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Hummer 6.5L Turbo Diesel Commercial Vehicle Shop Manual 2000 – 2003 -PDF DOWNLOAD


Hummer 6.5L Turbo Diesel Commercial Vehicle Shop Manual 2000 – 2003

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Hummer 6.5L Turbo Diesel Commercial Vehicle Shop Manual 2000 – 2003

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LANGUAGE:ENGLISH
PAGES:2122
DOWNLOADABLE:YES
FILE TYPE:PDF

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Hummer 6.5L Turbo Diesel Commercial Vehicle Shop Manual 2000 – 2003 

SAFETY SUMMARY :

Individuals who decide to perform their own repairs should have proper training and limit repairs to components which will not affect the safety of the vehicle or its occupants. When replacement parts are required, it is strongly recommended that they are purchased through an authorized HUMMER dealer.

  • It is essential that replacement parts meet or exceed manufacturerÕs specifications. Vehicle performance and personal safety may be impaired if other than original factory components are installed.
  • The installation of nonapproved accessories or conversions is not recommended as they could affect the vehicleÕs driving characteristics and personal safety.
  • AM General Corporation will not be liable for personal injury or damage to property resulting from the installation of nonapproved accessories or conversions to the HUMMER. Following the safety precautions as prescribed throughout this manual may greatly reduce the risks of personal injury and damage to the vehicle.
  • However, it is unlikely that AM General Corporation will account for all possibilities. Warnings, cautions, and notes are used throughout this service manual to assist service personnel in the performance of maintenance actions. These statements are designed as reminders for trained and experienced service personnel.

TABLE OF CONTENTS:

Hummer 6.5L Turbo Diesel Commercial Vehicle Shop Manual 2000 – 2003 

Engine:
Manufacturer GM Powertrain
Model 65 L (395 in 3)
TypeFour Cycle, Turbocharged Diesel, Liquid-Cooled
Power Output: 195 HP @ 3400 rpm/430 ft lb Torque @ 1800 rpm
Engine Dimensions:
Length 35 in (89 cm)
Width 28 in (71 cm)
Height 28 in (71 cm)
Net Weight, Dry 701 lb (318 kg)
Governed Speed:
Full Load 3,400 RPM
No Load 3,650 RPM
Idle Speed 700 RPM
Operating Speed 1,500-2,600 RPM
Cylinders:
Number8
Arrangement 90¡ V
Firing Order1-8-7-2-6-5-4-3 (Clockwise)
Bore 406 in (10312 mm)
Stroke 382 in (97 cm)
Displacement65 L (395 in 3)
Compression Ratio: 202:1
Lubricating System:
Type Pressure Feed
Operating Pressure:
(Minimum) 30 psi (2068 kPa) @ 2000 RPM
(Idle Minimum) 6 psi (413 kPa)
System Capacity (Filter Included) 8 qt (76 L)
Operating Temperature (Normal) 180¡-275¡ F (82¡-135¡ C)
Oil Pump High Output
Filter Paper Element, Spin On
Fuel/Air System:
Fuel Supply Pump Type Electronic
Fuel Filter Type Two Stage Fuel Filter /Water Separator
Glow Plug Type (11G) Fast Start
Starter:
Manufacturer Prestolite
Model MMO
Capacity (Peak) 60 hp
Voltage 12 V
Cooling System:
Type Liquid w/Fan and Radiator
Operating Temperature 190¡-235¡ F (88¡-113¡ C)
Filler Cap Pressure 15 psi (103 kPa)
Radiator Type 4 Row Core Downflow
Fan Type8 Blade,suction w/viscous drive
Fan Diameter 195 in (495 cm)
1-8 General Information, Lubrication and Maintenance
Thermostat:
Starts to Open 190¡ F (88¡ C)
Fully Open212¡ F (100¡ C)
Generator:
Manufacturer Delco
Output 124 AMP @ 1842 Engine RPM
Rated Voltage 1335 -159 V
Batteries:
Manufacturer Johnson Controls
Type Low Maintenance
Number 2
Voltage 12 V
Amperage
@ 0¡ F 800 Cold Cranking amps Each Battery
32¡ F 1000 Cold Cranking amps Each Battery
80¡ F 110 Reserve Capacity (Minutes)
Transmission:
Manufacturer GM Powertrain
Model 4L80-E
Type 4-Speed, Automatic
Converter Torque Ratio 22:1
Gear Ratios:
First 248:1
Second 148:1
Third 100:1
Fourth 075:1
Reverse 208:1
Oil Type Dexron
¨
III
Oil Pressure 35-324 psi (241-2,234 kPa)
Transfer Case:
Manufacturer New Venture Gear
Model242
Type Full Time Four-Wheel Drive
Gear Ratios
High and High Lock 1:1
Low Range 272:1
Oil Type Dexron
Geared Hub:
Manufacturer AM General Corporation design, made by Tremec
TypeSpur Gears
Gear Ratio192:1
Oil TypeSAE 80-90
Axle/Differential:
Manufacturer AM General Corporation design, made by Dana
Type:
Axle Fixed Mounted Differential W/ Independent Half Shafts
Differential Hypoid Torque Biasing (Paired Worm Gears)
General Information, Lubrication and Maintenance 1-9
05745159
Service Brake Caliper (Front):
Manufacturer Kelsey-Hayes
Piston Diameter 26 in (66 cm)
Service/Parking Brake Caliper (Rear):
Manufacturer Kelsey-Hayes
Piston Diameter 26 in (66 cm)
Service/Parking Brake Rotor:
Manufacturer Kelsey-Hayes
Diameter 105 in (2667 mm)
Thickness 087 in (22 mm)
Minimum Thickness081 in (207 mm)
Steering System:
Steering Gear:
Manufacturer Saginaw
Type Recirculating Ball, Worm and Nut
Ratio 13/16:1
Power Steering Pump:
Manufacturer Saginaw
Output Pressure (Max) 1,465 – 1,515 psi (10,101 – 10,446 kPa)
Flow Rate (Max) 26 gpm (98 Lpm)
Capacity (@ 1500 RPM) 26 gpm (98 Lpm)
Reservoir Remote
Frame:
Manufacturer AM General Corporation design, made by Dana
Type Steel Box
No of Crossmembers5
Air Conditioner:
Manufacturer (Compressor) GM-Harrison
Model HD-6
Field (Coil) 12 V
Oil Capacity 8 fl oz (237 ml)
Refrigerant R-134a
Capacity (system + 2 oz of oil) 32 lb (145 kg)
Winch:
Manufacturer Warn
Model 12,000 lb, 12VDC HUMMER
Type Electric Drive, Thermal Cutoff Switch
Capacity 12,000 lb (5,448 kg)
Wheels and Tires:
Manufacturer Goodyear Tire Size 37 in X 125R-165
Wheel Type:
Standard One-Piece
Size165 x 825 in
1-10 General Information, Lubrication and Maintenance
________________
¨
FLUID CAPACITIES
Cooling System 26 qt (25 L)
Engine:
Crankcase (oil pan) only 7 qt (66 L)
Crankcase and Filter 8 qt (76 L)
Fuel Tank25 gal (95 L)
Auxiliary Fuel Tank 17 gal (643 L)
Axle (front/rear) 2 qt (19 L)
Transmission:
Drain and Refill (with Pan Removed) 77 qt (73 L)
W/Dry Converter 135 qt (128 L)
Transfer Case 35 qt (33 L)
Geared Hub 1 pt (047 L)
Steering System 1 qt (095 L)
Brake Hydraulic System (DOT 3)
Master Cylinder 164 pt (078 L)
Total System 312 pt (15 L)
Windshield Washer Reservoir25 gal (95 L)
VEHICLE WEIGHTS
Curb Weight (10,300/10,800 GVWR):
Two-Door Enlarged Cab (Hard Top) (XLC2) 6,460 lb (2,930 kg)
Four Door Open Top (w/ full doors) (HMCO) 6,710 lb (3,044 kg)
Four Door Hard Top (HMC4) 6,860 lb (3,112 kg)
Four-Door Station Wagon (HMCS) 7,050 lb (3,198 kg)
Payload (10,300 GVWR):
Two-Door Enlarged Cab (Hard Top) (XLC2) 3,840 lb (1,742 kg)
Four-Door Open Top (w/ full doors) (HMCO) 3,590 lb (1,628 kg)
Four Door Hard Top (HMC4) 3,440 lb (1,560 kg)
Four-Door Station Wagon (HMCS) 3,250 lb (1,474 kg)
Payload (10,800 GVWR):
Two-Door Enlarged Cab (Hard Top) (XLC2) 4,340 lb (1,968 kg)
Four-Door Open Top (w/ full doors) (HMCO) 4,090 lb (1,855 kg)
Four Door Hard Top (HMC4) 3,940 lb (1,768 kg)
Four-Door Station Wagon (HMCS) 3,750 lb (1,700 kg)
Gross Vehicle Weight (GVW) 10,300 lb (4,676 kg)/10,800 lb (4,899 kg)
Gross Axle Weight Rating (GAWR):
Front 4,100 lb (1,860 kg)
Rear 6,800 lb (3,084 kg)
Gross Combination Weight (GCW) 14,800 lb (6,719 kg)
Maximum Towed Load:
Two-Door Enlarged Cab (Hard Top) (XLC2) 8,340 lb (3,783 kg)
Four-Door Open Top (w/ full doors) (HMCO) 8,090 lb (3,670 kg)
Four-Door Hard Top (HMC4) 7,940 lb (3,602 kg)
Four-Door Station Wagon (HMCS) 7,750 lb (3,515 kg)
General Information, Lubrication and Maintenance 1-11
05745159
Turbo Diesel Engine — (12,100 lb (5,489 kg) GVWR Vehicles — Fleet Vehicles Only
Curb Weight (12,100 GVWR):
Two-Door Enlarged Cab (Hard Top) (XLC2) 6,720 lb (3,048 kg)
Four Door Hard Top (HMC4) 7,120 lb (3,230 kg)
Four-Door Station Wagon (HMCS) 7,310 lb (3,316 kg)
Payload (12,100 GVWR):
Two-Door Enlarged Cab (Hard Top) (XLC2) 5,380 lb (2,440 kg)
Four Door Hard Top (HMC4) 4,980 lb (2,258 kg)
Four-Door Station Wagon (HMCS) 4,790 lb (2,172 kg)
Gross Vehicle Weight (GVW) 12,100 lb (5,488 kg)
Gross Axle Weight Rating (GAWR):
Front 4,400 lb (1,995 kg)
Rear 7,700 lb (3,492 kg)
Gross Combination Weight (GCW) 16,500 lb (6,719 kg)
Maximum Towed Load:
Two-Door Enlarged Cab (Hard Top) (XLC2) 9,780 lb (4,436 kg)
Four-Door Hard Top (HMC4) 9,380 lb (4,254 kg)
Four-Door Station Wagon (HMCS) 9,190 lb (4,168 kg)
VEHICLE DIMENSIONS
Length (see Note)1845 in (4,686 mm):
Height 75 in (1905 mm)
Width (without mirrors) 8650 in (2197 mm)
Ground Clearance 16 in (41 cm) (at GVW)
Wheelbase 130 in (330 cm)
Track Width 72 in (183 m)

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