2003-2009 Hummer H2 Service & Repair Manual

GMT/05-H-ELV H2 VEHICLE DISMANTLING MANUAL

Cautions Provide additional support when a vehicle is on a hoist in the following ways: • Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off. • Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off. Disconnect the battery prior to fluid removal and dismantling in order to reduce risk of fire and personal injury. Always wear safety goggles when working with fuel in order to protect the eyes from splash. Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Relieve the fuel system pressure before dismantling fuel system components in order to reduce the risk of fire and personal injury. Drain the fuel from the complete system, including injector nozzle(s), the fuel pump, all fuel pipes, and the fuel tank. Draining the fuel will reduce the risk of fire and personal injury. Provide proper ventilation when working with fuel in enclosed areas where fuel vapors can collect. The lack of adequate ventilation may result in personal injury. This vehicle has a Supplemental Inflatable Restraint (SIR), “airbag” system. When performing disassembly on or near the SIR components or the SIR wiring, refer to cautions below. Failure to follow the cautions could cause airbag deployment or personal injury. • Be careful when handling a SIR sensor. Do not strike or jolt a SIR sensor. • Do not carry the inflator module by the wires or connector on the inflator module. • Make sure the airbag opening points away from you. • When storing an undeployed inflator module, make sure the airbag opening points away from the surface on which the inflator module rests. • Provide free space for the airbag to expand in case of an accidental deployment. Follow all applicable local laws and ordinances while performing procedures and processes related to these activities. The specifications and designs described herein are believed to be correct as of the time this book was approved for printing.

i Table of Contents Section Page No. Introduction...............................................................................................1 Activity Area 0...........................................................................................2 Activity Area 1...........................................................................................4 Activity Area 2...........................................................................................6 Activity Area 3...................................................................................…...10 Activity Area 4.........................................................................................12 Activity Area 5.........................................................................................14 Activity Area 6.........................................................................................16 Activity Area 7.........................................................................................18

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1 INTRODUCTION This manual contains dismantling data for the following vehicles: MODEL YEAR MAKE MODEL VARIANT ENGINE TRANSMISSION 2005 Hummer H2 4X4 6.0L V8 4L65-E

2 2005 H2 ACTIVITY AREA 0 PRETREATMENT 0.1 Oil 0.2 Oil 0.3 Multiple 0.4 Oil 0.5 Coolant 0.6 Refrigerant 0.7 Multiple 0.8 Multiple 0.9 EPDM 0.10 PE 0.12 Oil 0.13 Oil 0.14 Oil 0.15 Oil 0.16 Multiple 0.11 EPDM 0.17 Lead 0.17 Lead

3 Dismantling Manual 2005 Hummer H2 Activity Area 0 -- Pretreatment Area: Pretreatment Model: H2 Activity Ref Area # Part Name Material Qty Total Volume or Weight 0.1 Engine oil Oil 5.7 L 0.2 Front axle oil Oil .08 L 0.3 Engine oil filter Multiple 1 0.55 kg 0.4 Steering oil Oil 1.10 L 0.5 Coolant Coolant 14.0 L 0.6 Refrigerant 134A Refrigerant 134 0.80 kg 0.7 Passenger air bag Multiple 1 3.84 kg 0.8 Driver side air bag Multiple 1 1.03 kg 0.9 Spare tire EPDM 1 15.35 kg 0.10 Fuel tank PE 1 16.14 kg 0.11 Tires EPDM 4 61.48 kg 0.12 Rear axle oil Oil 1.9 L 0.13 Transfer case oil Oil 1.40 L 0.14 Transmission oil Oil 10.60 L 0.15 Brake fluid Oil 0.70 L 0.16 Battery Multiple, including lead 1 21.6 kg 0.17 Wheel weights Lead 4 0.20 kg Information & Comments: Total Volume or Weight = single part material multiplied by the quantity.

4 1.1 GLASS 1.2 GLASS 1.3 GLASS 1.4 GLASS 1.4 GLASS 1.5 GLASS 1.2 GLASS 1.3 GLASS 2005 H2 ACTIVITY AREA 1 DOORS AND GLAZING GLASS

5 Dismantling Manual 2005 Hummer H2 Activity Area 1 -- Doors and Glazing Area: Doors and Glazing Model: H2 Activity Ref Area # Part Name Material Qty Total Material Weight (kg) 1.1 Windshield Glass 1 12.91 1.2 Front door window Glass 2 9.17 1.3 Rear side door window Glass 2 8.96 1.4 Rear body side window Glass 2 6.80 1.5 Liftgate glass Glass 1 6.49 Information & Comments: Total Material Weight = weight of single part material multiplied by the quantity.

6 2005 H2 ACTIVITY AREA 2 EXTERIOR TRIM 2.1 TEO 2.2 ASA+PC 2.4 TEO 2.5 TEO 2.5 TEO 2.3 ASA+PC 2.6 ASA+PC 2.6 ASA+PC 2.8 ASA+PC 2.10 ABS 2.11 TEO 2.11 TEO 2.12 TEO 2.12 TEO 2.12 TEO 2.13 TEO 2.13 TEO 2.15 ASA+PC 2.15 ASA+PC 2.14 TEO 2.16 ASA+PC 2.12 TEO 2.10 ABS 2.9 ABS 2.8 ASA+PC 2.7 PP 2.4 TEO ABS PP OTHER

2003-2009 Hummer H2 Service & Repair Manual

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