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VEHICLE DISMANTLING MANUAL

H2

GMT/05-H-ELV

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.

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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INTRODUCTION
This manual contains dismantling data for the following vehicles: MODEL YEAR
2005

MAKE
Hummer

MODEL
H2

VARIANT
4X4

ENGINE
6.0L V8

TRANSMISSION
4L65-E

2005 H2
ACTIVITY AREA 0 PRETREATMENT
0.7 Multiple
0.6 Refrigerant

0.8 Multiple

0.9 EPDM

0.5 Coolant

0.15 Oil

0.14 Oil

0.13 Oil

0.12 Oil

0.10 PE

0.17 Lead

0.4 Oil

0.3 Multiple

0.2 Oil

0.1 Oil

0.16 Multiple
0.17 Lead

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

2005 H2
ACTIVITY AREA 1 DOORS AND GLAZING

1.2 GLASS

1.3 GLASS

1.4 GLASS

1.5 GLASS

1.1 GLASS 1.2 GLASS 1.3 GLASS 1.4 GLASS

GLASS

Dismantling Manual Dismantling Manual


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

Information & Comments: Total Material Weight = weight of single part material multiplied by the quantity.

2005 H2
ACTIVITY AREA 2 EXTERIOR TRIM
2.15 ASA+PC 2.12 TEO 2.13 TEO 2.16 ASA+PC 2.15 ASA+PC

2.12 TEO 2.11 TEO 2.4 TEO 2.8 ASA+PC 2.5 TEO 2.7 PP 2.6 ASA+PC 2.3 ASA+PC 2.2 ASA+PC
ABS PP OTHER

2.14 TEO

2.10 ABS 2.9 ABS

2.10 ABS

2.13 TEO

2.6 ASA+PC

2.8 ASA+PC

2.11 TEO

2.4 TEO 2.1 TEO

2.5 TEO

2.12 TEO

2.12 TEO

Dismantling Manual
2005 Hummer H2 Activity Area 2 -- Exterior Trim
Area: Exterior Trim Qty Activity Ref Area # 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 Information & Comments: Total Material Weight = weight of single part material multiplied by the quantity. Part Name Front license plate bracket Lower grill Hood grill Front upper fender flare, lh, rh Lower front fender flare, lh, rh Hood handle Front fender reinforcement hole cover Front intake air duct cover, lh, rh Air inlet grill center Air inlet grill, lh, rh Molding rocker panel, lh, rh Rocker panel protector step, lh, rh Rear fender flare, lh, rh Rear bumper trim panel Quarter panel applique, lh, rh Liftgate applique Material TEO ASA+PC ASA+PC TEO TEO ASA+PC PP ASA+PC ABS ABS TEO TEO TEO TEO ASA+PC ASA+PC 1 1 1 2 2 2 1 2 1 2 2 4 2 1 2 1 Model: H2 Total Material Weight (kg) 0.17 0.49 1.41 0.47 0.59 0.25 0.13 0.25 2.47 0.84 2.65 1.39 1.07 0.43 0.74 0.58

2005 H2
ACTIVITY AREA 2 (continued) EXTERIOR TRIM

2.18 PPE+PA 2.20 SMC 2.21 ASA+PC

2.22 PP

2.22 PP

2.21 ASA+PC 2.18 PPE+PA

2.19 PP 2.19 PP

2.20 SMC

2.18 PPE+PA

2.17 TEO
PP OTHER

2.17 TEO

2.18 PPE+PA
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Dismantling Manual
2005 Hummer H2 Activity Area 2 -- Exterior Trim (continued)
Area: Exterior Trim Qty Qty 2 4 2 2 2 2 Model: H2 Total Material Total Material Weight (kg) Weight (kg) 0.57 0.83 3.31 3.72 0.31 2.65

Activity Ref Area # Activity Ref Area # 2.17 2.18 2.19 2.20 2.21 2.22 Information & Comments:

Part Name Part Name Bumper end panel Wheel covers Front wheel shield, lh, rh Front fender, lh, rh Windshield molding, lh, rh Rear wheel shield, lh, rh

Material Material TEO PPE+PA PP SMC ASA+PC PP

Total Material Weight = weight of single part material multiplied by the quantity.

2005 H2
ACTIVITY AREA 3 INSTRUMENT PANEL

3.6 PC+ABS 3.3 PC+ABS

3.5 PC+ABS

3.7 PC+ABS

3.3 PC+ABS 3.4 PC+ABS 3.2 PC+ABS 3.3 PC+ABS

PP
ABS

3.1 PP

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Dismantling Manual
2005 Hummer H2 Activity Area 3 -- Instrument Panel
Area: Instrument Panel Qty Activity Ref Area # 3.1 3.2 3.3 3.4 3.5 3.6 3.7 Information & Comments: Total Material Weight = weight of single part material multiplied by the quantity. Part Name Fuse block cover Transmission shifter bezel IP side trim panel, lh, rh IP bolster IP bezel, rh Upper IP bezel Dash bezel Material PP PC+ABS PC+ABS PC+ABS PC+ABS PC+ABS PC+ABS 1 1 3 1 1 1 1 Model: H2 Total Material Weight (kg) 0.11 0.47 0.38 1.36 0.30 0.51 0.42

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2005 H2
ACTIVITY AREA 4 SEATING

4.6 PUR 4.5 PUR 4.4 PUR

4.4 PUR

4.3 PUR 4.2 PUR 4.1 PUR


PUR

4.3 PUR

4.2 PUR

4.1 PUR

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Dismantling Manual
2005 Hummer H2 Activity Area 4 -- Seating
Area: Seating Qty Activity Ref Area # 4.1 4.2 4.3 4.4 4.5 4.6 Information & Comments: Total Material Weight = weight of single part material multiplied by the quantity. Part Name Front seat foam, lower, rh, lh Front seat foam, upper, rh, lh Rear seat foam, lower, rh, lh Rear seat foam, upper, rh, lh Third row seat foam, lower Third row seat foam, upper Material PUR PUR PUR PUR PUR PUR 2 2 2 2 1 1 Model: Hummer H2 Total Material Weight (kg) 1.76 1.93 2.30 1.85 0.88 0.89

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2005 H2
ACTIVITY AREA 5 INTERIOR TRIM
5.9 ABS

5.10 ABS 5.8 HCPP

5.7 ABS 5.2 ABS 5.6 ABS

5.4 ABS 5.3 ABS

5.5 ABS

5.8 HCPP 5.6 ABS 5.3 ABS 5.5 ABS 5.7 ABS 5.9 ABS

5.10 ABS

5.1 ABS

5.1 ABS
ABS HCPP

5.2 ABS

5.4 ABS

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Dismantling Manual
2005 Hummer H2 Activity Area 5 -- Interior Trim
Area: Interior Trim Qty Activity Ref Area # 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 Information & Comments: Total Material Weight = weight of single part material multiplied by the quantity. Part Name H-pillar trim panel, lh, rh Front door interior sill trim plate, lh, rh Front door exterior sill, lh, rh C-pillar garnish molding, lh, rh Rear door interior sill trim plate, lh, rh Rear door exterior sill plate, lh, rh Rear door exterior sill plate, lh, rh Rear seat outer hinge cover, lh, rh Rear side rear door garnish molding, lh, rh L-pillar garnish molding, lh, rh Material ABS ABS ABS ABS ABS ABS ABS HCPP ABS ABS 2 2 2 2 2 2 2 2 2 2 Model: Hummer H2 Total Material Weight (kg) 0.57 0.48 0.51 0.19 2.14 0.47 0.13 0.33 0.33 2.33

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2005 H2
ACTIVITY AREA 6 ENGINE COMPARTMENT

6.3 PE 6.4 PP 6.2 PP

6.5 PP

6.6 PP 6.1 PP

PE PP

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Dismantling Manual
2005 Hummer H2 Activity Area 6 -- Engine Compartment
Area: Engine Compartment Qty Activity Ref Area # 6.1 6.2 6.3 6.4 6.5 6.6 Information & Comments: Total Material Weight = weight of single part material multiplied by the quantity. Part Name Coolant bottle Air cleaner housing Washer solvent bottle Fan Shroud Under hood junction block cover Under hood PCM cover Material PP PP PE PP PP PP 1 1 1 1 1 1 Model: H2 Total Material Weight (kg) 1.52 1.27 0.54 1.82 0.28 0.51

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2005 H2
ACTIVITY AREA 7 LOAD SPACE

7.7 ABS

7.6 ABS 7.4 ABS 7.3 ABS 7.5 ABS 7.3 ABS

7.6 ABS 7.4 ABS

7.2 ABS

7.2 ABS

7.1 ABS
ABS

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Dismantling Manual
2005 Hummer H2 Activity Area 7 -- Load Space
Area: Load Space Qty Activity Ref Area # 7.1 7.2 7.3 7.4 7.5 7.6 7.7 Information & Comments: Total Material Weight = weight of single part material multiplied by the quantity. Part Name Liftgate sill plate Rear corner lower trim panel Tray Rear corner upper trim panel Rear opening upper garnish Rear side upper garnish molding Liftgate trim panel Material ABS ABS ABS ABS ABS ABS ABS 1 2 2 2 1 2 1 Model: H2 Total Material Weight (kg) 0.80 4.80 1.19 0.65 1.16 0.77 3.60

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VEHICLE DISMANTLING MANUAL

GMT/05-H-ELV

Revised October 18, 2004

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