striker Replacement  

Inner Flexible Latch Replacement  

Engine Access Cover Maintenance  

Former Assembly Replacement, “A” Pillar  

Front Console Replacement  

Front License Plate Bracket Replacement  

Front Striker Replacement  

Fuel Filler Housing Replacement  

General Body Information

Glovebox Replacement 

Hood

Center Hood Stop Replacement  

Front Hood Screen Replacement  

Grille and Screen Replacement  

Guide Bracket Assembly Replacement  

Hood and Hinge Replacement  

Hood Latch And Prop Rod  

Hood Prop Rod and Bracket Replacement  

Hood Release Cable Replacement  

Hood Retainer Bracket, L  

Hood Retainer Bracket, R  

Latch and Bracket Replacement  

Outer Hood Seal Replacement  

Right Close-Out Seal and Retainer  

Side Hood Stop Replacement  

Rear License Plate Bracket Replacement  

Rear Striker Assembly Replacement

Rear Support Bow Bracket, Station Wagon  

Rear Vertical Door

Door Frame and Seal Replacement  

Door Handle Replacement  

Door Latch and Latch Rod Replacement  

Door Replacement  

Door Stop Replacement  

Window Replacement  

Roadside Emergency Equipment  

Seat Belts

Seat Belt Assembly Replacement  

Seats

Front Seats  

Reclining Seat Replacement  

Standard Seat Pedestal Repair  

Slant Back

Glass and Body  

Slant Door and Torsion Assembly Replacement  

Slant Door Handle, Latch, And Lock Actuator  

Wiper Motor and Components  

Soft Top

Mounting Components and Accessories  

Soft Top Support/Roll Cage Assembly  

Horn

Horn Assembly Replacement  

Mounting Bracket Replacement  

Instrument Panel

Dashpad Replacement  

Gauge Replacement  

Gauges and Switches  

Indicator Lamp Replacement  

Instrument Panel Replacement  

Switch Replacement  

Interior Trim

B-Bar Replacement  

Driver’s Compartment Trim Replacement  

Floor Carpeting and Padding Replacement  

Inner Kick Panels Replacement  

Outer Kick Panel Replacement  

Passenger’s Compartment Trim  

Replacement  

Station Wagon Rear Compartment Trim  

Four-Passenger Soft Top  

License Plate Brackets  

Lift Gate Assembly  

Lights

Backup Light Switch Replacement  

Front Courtesy Light  

Interior and Exterior Lighting  

Backup Light Switch  

Cargo Light  

Courtesy Light  

Domelight Replacement  

Front Turn Signal Light Replacement  

Identification Light Replacement  

Maplight Replacement  

Optional Trouble Light Replacement  

Rear Turn Signal Light Replacement  

Service Headlight Assembly  

Service Headlight Electrical Connector and

Grommet Replacement  

Side Marker Light Assembly  

Side Marker Light Lens and Lamp  

Underhood Light Replacement  

Rear Seat Courtesy Light  

Stoplight Switch Replacement  

Load Barrier and Mounting Brackets  

Mirrors  

Lighted Visor Mirror Replacement  

Power Mirrors  

Rearview Mirror Replacement  

Side Mirror Replacement  

Speedometer/Odometer Replacement  

Splash Shield (Engine) Replacement  

Tachometer Replacement  

Tailgate

Chain Brackets Replacement  

Chain Replacement  

Tailgate and Seals Replacement  

Tire Jack

Jack and Triangle Warning Kit

Hold-Down Bracket Replacement  

Visor Replacement  

Water Leak Detection and Repair  

Windshield

Assembly Maintenance  

Glass and Weatherstrip Replacement  

Heated Windshield  

Reservoir and Pump Assembly  

Washer Hoses Replacement  

Washer Nozzle Replacement  

Washer System and Components  

Windshield Assembly  

Wiper Jumper Harness Replacement  

Wiper Linkage Replacement  

Wiper Motor Assembly Replacement  

Wiper Pivot Replacement  

Wiper System and Components  

 

Section 11

Heating/Ventilation/Air Conditioning (HVAC):

 

A/C System Refrigerant and Capacity  

Air Conditioning/Heater Duct Replacement  

Ambient Temperature Switch  

Auxiliary HVAC Unit

A/C Drain Tube(s) Replacement  

Blower Motor Replacement  

Blower Switch Replacement  

Evaporator/Heater Core Replacement  

Expansion Valve Replacement  

Heater Hose Replacement  

High-Pressure Hose Replacement  

Low-Pressure Hose Replacement  

Replacement  

Blend Door Motor  

Blower Motor Resistor Replacement  

Climate Control System

A/C Pressure Hose Replacement  

Condenser Replacement  

Control Head Replacement  

Heater Hose Replacement  

Heater/A/C Diagnosis  

System Performance Checks  

Compressor

Clutch Core Replacement  

Clutch Rotor and/or Bearing Replacement  

Description  

Replacement  

Shaft Seal Replacement  

Condenser  

Controls  

Defrost Duct and Windshield Nozzles Replacement  

Drain Tube Replacement 

Essential Tools  

Evaporator  

Air Intake Assembly Replacement  

Cycling Switch Replacement  

Heater Hose Replacement  

High Pressure Cutoff Switch  

Low Pressure Cutoff Switch  

Main HVAC Unit

Blower Motor  

Diverter Doors  

Evaporator  

Expansion Valve  

Heat Unit Cowl Insulation Replacement  

Heater Core  

High Pressure Cutoff Switch  

Replacement  

Thermostatic Cycling Switch  

Pressure Hose Torque Specifications  

Rear Console Replacement  

Receiver Dryer Replacement  

Receiver/Dryer

Receiver/Dryer Pressure Switch Replacement  

Special Tools  

Specifications  

System Description

System Diagnosis  

System Performance Checks

Unit Service  

Vacuum Door Motor  

Water Control Valve  

Water Control Valve Replacement

 

Section 12

Electrical System:

Audio

Antenna System Test  

CD Changer (Delco) Replacement  

Diagnosis-Delco Audio System  

Corrective Action  

Identifying Concerns  

Electrical Harness Replacement, Delco Monsoon

(Models 83, 84 & 91)  

Electrical Harness Replacement, Delco Standard

(Model 89)  

Electrical Harness Replacement, Delco Standard

(Model 90)  

Electrical Harness Replacement, Delco Standard

(Models 83, 84 & 91)  

Generator Whine Concerns  

Overhead Console, Speaker and Amplifier

Replacement (Delco Monsoon)  

Radio (Delco) Replacement  

Rear Seat Audio (RSA) Unit Replacement  

Symptom Table  

System Description  

Test Antenna  

Battery

Battery Charging  

Cable Maintenance  

Power Distribution  

Replacement  

Splash Shield and Seal Service  

Tray Replacement  

Brake Shift Interlock System

Brake Shift Interlock Cable Inoperative  

Ignition Switch Replacement  

Shift Interlock Cable Schematic  

Charging System

Alternator  

Alternator Overhaul  

Diagnostics  

Cigarette Lighter Replacement  

Cruise Control

Cruise Control Inoperative VIN Z  

Cruise Control Schematic  

Cruise Control Systems  

CTIS

CTIS Compressor Inoperative  

CTIS Exhaust Valve Inoperative  

CTIS Front Inflate Valve Inoperative  

CTIS Rear Inflate Valve Inoperative  

CTIS Schematic  

Digital Ratio Adapter  

Power Locks

Cargo Door Lock Inoperative  

Front Door Harness Replacement  

General Replacement  

Keyless Entry & Theft Detterent System Operating

Instructions  

Keyless Entry Programming  

Keyless Entry System Features  

Power Locks HMC4, XLC2 , HMSB  

Power Locks HMCS W/ Remote Entry  

Power Locks Inoperative  

Rear Door and Jumper Harness  

Remote Entry Module Power/Ground  

Remote Entry System Inoperative  

Slant Door Lock Inoperative  

Power Mirrors

Ambient Temperature Sensor  

Auto-Dimming Compass Mirror Calibration and

Zone Adjustments  

Auto-Dimming Rear View Mirror  

Compass Mirror Display Inoperative  

Compass Mirror Schematic  

Power Side Mirror  

Power Window and Door Locks

Front Door Harness Replacement  

Power Windows

Power Window Schematic  

Power Windows Inoperative, All Windows  

Power Windows and Door Locks

Rear Door Harness Replacement  

Starter  

Diagnostics  

Overhaul  

Windshield  

Wipers

Rear Window Wiper Inoperative  

Rear Wiper Motor Schematic  

Windshield Wiper Motor Inoperative All Speeds  

Windshield Wipers Intermittent Speeds Inoperative  

Wiper/Washer Schematic  

Fuel System

Fuel Lift Pump Inoperative  

Fuel Lift Pump Schematic  

Fuel Manager Schematic  

Fuel Selector Valve Schematic  

Fuel Tank Selector System Inoperative  

General Information

Auxiliary Power Point, Interior Fuse Box  

Auxiliary Power Studs, Exterior Fuse Box  

Circuit Faults  

Diagnostic Tests  

Fuse/Relay Location and Identification  

Ground Points  

Preliminary Checks  

Glow Plugs

Diagnostics  

Schematic  

Heated Glass

Both Heated Windshields Inoperative  

Heated Windshield Schematic  

Left Heated Windshield Inoperative  

Rear Window Defroster Inoperative  

Rear Window Defroster Schematic  

Right Heated Windshield Inoperative  

Horn

Horn Replacement  

Horn Schematic  

Horns Inoperative  

HVAC Systems

HVAC Blower Schematic  

HVAC Compressor Inoperative  

HVAC Compressor Schematic  

HVAC Main Blower Inoperative ALL BUT High  

HVAC Temp Blend Door/Rear Blower  

HVAC Temperature Door Inoperative  

Instrument Panel

Engine Temperature Gauge Inoperative  

Fuel Gauge Inoperative  

Gauge Replacement  

Gauges and Switches  

Gauges Schematic  

Low Coolant Lamp Inoperative  

Oil Pressure Gauge Inoperative  

Replacement  

Lighting Systems

Key/Headlight Chime Schematic  

Lights Schematic  

 

Section 13

Accessories:

Air Restriction Gauge  

Auxiliary Seat

Belt Replacement

Frame Replacement

Locking Pin Replacement  

Replacement

Brushguard Assembly Replacement  

Delco Compact Disc Changer Replacement  

Dual Oil Filter  

Hourmeter

Off Road Light Package  

Roof Rack

Clamp Replacement

Crossbar Replacement  

End Replacement

Running Board Replacement  

Seat Heater  

Spare Tire Carrier

Cargo Deck Mounted  

Swing-Away  

Trailer Hitch Replacement  

Trailer Towing Connector

Underbody Protection

Front Shield Replacement  

Intermediate Shield Replacement  

Rear Shield Replacement  

Skid Plate Replacement  

Transfer Case Shield Replacement  

Rocker Panel Protection Replacement  

Winch

Assembly Repair  

Cable Replacement  

Electric Thermal Switch/Brush Assembly  

Replacement  

Troubleshooting  

 

BONUS – FULL PARTS CATALOG!

 

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 Language: English 
Format: PDF – Indexed and Searchable

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