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HUMMER H2 2003-2009 Factory Repair Service Workshop Manual

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🏷️ Basic Information Identification Make: HUMMER Model: H2 Model Designation: H2 SUV/SUT Generation Generation Code: First Generation (GMT825 platform) Codes Platform Code: GMT825 👋 Introduction Market Position Segment: Luxury Full-Size SUV / Off-Road Vehicle Competitive Analysis Competitors: Cadillac Escalade, Lincoln Navigator, Ford Excursion (though larger) Key Features Distinctive Traits: Aggressive styling, exceptional off-road capability, powerful V8 engine, spacious interior, towing capacity. 📋 Manual Details Coverage Areas Market: US/Canada Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul and component repair procedures for the 6.0L V8 engine. Emission Control: Diagnosis and repair of emission control systems, including catalytic converters, EVAP, and O2 sensors. Fuel Systems: Fuel pump, injectors, fuel lines, pressure regulator, and evaporative emissions control system. Cooling Systems: Radiator, water pump, thermostat, coolant hoses, and fan assembly. Lubrication: Oil pump, oil filter, oil pan, and lubrication passages. Ignition: Spark plugs, ignition coils, crankshaft position sensor, and camshaft position sensor. Starter: Starter motor diagnosis and replacement. Charging System: Alternator, voltage regulator, and battery charging system. Clutch: Clutch assembly and hydraulic system (for manual transmission variants, though less common). Manual Transmission: Disassembly, inspection, and repair of the manual gearbox (if applicable). Automatic Transmission: Detailed diagnostics, repair, and overhaul procedures for the 4L65E automatic transmission. Transfer Case: Service and repair of the 4WD transfer case (e.g., NVG246 or similar). Propeller Shaft: Drive shafts, universal joints, and CV joints. Suspension And Axle: Front and rear suspension components, shock absorbers, springs, control arms, and axle assemblies. Brake: Brake system diagnosis, rotor/pad replacement, caliper service, ABS, and hydraulic lines. Steering: Power steering system, steering column, tie rods, and steering rack/gearbox. Restraint System: Airbag system diagnosis, sensors, and seatbelt service. Body Electrical: Headlights, taillights, interior lighting, power windows, locks, mirrors, and related modules. Body: Body panel alignment, door repairs, glass replacement, and chassis components. Air Conditioning: HVAC system diagnosis, refrigerant service, compressor, condenser, and evaporator. Diagnostics: Diagnostic trouble codes (DTCs), diagnostic procedures, and troubleshooting flowcharts. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, and general inspections. Repair: Step-by-step repair instructions for all major vehicle systems. Troubleshooting: Systematic diagnostic procedures and troubleshooting guides for common and complex issues. Rebuilds: Detailed instructions for engine, transmission, and transfer case rebuilds. Electrical Diagnostics: Wiring diagrams, circuit tests, and component testing for all electrical systems. Technical Depth Depth: Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds. 📊 Manual Specifications File Format File Type: PDF Compatibility: Windows (95/98/ME/XP/Vista/7/8/8.1/10), Linux, MAC OS, iOS, Android Searchability: Searchable text within the PDF document. Print Quality Quality: High-resolution scans with clear, readable text and detailed illustrations. Binding Type Type: Digital (PDF) Paper Type Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: Vortec 6000 (L59) Engine Type: 6.0L V8 OHV 16-valve Performance Horsepower Std: 325 hp @ 5200 rpm Torque Std: 370 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Sequential Electronic Fuel Injection (SFI) Fuel Type: Regular Unleaded Gasoline (87 octane recommended) Displacement Displacement Liters: 5.97 Displacement Ci: 365 🔧 Transmission Standard Transmission Type: 4-Speed Automatic (4L65-E) Drive Type: Full-Time 4WD Optional Transmission Type: 5-Speed Manual (Rare/Export only) Features Transfer Case Type: 2-Speed Electronic Transfer Case with Full-Time 4WD 📐 Dimensions Exterior Length In: 207.5 Width In: 81.3 Height In: 79.2 Wheelbase In: 130 Weights Curb Weight Lbs: 6,720 Gvwr Lbs: 8,600 Towing Capacity Lbs: 7,000 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 3-star (early models, higher center of gravity) Active Features Traction Control: Standard (includes ABS and StabiliTrak) ABS: Standard 4-wheel antilock disc brakes Passive Features Airbags: Front airbags, optional side-impact airbags Seatbelts: 3-point seatbelts with pretensioners 💡 Technology Features Infotainment Head Unit: Optional premium audio systems, CD player, navigation available on higher trims. Driver Assistance Cruise Control: Standard Connectivity Remote Keyless Entry: Standard 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 miles or 6 months (whichever comes first) under normal driving conditions. Tire Rotation Interval: Every 7,500 miles or 6 months. Transmission Fluid Change: Every 50,000-100,000 miles (check severe service intervals in manual). Fluid Specifications Engine Oil Type: SAE 5W-30 Synthetic Blend (GM spec: dexos1 or API SN equivalent) Engine Oil Capacity: 7 Quarts (with filter) Coolant Type: GM DEX-COOL (Orange) or equivalent extended life coolant (50/50 mix). Transmission Fluid Type: Dexron VI (Automatic Transmission) Brake Fluid Type: DOT 3 Known Issues Common Problems: Fuel pump failure, HVAC blower motor issues, power steering leaks, suspension component wear (ball joints, control arms), potential transmission fluid leaks. Durability Notes: Generally robust drivetrain, but the sheer weight and robust off-road nature can accelerate wear on certain components if not maintained. 📚 Vehicle History Brand Heritage Brand Origin: HUMMER was originally a brand of off-road vehicles, stemming from AM General's High Mobility Multipurpose Wheeled Vehicle (HMMWV). Model Evolution Development: The...
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HUMMER H2 2003-2009 Factory Repair Service Workshop Manual
🏷️ Basic Information
Identification
Make:
HUMMER
Model:
H2
Model Designation:
H2 SUV/SUT
Generation
Generation Code:
First Generation (GMT825 platform)
Codes
Platform Code:
GMT825
👋 Introduction
Market Position
Segment:
Luxury Full-Size SUV / Off-Road Vehicle
Competitive Analysis
Competitors:
Cadillac Escalade, Lincoln Navigator, Ford Excursion (though larger)
Key Features
Distinctive Traits:
Aggressive styling, exceptional off-road capability, powerful V8 engine, spacious interior, towing capacity.
📋 Manual Details
Coverage Areas
Market:
US/Canada
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul and component repair procedures for the 6.0L V8 engine.
Emission Control:
Diagnosis and repair of emission control systems, including catalytic converters, EVAP, and O2 sensors.
Fuel Systems:
Fuel pump, injectors, fuel lines, pressure regulator, and evaporative emissions control system.
Cooling Systems:
Radiator, water pump, thermostat, coolant hoses, and fan assembly.
Lubrication:
Oil pump, oil filter, oil pan, and lubrication passages.
Ignition:
Spark plugs, ignition coils, crankshaft position sensor, and camshaft position sensor.
Starter:
Starter motor diagnosis and replacement.
Charging System:
Alternator, voltage regulator, and battery charging system.
Clutch:
Clutch assembly and hydraulic system (for manual transmission variants, though less common).
Manual Transmission:
Disassembly, inspection, and repair of the manual gearbox (if applicable).
Automatic Transmission:
Detailed diagnostics, repair, and overhaul procedures for the 4L65E automatic transmission.
Transfer Case:
Service and repair of the 4WD transfer case (e.g., NVG246 or similar).
Propeller Shaft:
Drive shafts, universal joints, and CV joints.
Suspension And Axle:
Front and rear suspension components, shock absorbers, springs, control arms, and axle assemblies.
Brake:
Brake system diagnosis, rotor/pad replacement, caliper service, ABS, and hydraulic lines.
Steering:
Power steering system, steering column, tie rods, and steering rack/gearbox.
Restraint System:
Airbag system diagnosis, sensors, and seatbelt service.
Body Electrical:
Headlights, taillights, interior lighting, power windows, locks, mirrors, and related modules.
Body:
Body panel alignment, door repairs, glass replacement, and chassis components.
Air Conditioning:
HVAC system diagnosis, refrigerant service, compressor, condenser, and evaporator.
Diagnostics:
Diagnostic trouble codes (DTCs), diagnostic procedures, and troubleshooting flowcharts.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, and general inspections.
Repair:
Step-by-step repair instructions for all major vehicle systems.
Troubleshooting:
Systematic diagnostic procedures and troubleshooting guides for common and complex issues.
Rebuilds:
Detailed instructions for engine, transmission, and transfer case rebuilds.
Electrical Diagnostics:
Wiring diagrams, circuit tests, and component testing for all electrical systems.
Technical Depth
Depth:
Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds.
📊 Manual Specifications
File Format
File Type:
PDF
Compatibility:
Windows (95/98/ME/XP/Vista/7/8/8.1/10), Linux, MAC OS, iOS, Android
Searchability:
Searchable text within the PDF document.
Print Quality
Quality:
High-resolution scans with clear, readable text and detailed illustrations.
Binding Type
Type:
Digital (PDF)
Paper Type
Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
Vortec 6000 (L59)
Engine Type:
6.0L V8 OHV 16-valve
Performance
Horsepower Std:
325 hp @ 5200 rpm
Torque Std:
370 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Sequential Electronic Fuel Injection (SFI)
Fuel Type:
Regular Unleaded Gasoline (87 octane recommended)
Displacement
Displacement Liters:
5.97
Displacement Ci:
365
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic (4L65-E)
Drive Type:
Full-Time 4WD
Optional
Transmission Type:
5-Speed Manual (Rare/Export only)
Features
Transfer Case Type:
2-Speed Electronic Transfer Case with Full-Time 4WD
📐 Dimensions
Exterior
Length In:
207.5
Width In:
81.3
Height In:
79.2
Wheelbase In:
130
Weights
Curb Weight Lbs:
6,720
Gvwr Lbs:
8,600
Towing Capacity Lbs:
7,000
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
3-star (early models, higher center of gravity)
Active Features
Traction Control:
Standard (includes ABS and StabiliTrak)
ABS:
Standard 4-wheel antilock disc brakes
Passive Features
Airbags:
Front airbags, optional side-impact airbags
Seatbelts:
3-point seatbelts with pretensioners
💡 Technology Features
Infotainment
Head Unit:
Optional premium audio systems, CD player, navigation available on higher trims.
Driver Assistance
Cruise Control:
Standard
Connectivity
Remote Keyless Entry:
Standard
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months (whichever comes first) under normal driving conditions.
Tire Rotation Interval:
Every 7,500 miles or 6 months.
Transmission Fluid Change:
Every 50,000-100,000 miles (check severe service intervals in manual).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 Synthetic Blend (GM spec: dexos1 or API SN equivalent)
Engine Oil Capacity:
7 Quarts (with filter)
Coolant Type:
GM DEX-COOL (Orange) or equivalent extended life coolant (50/50 mix).
Transmission Fluid Type:
Dexron VI (Automatic Transmission)
Brake Fluid Type:
DOT 3
Known Issues
Common Problems:
Fuel pump failure, HVAC blower motor issues, power steering leaks, suspension component wear (ball joints, control arms), potential transmission fluid leaks.
Durability Notes:
Generally robust drivetrain, but the sheer weight and robust off-road nature can accelerate wear on certain components if not maintained.
📚 Vehicle History
Brand Heritage
Brand Origin:
HUMMER was originally a brand of off-road vehicles, stemming from AM General's High Mobility Multipurpose Wheeled Vehicle (HMMWV).
Model Evolution
Development:
The H2 was developed by General Motors, building on the HUMMER brand's rugged image but with a more civilian and luxurious focus. It shared GM's GMT825 truck platform.
Production
Start Year:
2003
End Year:
2009
Manufacturing Location:
Mishawaka, Indiana, USA
🏆 Awards & Recognition
Recognitions
Awards:
While specific awards are rare, the H2 was known for its distinctive styling and off-road prowess, garnering significant media attention and a cult following.
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