G VAN (GMT 600)
Contents
1. GMT 600 315 318 319 03 32 Front Axle Tire Data Chart PAGE MAX TIRE WIDTH GROUND CLEARANCE MINIMUM GROUND CLEARANCE TO BE CALCULATED BY USING GROSS AXLE HEIGHT AND RECOMMENDED TIRE PRESSURE WHEEL GROUND MAX TIRE SERIES GVW RANGE TRACK DFFSET CLEARANCE WIDTH 531503 7225 75 160 10000 1721 2 119 4 208 2 228 0 LT225 7588 16 344 9 11000 1721 2 1i9 4 208 2 228 0 LT225 75R160 344 9 12000 1721 2 119 4 208 2 228 0 LT245 75RIGE 357 5 9500 1721 2 17 0 221 2 228 0 531532 17225 758160 11500 1721 2 119 4 208 2 228 0 LT225 75R160 344 9 12300 1721 2 119 4 228 0 Lr245 75RI6E 357 9 9500 1721 2 17 0 228 0 631803 225 75RI6D 344 9 10000 1721 2 119 4 228 0 tT225 75 160 344 9 11000 1721 2 119 4 228 0 2200 LT225 758160 344 9 12000 1721 2 4119 4 228 0 LT225 758160 344 9 11500 1721 2 119 4 228 0 225 758160 344 9 12300 1721 2 119 4 228 0 G31903 LT225 75 160 344 9 12000 1721 2 119 4 228 0 631932 7225 758160 344 9 12300 1721 2 119 4 228 0 Eech G Van GMT 600 2001 47 PAGE GMT 600 315 318 319 03 32 Rear Axle Tire Data Chart 1066 8 42 0 OUTSIDE FRAME section A A ROTATED 90 MINIMUM GROUND CLEARANCE TO BE CALCULATED INCHES BY USI2. PAGE Van GMT 600 BODY BUILDERS INSTRUCTIONS The Incomplete Vehicle Document IVD is supplied with each incomplete vehicle and provides information that should be used by intermediate and final stage manufacturers in determining conformity to applicable Federal Motor Vehicle Safety Standards FMVSS The IVD also includes information which must be followed in order to ensure that Environmental Protection Agency EPA and California emissions certification requirements and NHTSA Fuel Regulations are met The Body Builders Book contains information that may be used in addition to the IVD for any manufacturer making alterations to a GM complete incomplete vehicle No alteration should be made to the incomplete vehicle which either directly or indirectly results in any component assembly or system being in nonconformance with any applicable Federal Motor Vehicle Safety Standard or Emission Regulation Intermediate and final stage manufacturers should be familiar with all Federal Motor Vehicle Safety Standards and Emission Regulations and aware of their specific responsibilities as manufacturers For further assistance contact Upfitter Integration at 1 800 875 4742 or go to our Web site at http www gmupfitter com Section 0 General Instructions Check for proper clearance between body members and chassis components which may in any way affect the reliability and performance of the vehicle by developing abrasion
3. 5 1770 6 1356 0 1835 0 G Van GMT 600 2001 52 PAGE GMT 600 217 317 05 06 Heavy D Converter Assembl Engine Options L31 California L35 CATALYTIC EXHAUST CATALYTIC CONVERTER RESONATOR CONVERTER 290 0 327 9 11 41 12 91 CENTERL INE OF VEHICLE CENTERLINE OF FRONT AXLE 634 5 24 98 CONVERTER ASSEMBLY OPTION 1 31 CONVERTER ASSEMBLY OPTION L35 HEAVY DUTY CAL HEAVY DUTY A 135 995 4 1328 6 578 39 181 52 30 22 X 155 503 4 1836 6 1086 4 ES 18 72 30 42 77 LI INCHES G Van GMT 600 2001 53 PAGE GMT 600 G 217 317 05 06 Heavy D Converter Assembly Engine Options L31 L29 EXHAUST EXHAUST RESONATOR CATALYTIC RESONATOR 290 0 CATALYTIC 11 42 CONVERTER 11 42 CONVERTER 327 7 CENTERL INE OF 12 90 VEHICLE 12 92 MUFFLER MUR EEES CENTERLINE OF CENTERLINE OF 77 FRONT AXLE FRONT AXLE 1383 5 1383 5 54 47 54 471 8 11 8 111 CONVERTER ASSEMBLY OPTION L31 e 577 6 576 9 1085 7 1084 9 42 741 42 71 INCHES CONVERTER ASSEMBLY OPTION L29 HEAVY DUTY G Van GMT 600 2001 GMT 600 PAGE 217 317 05 06 Heavy D Converter Assembly Engine Option L65 E gi CENTERLINE OF
4. 5689 5 224 00 5 1 84 0 23 35 rear Aur Dal TO OF VEHICLE i SECTION 51 0 d 135 0 2 01 5 31 663 0 26 10 OUTSIDE OF METAL NORMAL TOP OF SEN DIMENSIONS OF MOUNTING HOLES AND FRAME OUTLINE ARE el OPPOSITE ABOUT CENTERLINE OF INCHES G Van GMT 600 2001 GMT 600 319 03 32 Heavy D Cutaway Crossmember Arrangement W Soft Mt amp Park routin 41 4495 8 WHEELBASE 1408 3 177 00 55 45 640 2 25 20 AA PoE rq d 533 4 21 00 u Se zo c Pu n 1272 19 39 Re SR ES S SS P ni m t Em m Le 1768 0 4 69 61 MOUNT 2685 0 105 71 15037137 3213 3 126 51 FRAME OF FRONT AXLE 4026 1 158 51 q 4978 6 RETAINER 196 01 9532 3 217 81 j 6149 5 242 11 OF REAR AXLE 51 0 593 1 Sat 23 35 SS E TO OF VEHICLE OUTSIDE OF METAL SECTION NORMAL TOP OF FRAME d 135 0 DIMENSIONS OF MOUNTING HOLES AND FRAME 5 31 OUTLINE ARE SYMMETRICALLY OPPOSITE ZEN ABOUT CENTERLINE OF VEHICLE INCHES G Van GMT 600 2001 PAGE GMT 600 114 214 217 314 317 05 06 Spare Ti
5. G Van GMT 600 2001 35 GAL DRAW CAPACITY 11 01 CENTERLINE OF REAR AXLE z INCHES PAGE GMT 600 315 318 319 03 32 General Arrangement 35 Gallon and 55 Gallon 1750 0 168 901 CENTERL INE 886 6 1178 1 OF VEHICLE 134 91 46 381 137 4 CENTERL INE OF VEHICLE 443 3 45 34 17 451 13 79 1151 1 CAPACITY 45 32 1100 4 35 93 43 321 CENTERLINE OF REAR AXLE CENTERLINE OF REAR AXLE 267 0 10 51 H 12 37 10 021 10 87 OUTSIDE TOP OF OUTSIDE TOP OF FRAME TO BOTTOM FRAME TO BOTTOM INCHES OF FUEL TANK OF FUEL TANK G Van GMT 600 2001 PAGE GMT 600 G 114 214 217 314 317 05 06 Muffler Arrangement 135 155 Wheelbase 303 0 11 93 CENTERL INE OF 267 2 10 52 OUTSIDE OF METAL 25 16 1468 9 57 83 G Van GMT 600 2001 51 GMT 600 114 214 217 314 317 05 06 Light Duty Converter Assembly Engine Options L30 L31 L35 CATALYTIC CONVERTER CATALYTIC CONVERTER 12 59 12 99 CENTERLINE OF VEHICLE CENTERLINE OF FRONT AXLE CONVERTER ASSEMBLY OPTION L30 L35 CONVERTER ASSEMBLY OPTION LIGHT DUTY LIGHT DUTY A B C 1262 6 848 0 1327 0 49 71 33 38 52 24 69 71 53 38 72 24
6. GMT 600 57 PAGE G 318 319 03 32 Heavy D Cutaway Converter Assembly G Van GMT 600 2001 159 CT EE CATALYTIC CONVERTER Ln Im 177 Wheelbase Engine Options L 29 1 31 1688 6 66 48 16 37 291 1 11 46 4038 6 159 00 4495 8 177 00 293 3 TYP 11 55 MUFFLER 631800 h 631900 nh 281 3 11 07 2939 3 3396 5 7 24 02 oe 1 CENTERLINE REAR AXLE D q 26 2 za Ww 278 0 10 94 5 120 00 INCHES NOTES G31800 631900 4 129 131 PAGE GMT 600 G 315 318 319 03 32 Heavy D Cutaway Converter Assembly 139 159 177 Wheelbase Engine Option L65 346 0 13 62 66 48 ii pL CONVERTER S ui H MUFFLER 610 0 24 021 27 711 11 07 631500 631800 631900 1597 1777 2939 3 3396 5 95 72 115 72 133 721 INCHES G Van GMT 600 2001
7. CENTERL INE f 24 83 OF VEHICLE 120 47 F lt 1408 3 55 45 30 241 E 1742 7 e 429 168 61 CENTERLINE 1009 FRONT AXLE i 332 6 113 09 CENTERLINE OF REAR AXLE 663 0 72 6 26 10 2 86 2 14 OUTSIDE OF METAL NORMAL TOP OF 14 2550 6 112 231 202 1 7 96 INCHES 461 0 18 151 DIMENSIONS OF MOUNTING HOLES AND FRAME OUTLINE ARE SYMMETRICALLY OPPOSITE ABOUT CFNTFRI INE OF VEHICLF G Van GMT 600 2001 37 PAGE GMT 600 G 217 05 06 Light D Crossmember Assembly 155 Wheelbase 3937 0 155 001 WHEELBASE 1091 0 1112 3 42 951 143 79 908 5 35 77 640 4 25 21 451 0 17 76 389 7 15 34 26 30 CENTERL INE P OF VEHICLE 24 83 aA sn 24 38 520 0 20 471 1408 3 55 45 rf 2250 7 88 61 12 10 768 0 Moos 30 24 44 38 CENTERLINE OF FRONT AXLE 1000 CENTERLINE OF REAR AXLE 332 8 13 10 64 2 663 0 2 53 26 10 3347 7 131 80 i 42 7 53 7 1 68 2 11 54 7 2 181 45 6 1 80 11 a D ES TN OUTSIDE OF METAL NORMAL TOP OF FRAME INCHES 155 3 6 11 I 3359 1 132 2
8. continuously never come on or cycle on and off excessively This may result in a reduction of fuel economy engine overheat at times or annoying cycling 4 Heavy duty cooling equipment is required when air conditioning auxiliary belt driven equipment snow plows winches etc are installed 5 Continuous coolant flow is necessary from the heater connection on the engine to the heater connection on the radiator or water pump in order to control transmission oil temperatures during closed thermostat warm up operation Do not alter this flow as it may result in premature engine or transmission failure 6 Ifa heater unit is not installed in the vehicle or a heater shut off valve is required a line connecting the heater connection on the engine to the heater connection on the radiator or water pump must be installed When a shut off valve is required in the heating system it must be teed into the system in such a manner as to maintain continuous flow between engine heater connection radiator heater connection at all times Do not over fill coolant recovery or surge tank containers Be sure to add coolantto system after adding capacity to system heaters The use of environmentally friendly long life coolant is required G Van GMT 600 2001 GMT 600 21 G 114 214 217 314 317 05 06 General Arrangement REFER TO FRAME DRAWING REFER TO EXHAUST DRAWING CENTERLINE OF F
9. Gaseous Fuel Conversions All truck gasoline engines may be converted to use liquified petroleum gas LPG or natural gas NG Some conversions may cause harmful effects to the engine Such fuel systems may require assurances from alternate fuel system manufacturers and or installers that the equipment will not cause damage to the engine or the exhaust system In the use of dual fuel systems the intermediate or final stage manufacturer should strictly adhere to the manufacturer s procedures for switching from gasoline to gaseous fuel operation Improper switching procedures may result in overheating and damage to the exhaust system and the vehicle The gaseous fuel tank should not be mounted in an enclosed area of the vehicle such as the passenger compartment etc and the system should be vented to the outside of the vehicle In addition vehicles converted to gaseous fuels should not be stored in enclosed places such as garages Further General Motors cautions purchasers that the design location and installation of any type of fuel storage system involves significant technical and engineering considerations and that these statements on gaseous fuel conversions should not be interpreted to be an approval by General Motors of any modification to the original equipment fuel system Conversions to gaseous fuel should be made in conformance with applicable Federal and State regulations Removal of emission control components and or the addition of gaseou
10. 1 SEAT ROW 2 SEAT ROW 3 PASSENGER 3 PASS BENCH 3 PASS BENCH 4 PASS BENCH 44590 1578 7 57 44 62 15 SHOULDER SHOULDER L 2115 0 1546220 ROOM H 1160 0 Ha 1153 5 W 533 0 Wie L 3003 0 L 4629 0 1153 5 H 1153 5 W 238 5 W 232 0 x L 4629 0 1153 5 Wz 81 0 DRIVER W 148 5 hus pus W 533 0 535 5 2 227 NOTE CUTAWAY H POINTS FOR DRIVER AND PASS SAME AS ABOVE 63 85 55 51 56 14 HIP ROOM HIPROOM HIP ROOM HIP ROOM H POINT 39 19 DRIVER S ENGER E ee H POINTS 41 17 160 0 FORWARD EFFECTIVE 6 29 TRAVEL LEG ROOM 60 0 REARWARD EFFECTIVE 2 36 TRAVEL LEG ROOM G Van GMT 600 2001 GMT 600 PAGE 593 04 23 34 217 317 05 06 155 Wheelbase Exterior 1038 0 40 86 USABLE OPENING WITH SLIDING CARGO DOOR 538 0 21 18 165 TYP TYP BOTH SIDES 1781 8 70 54 WIDTH 1260 1 49 61 B OPEN MAX 431 8 17 00 He 297 4 11 71 M 1940 4 gt 76 39 MAX SWING CENTERL INE OF REAR AXLE 13 56 TOP OF 91 BODY MOUNT 52 14 G Van GMT 600 2001 6065 9 238 81 OVERALLI 810 4 131 91 881 9 34 72 932 4 0
11. R 134A refrigerant are equipped with metric fittings to prevent interchange with R 12 refrigerant components Do not interchange R 134A components refrigerant oil or service equipment with R 12 components refrigerant oil or service equipment Rear Air Conditioning The A C and heater lines are usually routed between the vehicle floor and the exhaust system heat shields The electrical connectors for the rear HVAC are usually routed on the inside right rear pillar and it also has a switch on the front dash to control the rear air NOTE It is imperative that the design of the HVAC lines and materials selected by the Conversion Companies upfitter or HVAC supplier provide mechanical attachments to the vehicle to protect against abrasion engine roll and vibration The lines must also be insulated to protect against engine or exhaust system heat Please be aware that an improperly installed HVAC system by the SVM may damage OEM and or van conversion system components This unit may be equipped with A C quick connect fittings on the liquid tube high pressure and the suction low pressure return tube These fittings are designed to accept matching Aeroquip connecting fittings attached to pre charged lines This allows a one time only connection to the O E M charged A C system without having to discharge evacuate and recharge for the connection of a rear A C system These quick connects must be used for warranty coverage of the A C system A mo
12. VEHICLE CATALYTIC CONVERTER 13 62 G Van GMT 600 2001 CONVERTER ASSEMBLY OPTION L65 HEAVY DUTY 1259 4 49 58 1767 4 69 58 INCHES GMT 600 55 315 03 32 Heavy Duty Cutaway Converter Muffler Assembly Engine Options L29 L31 CATAL YT CONVERT MUFFLER lt FRONT AXLE OUTSIDE OF METAL NORMAL TOP OF ZS 52 40 1630 3 64 19 40 66 6 REAR AXLE 637 9 167 0 6 58 NOTES 631500 amp 119 131 II G Van GMT 600 2001 INCHES 97 0 25 11 j 8 am 217 2 8 55 9 84 310 0 12 20 GMT 600 PAGE G G Van GMT 600 2001 315 03 32 Heavy D Engine Option L18 CATALYTIC CONVERTER 268 2 168 5 6 63 TYP 178 8 7 04 Cutaway Converter Muffler Assembly MUFFLER ft o_o 272 5 10 73 TYP 3531 0 139 02 LJ 137 4 5 41 N WHEEL BASE 49 2 220 5 1 94 8 68 40 54 52 40 1630 3 64 19 FRONT AXLE 6 63 TYP 12 20 324 8 12 79 REAR AXLE 1 INCHES
13. be within certain limits The Body Builder must use all appropriate data Note to Body Builder Final Stage Manufacturer Failure to keep body and payload CG at least 26 inches forward of centerline of rear axle will result in degradation of trailer towing capacity Consult the Trailer Towing Guide to determine maximum tongue load for your vehicle G Van GMT 600 2001 PAGE GMT 600 Section 3 Front Suspension See chassis data information for clearances and assistance in calculating trim heights Since there is a large variation in completed vehicle front weight due to differences in body weight and equipment care must be taken not to exceed the GAWR GVWR Also the front suspension alignment must be checked and reset if necessary after the vehicle is completed Caster and camber should be set with reference to the A dimensions See The G Van Service Manual for complete alignment procedure specifications and measurement of the A dimension under Diagnosis and Front Alignment section Section 4 Rear Suspension Due to differences in body weight and equipment care must be taken not to exceed the GAWR GVWR Clearance to body should be provided for the suspension axle driveshaft and tires under the following conditions 1 Axle in full jounce against the metal to metal stop 2 Axle at 4 59 roll with one side of axle in full jounce at the metal to metal stop and 3 Axle at design positio
14. capacity than those offered as original equipment by vehicle manufacturer is not approved for use on original equipment wheels Any usage of higher capacity tires must be accompanied by higher capacity wheels However the wheel offset and distance from centerline of rim to wheel mounting face must be the same as the replaced original equipment wheel to ensure proper wheel bearing loading and clearance of tires to body and chassis components Increasing tire and wheel capacity does not increase vehicle GVW ratings It is recommended that tire chain clearance guideline from the Society of Automotive Engineers J 683 be adhered to in designing rear wheelhouse clearance Check tires and inflate to recommended tire pressure according to the tire pressure information provided in the Owner s Manual and tire inflation label provided with the vehicle Any substitution of tires may affect Speedometer Odometer accuracy tire wear fuel economy ride and handling and stopping distances Section 12 Electrical Battery and Battery Cables The vehicle battery should be located and positioned to make use of the existing battery cables If the battery requires relocation and longer cables are required a proportionately larger gauge wire must be used If in relocating the battery the negative ground cable is attached to the frame rail a cable of similar gauge must be provided between the frame rail and the engine This is required due to the heavy electrical
15. the under dash seat locations for control modules must be protected from moisture water when cleaning vehicle Section 7 Transmission This product is equipped with a neutral park start safety switch mounted on the transmission which interfaces with the vehicle starter circuit The starter will only operate with the shift lever in the neutral or park position Models equipped with brake transmission shift interlock BTSI require full application of the regular brakes before shifting from park when the ignition key is in the run position Section 8 Fuel and Exhaust Fuel Systems Due to the critical nature of sealing the fuel system anyone making modifications or alterations to the existing system must assume complete responsibility for the system reliability performance and compliance to FMVSS 301 and emission standards Section 8 continued on next page G Van GMT 600 2001 12 PAGE GMT 600 Section 8 continued from previous page The completed fuel system is certified to be in compliance with the Federal and California Vehicle Emission Standards Any alterations to systems or components and their environment could void compliance Systems include e Fuel tank metering unit lines including purge control solenoids and canister or canisters Environment Includes e Heat sources heat shields system component relocation For these reasons NO ALTERATION THE FUEL SYSTEM IS REC
16. 33 4 26 30 1 21 09 1 OF NE Ex 19 39 5 s j SKS SOFT MOUNT 520 0 G Vd 20 47 1408 3 55 45 EE 1630 8 64 20 1974 5 77 74 2245 3 68 40 3058 1 120 40 RETAINER 4010 5 OF FRONT AXLE TRY 157 89 4564 3 179 70 5181 5 204 00 G53D 6 OF REAR AXLE 4 0 3 31 3 3 TO OF VEHICLE OUTSIDE OF METAL NORMAL TOP OF FRAME 135 0 51 0 sec A A 5 31 2 01 DIMENSIONS OF MOUNTING HOLES AND FRAME FRAME OUTLINE IS SYMMETRICALL Y OPPOSITE ABOUT CENTERLINE OF VEHICLE INCHES G Van GMT 600 2001 PAGE GMT 600 G 318 03 32 Heavy D Cutaway Crossmember Arrangement W Soft Mt loc amp Park Brk routing 4038 6 WHEELBASE 1739 0 159 00 68 46 770 0 1385 8 54 56 640 2 25 21 SOFT MOUNT gt 55 45 Be 15037137 1768 0 59 61 FRAME 2482 5 97 74 2753 3 RETAINER 108 40 Lem 3566 1 140 40 OF FRONT AXLE OX 4518 6 177 90 5072 3 199 70 74
17. 48 30 INCHES DAYLIGHT OPENING G Van GMT 600 2001 487 4 494 3 19 19 19 46 3937 0 I WH ASE 155 0 494 3 507 4 504 5 19 46 19 98 19 86 GMT 600 G 114 214 217 314 317 05 06 Sign Area 2959 1 116 51 1554 5 1440 2 61 2 56 71 SE 3937 0 1155 0 WHEELBASE INCHES G Van GMT 600 2001 PAGE 31 G VAN GMT 600 315 318 319 03 32 Cutaway Exterior OVERALL 807 4 31 79 884 3 PAGE 32 CENTERL INE SECTION A A OF VEHICLE BACK OF CAB 2951 6 CD 116 20 2860 1 1499 1 112 60 58 02 SPARE TIRE MOUNTING LOCATION SHIPPING ONLY 1513 8 59 58 DIESEL BATTERY OUTSIDE OF METAL NORMAL TOP OF 1 BODY MOUNT TOP OF FRAME 79 19 OVERALL 139 A 2031 8 2539 8 2997 0 6129 8 6637 8 7095 0 80 00 1100 00 1118 00 148 451 L168 451 186 45 241 33 1261 3341279 331 INCHES G Van GMT 600 2001 33 PAGE GMT 600 315 318 319 03 32 Cutaway Interior H POINTS FOR CUTAWAYS PASSENGER L 2115 0 DRIVER L 2115 0 H 1160 0 W 533 0 L CENTERLINE OF VEHICLE HIP ROOM PASSENGER S
18. 5 201 5 1 001 341 6 13 45 10 2 1 90 7 93 580 8 460 8 18 14 DIMENSIONS OF MOUNTING HOLES AND FRAME OUTLINE ARE SYMMETRICALLY OPPOSITE ABOUT CENTERLINE OF VEHICLE 22 871 G Van GMT 600 2001 GMT 600 38 PAGE 217 317 05 06 Heavy D Crossmember Arrangement 155 Wheelbase p2 3937 0 WHEELBASE 155 00 1112 3 1091 0 42 96 908 5 43 791 451 0 17 76 35 77 389 7 15 34 668 1 26 301 eem 21 66 CENTERL INE OF VEHICLE 520 0 20 471 IS 1408 3 55 451 j 2250 7 i 88 61 CENTERLINE OF FRONT AXLE 24 38 24 83 12 101 768 0 E 1127 3 44 381 30 241 yo c OF REAR AXLE 3348 3 131 82 53 4 332 8 113 101 o OUTSIDE OF METAL NORMAL TOP OF FRAME INCHES 132 25 DIMENSIONS OF MOUNTING HOLES AND FRAME OUTLINE ARE SYMMETRICALLY OPPOSITE ABOUT CENTERLINE OF VEHICLE G Van GMT 600 2001 201 5 7 93 580 8 22 87 113 45 460 8 18 142 39 PAGE GMT 600 G 315 03 32 Heavy D Cutaway Crossmember Arrangement W Soft Mt loc Park routin 53531 0 WHEELBASE 1739 0 139 02 68 46 256 2 1 10 09 9681 5
19. 5 7SRI6E 357 9 9500 1721 2 17 0 221 2 248 0 631705 LT245 75R16 357 9 9500 1721 2 17 0 221 2 248 0 631706 LT245 76616 357 9 9500 1721 2 17 0 221 2 248 0 G Van GMT 600 2001 PAGE GMT 600 114 214 217 314 317 05 O6 Rear Axle Tire Data Chart 913 3 35 95 INSIDE FRAME section ROTATED 90 MINIMUM GROUND CLEARANCE TO BE CALCULATED BY USING GROSS AXLE HEIGHT AND RECOMMENDED INCHES TIRE PRESSURE SERIES TIRE SLR WHEEL DIM B 611405 P215 75815 313 9 SINGLE 1944 0 1492 0 P235 7SRISXLS 325 9 SINGLE 1478 0 611406 P235 75 5 5 325 9 SINGLE 1718 0 521405 11225 758160 344 9 SINGLE 1700 0 1928 0 1472 0 LTz25 75RI6E 345 9 SINGLE 1708 0 1480 0 621406 11225 75 345 9 SINGLE 1708 0 381 0 G21705 LT225 75RI6D 344 9 SINGLE 1700 0 1928 0 1472 0 381 0 LT225 75RI6E 345 9 SINGLE 1708 0 1936 0 1480 0 381 0 621706 11225 75RI60 344 9 SINGLE 1708 1480 0 381 0 O G31405 LT245 75RI6E SINGLE 1708 0 1951 0 1465 0 394 0 G31405 LT245 75RI6E SINGLE 1708 0 1951 0 1465 0 394 0 631705 7245 75RIG6E SINGLE 1708 G31706 LT245 75RIG6E SINGLE 1708 1951 0 1465 0 394 0 1951 0 1465 0 394 0 G Van GMT 600 2001
20. 5264 Kent Moore P N J 38125 4 This kit contains instructions tools and components for making repairs to wiring harness components This kit would also greatly assist in accomplishing necessary add on wiring such as body marker lamps so that system reliability durability is maintained Electrical wiring components can be obtained through your authorized GM dealer Many Packard Electric components are also available through Pioneer Standard Company 1 800 PACKARD Pioneer may also be able to assist in making necessary wiring additions by providing custom wiring stubs or jumpers to your specifications Fusible Link Repair Procedure 1 Cut damaged fusible link from wiring harness assembly splice 2 Strip insulation from harness wire as required to splice on new fusible link 3 Fabricate a new fusible link wire approximately 6 to 8 in long from the same wire size as the original link Acceptable fusible link material will be imprinted with the wire size and the wording to identify it as fusible link Fusible link cable is not the same as normal vehicle wiring 4 Terminate fusible link harness wire with a suitable compression splice clip and solder with an electrical grade rosin core solder Wrap splice area with tape to provide electrical insulation as well as mechanical strain relief at the splice 5 Strip terminate solder and insulate remaining end of fusible link with appropriate termination to be compatible with the rest of the el
21. 63 4 38 711 37 91 979 9 1004 5 38 581 BTM OF FLR TYPICAL BODY CONTOUR L H SIDE 2673 5 FOLDED 1105 251 2042 5 80 41 1248 3 49 141 NO TRIM 49 981 BOTTOM OF FLOOR 50 301 1446 5 56 95 2006 3 78 98 INCHES TDOO5169 GMT 600 217 317 05 06 155 Wheelbase Interior 5 8 or 12 Passenger G 1045 9 41 17 EFFECTIVE LEG ROOM G Van GMT 600 2001 1465 0 57 67 SHOULDER 14590 67 44 SHOULDER OOM PAGE 25 H POINTS FOR 8 OR 12 PASSENGER 155 W B SEAT ROW 1 SEAT ROW 2 PASSENGER 3PASSBENCH PASS BENCH L 2115 0 Hz1160 0 Wz533 0 L 3003 0 1153 5 W 238 5 L 3003 0 H 1153 5 W 148 5 DRIVER L 2115 0 1 3003 0 1160 0 1153 5 63 85 HIP ROOM H POINT 1410 0 55 51 HIP ROOM 1410 5 55 53 HIP ROOM 995 6 29 19 68 50 HIP ROOM 975 0 5555 160 0 FORWARD 6 29 TRAVEL 60 0 REARWARD 2 36 TRAVEL LEG ROOM Wz 533 0 W 535 5 SEAT ROW 3 4 PASS BENCH 1 4629 0 H 1166 0 W 470 5 L 4629 0 H 1166 0 W 156 5 L 4629 0 H 1166 0 z 156 5 L 4629 0 H 1166 0 Wz 470 0 NOTE CUTAWAY H POINTS FOR DRIVER AND PASS SAME AS ABOVE BOTTOM OR FLOOR Van GMT 600 26 PAGE G 1748 0 68 82 SHOULDER 1465 0 57 67 SHOULDER ROO
22. EAT DRIVER S SEAT A 708 CG 160 0 FORWARD EFFECTIVE 6 29 TRAVEL OUTSIDE OF LEG ROOM METAL NORMAL 600 REARWARD TOP OF FRAME 2 36 TRAVEL G Van GMT 600 2001 PAGE GMT 600 G Cutaway Rear Flange BOTTOM OF FLOOR 739 TOP OF FRAME 637 G Van GMT 600 2001 35 PAGE GMT 600 G 114 214 05 O6 Light D Crossmember Arrangement 135 Wheelbase 1091 0 42 95 3429 0 WHEELBASE 908 5 135 00 35 77 640 4 451 0 25 21 17 75 26 30 0 sz 2 21 65 630 7 24 83 CENTERLINE OF VEHICLE 520 0 20 47 619 3 55 44 24 38 12 10 CENTERLINE OF EE AXLE 1742 7 768 0 68 611 30 241 CENTERL INE OF REAR AXLE 332 8 113 10 72 9 2 87 64 2 53 7 155 3 EH 2 53 663 0 2845 0 26 10 112 00 12 11 6 11 1 00 a METAL NORMAL 13 08 TOP OF FRAME 48 2 156 1 1 90 6 151 INCHES 112 25 341 6 13 45 DIMENSIONS OF MOUNTING HOLES AND FRAME OUTLINE ARE SYMMETRICALLY OPPOSITE 580 8 ABOUT CENTERLINE OF VEHICLE 22 871 G Van GMT 600 2001 36 PAGE GMT 600 G 214 314 05 O6 Heavy D Crossmember Arrangement 135 Wheelbase 3429 0 WHEELBASE 908 5 135 00 35 77 451 0 17 761 15 34 668 1 26 301 Le J oF
23. EMBLY MOUNTING t INCHES G Van GMT 600 2001 GMT 600 G 114 214 217 314 317 05 Stringer Locations Roof Bows CENTERLINE OF ner FRONT AXLE K 1838 2 72 41 C10005 509 0 20 04 STRINGER LOCATION G Van GMT 600 2001 PAGE 28 PAGE GMT 600 G 114 214 217 314 317Y 05 Stringer Locations Roof Bows 544 4 21 43 19 4 76 12 2 48 120 0 4 72 ROOF BOW TYPICAL SECTION A A 54 86 CENTERLINE OF J THIS ROOF BOW THIS ROOF BOW ONLY FR ALSO COMMON TO AVALIABLE WITH AY ONT AXLE 155 INCH WHEELBASE CUTAW r 1425 6 56 13 B8 53 06 1349 1 52 96 1333 6 5 12 563 0 22 16 24 2 95 191 0 ACCELERATOR 7 52 264 2 BRAKE 10 40 STRINGER LOCATION NEXT PAGE I 1 INCHES G Van GMT 600 2001 GMT 600 PAGE 114 214 217 314 317 05 06 Exterior Glass 3429 0 1135 0 WHEELBASE 503 0 499 6 19 80 19 70 1226
24. M 1452 0 1459 0 57 44 SHOULDER ROOM 57 16 SHOULDER ROOM m 1554 4 61 19 SHOULDER ROOM 63 85 HIP ROOM H POINT 1045 9 41 17 EFFECTIVE LEG ROOM 1032 0 40 63 1410 0 55 51 HIP ROOM 9920 39 05 EHR 55 53 HIP ROOM 995 6 39 19 56 81 HIP ROOM 987 5 38 87 EHR L 1550 3 61 03 HIP ROOM 970 6 98 21 EHR 8 29 TRAVEL 60 0 REARWARD 2 36 TRAVEL G Van GMT 600 2001 980 0 38 58 LEG ROOM 36 24 EFFECTIVE LEG ROOM 217 317 05 06 155 Wheelbase Interior 15 Passenger H POINTS FOR 15 PASSENGER 155 W B DRIVER L 2115 0 H 1160 0 Wz 533 0 L 3003 H 1153 5 Wz 535 5 L 3816 0 SEAT ROW 1 8 PASS BENCH SEAT ROW 2 8 PASS BENCH SEAT ROW 3 3 PASS BENCH SEAT ROW 4 4 PASS BENCH W 238 5 L 4629 0 H 1153 5 W 238 5 L 5420 5 1153 5 W 156 5 PASSENGER L 2115 0 H 1160 0 W 533 0 NOTE CUTAWAY H POINTS FOR DRIVER AND PASS SAME AS ABOVE DRIVER S SEAT BOTTOM OR FLOOR EHR EFFECTIVE HEADROOM 27 PAGE GMT 600 500000 Seat Riser Assembly Mountin aN Pest 14 ESL EECHER SE TOE LT SEAT RISER ASSEMBLY MOUNTING MI2 X 1 75 4 PLACES EACH SIDE 54 80 ST SEAT RISER ASS
25. NG GROSS AXLE WEIGHT AND RECOMMENDED TIRE PRESSURE xp WHEEL SERIES REAR WHEEL GVW TRACK OFFSET DIM B DIM C 031503 1 7245 75R16E SINGLE 9500 1708 0 17 0 1465 0 199 1 220 3 394 0 243 0 gt enen DUAL 10000 1852 4 146 3 253 4 LT225 758160 11000 1B52 4 127 0 LT225 75RI6D 12000 1852 4 127 0 631532 245 75RI6E SINGLE 9500 1708 0 LT225 75RI6D 127 0 2345 4 LT225 75RI60 DUAL 12300 127 0 2345 4 531803 LT225 75R16D DUAL 10000 1852 4 127 0 2345 4 1359 4 146 3 25 758160 DUAL 11000 2345 4 1359 4 1 225 ene DUAL 12000 1852 4 127 0 2345 4 1359 4 146 3 253 4 146 3 253 4 G31832 LT225 758160 DUAL 11500 1852 4 127 0 2345 4 1359 4 I LT225 758160 DUAL 12300 1852 4 127 0 2345 4 1359 4 146 3 253 4 631903 LT225 75RI60 344 9 DUAL 12000 1852 4 127 0 2345 4 1359 4 146 3 253 4 G31932 LT225 7SRI6D 344 9 DUAL 12300 1852 4 127 0 2345 4 1359 4 146 3 253 4 G Van GMT 600 2001 GMT 600 48 PAGE G 114 214 217 314 317 05 06 General Arrangement Fuel 135 155 Wheelbase 1828 3 71 98 15 53 CENTERL INE FRONT AXLE 306 8 12 07 7 24 OUTSIDE METAL OUTSIDE TOP OF NORMAL TOP OF FRAME FRAME TO BOTTOM OF SHIELO
26. OMMENDED If the fuel system is received from the manufacturer in an incomplete condition certification becomes the responsibility of the intermediate or final stage manufacturer Fuel Fill Fuel tank filler pipe location should be so situated and constructed as to prevent gasoline vapor from emitting to vents of pilot flamed devices and to body and engine compartment air inlets It is recommended that when mounting the fuel filler pipe assembly and vent hose that a minimum of 3 0 in clearance be provided to any body component to prevent contact between hoses and or mating parts and that retention be provided to ensure routing and prevent failure due to wear and fatigue Filler pipe and vent line must have a gravity fuel flow to tank at all times no fuel traps are allowed Alterations of fuel line routings could affect the completed vehicle and are therefore not desirable The complete fuel system must comply with FMVSS 301 as well as Federal and C A R B vapor emission requirements This vehicle is equipped with concentric fuel fill and vapor lines made from special materials in order to meet the Federal and California Evaporative Emission Standards Changing the length material and or routing of the fuel fill will require evaporative emission validation by the final stage manufacturer Fuel Lines Fuel line routing precautions 12 in minimum clearance to exhaust system is required or a metal shield must be provided Fuel lines should
27. RONT AXLE 1 INCHES UNLESS OTHERWISE SPECIFIED All DIMFENSIONS ARE TO OUTSIDE OF METAL G Van GMT 600 2001 CENTERLINE OF REFER TO FUEL TANK DRAWING REAR AXLE REFER TO BODY DRAWING ee e 2 d REFER TO TRAILER HITCH DRAWING GMT 600 G 114 214 314 05 O6 135 Wheelbase Exterior 5 8 or 12 Passenge 1038 0 40 86 USABLE 1054 9 WITH SL IDIN CARGO DOOR 78 211 1791 8 70 541 MAX WIDTH 41 53 142 538 0 165 TYP 21 18 55 1260 2 49 61 87 MAX 75 PROP ROD POS BOTH SIDES 17 00 297 4 c t 1940 4 76 39 MAX SWING INE OF REAR AXLE 56 17 1324 4 52 141 344 6 13 56 G Van GMT 600 2001 A TOP OF 41 BODY MOUNT 5557 9 218 811 OVERALL BOTTOM OF FLOOR 810 4 31 91 881 9 34 72 932 4 963 4 136 71 37 91 978 89 38 58 SECTION A A TYPICAL BODY CONTOUR L H SIOE 2359 0 92 87 FOLDED 2151 4 84 70 TRIM 1248 3 49 14 NO TRIMI OR OPEN 128 2 5 04 50 30 1446 5 56 95 2019 6 79 51 r PAGE 22 GMT 600 G 114 214 314 05 O6 135 Wheelbase Interior 5 8 or 12 Passenger 23 PAGE H POINTS FOR 5 8 OR 12 PASSENGER 135 W B SEAT ROW
28. and wear points from moving parts or degradation from extreme environment or thermal exposure or may increase interior noise Any attachments must consider chassis components for jounce and rebound motion at maximum GVW Check headlamp aim and all vehicle illumination systems for proper operation when the vehicle has been completed Re aim headlamps when necessary Check for proper operation of windshield washer wipers and defroster system In no case should any alterations affect the function physical or mechanical properties environment or vital spatial clearances of the components assemblies or systems Extreme care must be taken when working on vehicles which have been equipped with Powertrain Control Module PCM Sensing and Diagnostic Module SDM Air Bag Control Module and ABS Control Do not mount any components with large magnets such as stereo speakers in the area of the driver s seat due to the Sensing and Diagnostic Module SDM The Sensing and Diagnostic Module SDM located under the driver seat and 5 sensor at the lower radiator support cannot under any circumstance be moved from their present mounting locations Section O continued on next page G Van GMT 600 2001 PAGE NJ GMT 600 Section O continued from previous page Welding CAUTION Fuel tank and fuel lines must be drained and all vapors purged to ensure non combustible mixture before any welding brazing or
29. are not transferred into the battery posts due to slide tray movement Failure to do so can result in loose terminals poor starting or battery failure Battery acid leakage could result around posts not properly relieved of strain 7 The cable attachments at the battery terminal must not cause undue strain at these connections There should be no sharp bends in the cables adjacent to the connections The cables should be routed down from the terminals rather than horizontally from the terminals to prevent a lever action that may loosen connections Terminal corrosion inhibitors and other coatings should not be applied to the sealed electrical contact areas Terminal torque of the sealed terminal shall be 10 20 Nem freedom 14 20 Nem linehaul 8 Mounting Base Tray The tray should be of a substantial material sufficiently reinforced to resist flexing and cracking The tray must provide firm continuous support of the battery and not amplify vibration levels There must be no protrusions or projec tions in the tray or mountings that would damage the battery Cantilevered mountings are not recommended and the tray should be mounted flat so as not to aggravate electrolyte spillage or lead fatigue A rounded lip of adequate height to ensure stiffness and retention should be provided around the perimeter of the tray With the battery mounted in a vehicle a static force of 22 kg applied to a 6 54 sq cm area at any corner should not move the battery any mor
30. arts for your add on systems may not be available from a GM dealer Those installing aftermarket systems should provide information as to where and how to obtain service Labels SUNVISOR DOWN POSITION All labels on the vehicle any message applied to the vehicle or vehicle component that informs instructs or warns must appear on the completed vehicle so the user can read them easily and without obstruction NOTE In order to be in compliance with FMVSS 208 no LABEL INFLATABLE RESTRAINT SYSTEM CAUTION other label shall be installed on the same side of Print should be readable from Drivers Passenger position the sunvisor as the Inflatable Restraint Caution Air Bag Label Note Sunvisor with vanity mirror shown Install label in same location on sunvisor without mirror G Van GMT 600 2001 PAGE UJ Van GMT 600 Section 1 Body Accessory items such as refrigerator hot water heater furnace etc which operate on liquid propane gas should be located and protected to prevent exposure to any flame Body structures interior and accessory arrangements must be designed into the vehicle to provide for proper load distribution on both axles and notto exceed any gross axle weight ratings Lateral load equalization must also be maintained The resultant Center of Gravity of the unladen vehicle must be within the limits tabulated in the FMVSS 105 section of the Incomplete Vehicle Document Body insulat
31. ative The brake warning switch on models equipped with vacuum hydraulic brakes is located adjacent to the master cylinder vacuum unit This includes the brake system differential pressure The parking brake actuator switch is mounted on the park brake apply mechanism which is mounted on the L H body side inner under the instrument panel The park brake system is equipped with an automatic adjuster Do not separate the park brake cables unless the apply mechanism is blocked out The adjuster will wind in the cable until it can no longer be reconnected if not blocked pinned See the Pin UP procedure outlined in Section 5 Enabling the Park Brake Automatic Adjuster in the G Van Service Manual Section 6 Engine For additional information refer to Body Section 1 Air conditioning and auxiliary belt driven equipment installation recommendations No alterations or additions to the accessory drive belt system will be warranted on either multiple belt systems or serpentine belt systems The serpentine belt type of drive is designed as a total system incorporating a single poly V belt and an automatic tensioner In this type of system degrees of pulley wrap belt tension and pulley alignment are very critical factors Modification is not recommended The fan and fan clutch that come with the vehicles are matched to the equipment and conditions encountered in normal operation Substitution of the fan and or fan clutch may affect cooling pe
32. be clipped every 600 mm or less to prevent chafing Metal clips must have rubber or plastic liners Section 8 continued on next page G Van GMT 600 2001 13 PAGE GMT 600 Section 8 continued from previous page Use corrosion resistant steel tubing with short sections of approved electrically conductive hose to connect components Steel tube ends should be beaded for hose retention Fuel supply is pressurized by an in tank pump Coupled hose or electrically conductive quick connect must be used All engines require a fuel return system which returns excess fuel from the injection pump and injector nozzles back to fuel tanks Care should be taken that these lines are not blocked nor their hoses pinched The engine may run poorly or stall if these lines are restricted or blocked All gasoline engine vehicles are equipped with fuel evaporative emission control equipment which is certified to be in compliance with the Federal or applicable California Vehicle Emission Standards Alterations to fuel tank and metering unit lines canister or canisters canister filters canister purge control valves relay switches tank auxiliary vent valve engine speed controller or other devices systems are therefore not allowable since vehicle adherence to C A R B and Federal regulations may be affected Diesel powered vehicles incorporate water drain provisions in the fuel system These valves are only to be open
33. be made to the brake master cylinder location brake pedal push rod length or pedal position Ensure that the hydraulic brake system is free of air and hydraulic leaks Bleed brakes if required following procedures as outlined in the G Van Service Manual Ensure that the vacuum booster system or hydraulic booster system is functional and free of leaks Check master cylinder fluid level and fill as necessary Use only DOT3 Fluid from a sealed container Delco Supreme 11 is recommended Refer to Owner s Manual Check power steering fluid level for models equipped with hydraulic booster brake Refer to Owner s Manual Added floor covering or carpeting must not restrict service or parking brake pedal travel from released position to full pedal travel Section 5 continued on next page G Van GMT 600 2001 9 PAGE GMT 600 Section 5 continued from previous page No body part or chassis mounted component may be located within 2 0 in of brake hose routing in all wheel and axle positions exhaust system components must also have a minimum of 2 0 in clearance to brake hoses in closest positions Be sure to account for brake hose travel with suspension Note Heat shielding is likely required with clearances even greater than 2 0 in Keep the brake fluid temperature below the boiling point of water under all operating conditions Body builder is to verify that the brake warning switches are oper
34. d for proper installation of special bodies and or equipment on GM frames Failure to follow these recommendations could result in serious damage to the basic vehicle New soft mount provisions for RV and Commercial bodies vehicles 03 32 Locations found on the reference pages 38 40 in the Body Builders Manual Flanges Do not drill holes in frame flanges Within 20 mm 0 75 in of radius tangent and 25 mm 1 0 in of raw edge e Larger than 12 mm 0 50 in Closer to each other than twice the hole diameter NOTE The frame flanges holes recommendations might be affected by the soft mount provisions locations Holes Holes to mount brackets supports and out riggers must be drilled in the vertical side web with the following restrictions Material between edge of hole and inside of upper or lower flange must not be less than 37 mm 1 50 in for low carbon steel 36 000 PSI yield The minimum edge distance between any two 2 holes must be larger than twice the diameter of the larger hole holes should exceed 20 mm 0 75 in in diameter All holes should be drilled in the frame using appropriate drilling practice and safety precautions Section 2 continued on next page G Van GMT 600 2001 PAGE o GMT 600 Section 2 continued from previous page Alterations If the wheelbase is modified the alterer must take responsibility for compliance with affected motor ve
35. dification to the A C system which causes the A C plumbing lines to increase in length such as the addition of a rear after market evaporator and blower assembly will necessitate the following changes e Lubrication PAG refrigerant oil must be added to rear system to provide lubrication for compressor Refer to the G Van Service Manual for specifications Refrigerant Add R 134A refrigerant to system based on sizing of new tubes hoses and evaporator Contact your A C supplier for recommended charge e Label Revise modify GM charge label located on the front face of evaporator from factory recommended charge for a front system only to body builder s new recommended dual system per SAE J 639 This is important for servicing the A C system so that the technician knows the correct amount to add to the modified system Heater Defroster modifications should be made to the heater defroster system or coolant supply which could affect compliance to FMVSS 103 G Van GMT 600 2001 PAGE Ul GMT 600 Section 2 Frame Hole drilling welding modifications or alterations to the frame assembly are the responsibility of persons performing these operations These same individuals assume complete responsibility for frame assembly reliability performance after alterations and compliance to applicable FMVSS requirements The following procedures and specific precautionary instructions are recommende
36. e than 25 mm Battery trays are supplied with the chassis In the case of motor homes and diesel school buses the trays are secured to the frame rail The trays shipped on the rails may be relocated to other areas on the vehicle keeping in mind the recommendations noted above For other units the tray is supplied on the radiator support Section 12 continued on next page G Van GMT 600 2001 18 PAGE GMT 600 Section 12 continued from previous page 9 Freedom Battery The hold down must be able to prevent the battery movement relative to the mounting base or hold down Torque at the battery hold down shall be 15 20 Nem 133 177 Ibs in at the base clamp or 2 3 4 5 Nem 20 40 Ibs at the top bar A bottom hold down centrally located at the sides of the battery is recommended 10 Location The battery should be located in a well ventilated area where a temperature buildup does not occur The location should also provide protection to the battery to prevent damage from foreign objects The ends of the battery in the area of the vent ports should be free of obstructions so that the gasses generated during charging can be freely dissipated into the atmosphere 11 Accessibility The hold down should be convenient for tools and hands so that personal injury does not occur There should be clearance at the insulated and grounded terminals so that wrenches can be used without accidental gro
37. ectrical system 6 Forfurther information refer to the instruction manual in the wiring repair kit referenced elsewhere in this section Accessory Power Supply Feeds For power requirements to service additional devices to be added by body builder upfitter the power supply source must be from the studs on the underhood electrical center mounted on the left hand shear wall in the engine compartment A junction block has been provided behind the driver s side pillar Both switched and unswitched power junction terminals are available See Owner s Manual for compatibility All additional loads should utilize these terminals NOTE A ground stud has also been provided above the junction block G Van GMT 600 2001 20 PAGE GMT 600 Section 13 Cooling To provide satisfactory engine cooling and A C performance the following conditions must be met 1 Do not locate any large objects such as batteries spare tires lights sirens etc in front of the radiator core A C condenser or grille They restrict air flow into the radiator core and influence fan blade stress and or A C head pressure 2 Grille opening size configuration and the external baffles provided should not be altered in any manner Any reduction in cooling ability may adversely affect engine transmission performance 3 Fan clutches not conforming to the original equipment specifications may not operate correctly and may stay on
38. ed when removing water and contaminants from the fuel system Fuel Tank The tank must have a minimum clearance of 2 in top front rear and side to body and other supports Tank may be pressurized to 1 25 PSI maximum to check for final line leakage or for forcing fuel through the system Pressures greater than this amount may be detrimental and affect tank durability The use of auxiliary fuel tanks is not recommended If an auxiliary fuel tank is added the alterer must take responsibility for compliance with affected motor vehicle safety and emission standards Also if an auxiliary fuel tank is added to a gasoline powered vehicle the fuel must be drawn through a pipe atthe top of the tank balance line between tanks is not permitted Venting of auxiliary tank to be provided via purge canister and not to atmosphere Gasoline fueled vehicles are now equipped with a fuel pump return line If an auxiliary tank is added the tank selector valve must include a port which returns fuel to the tank from which the fuel is being drawn Similarly addition of another fuel line for an auxiliary fuel user such as a generator will require emission revalidation In gasoline engines the fuel pump is located in the fuel tank The battery must be disconnected before starting any work on the fuel System Section 8 continued on next page G Van GMT 600 2001 PAGE GMT 600 Section 8 continued from previous page
39. he dash fitting Flexible components hoses wires conduits etc must not be routed within 2 0 in 50 mm of moving parts or accelerator linkage unless routing is positively controlled Caution must be taken so that the accelerator pedal mounting and location remains unchanged Guidelines for accelerator pedal locations are as follows a Ensure that the accelerator can freely operate from idle to wide open throttle position and return Make sure that the pedal will not hang up on any nearby items such as carpets floor screws wiring harnesses etc Engine cover should have at least one inch 25 mm clearance to side of accelerator pedal with the carpet mat installed b Accelerator to brake pedal relationship has been designed to provide minimum driver movement and should not be altered in any way The gasoline engine induction and or ignition system is certified in compliance with the Federal Vehicle Emission Standards Any alterations to the systems or components could void compliance and render the vehicle illegal Systems include Fuel system Port Fuel Injection and associated tubes hoses and pipes air cleaner outside air hose and spacer heat stove and heat stove pipe fuel pump and inlet manifold fuel vapor canister Exhaust system Ignition system distributor and initial spark timing setting spark plugs and spark plug wires Crankcase ventilation system The diesel engine induction and injector pump system is cert
40. hicle safety and emission standards and for warranty on items such as driveshafts universal joints center bearings and rear transmission tailshaft transfer case and transmission case fractures output shaft bushings bearings brakes fuel systems and any other related component failures Additionally the customer must be alerted in the modifier s owner s manual that parts for the reworked area are not available through the General Motors Service Parts System Shear Plate Attachments Attachments of shear plates should be accomplished by using existing manufacturing holes already available When additional holes are required for shear plate attachment they should be no larger than 20 mm 0 75 in in diameter Holes areto be drilled no closer than 63 5 mm 2 5 in apart For holes drilled forward of the rear axle centers are to be no closer than 63 5 mm 2 5 in from the top or bottom flanges and no closer than 89 mm 3 5 in from any suspension attachments For frame holes drilled rearward of the rear spring hanger bracket hole centers are to be no closer than 51 mm 2 0 in from the top or bottom flange and no closer than 89 mm 3 5 in from suspension attachments Required large holes such as 20 mm 75 in diameter or larger should be kept to a minimum required opening Tubes should be welded in place if holes in excess of 25 mm 1 0 in diameter are required Trailer Towing The Incomplete Vehicle Document specifies that the CG location
41. ified to be in compliance with the Federal Vehicle Emission Standards and or Noise Standards Any alterations to the system or components could void compliance and render the vehicle illegal Section 6 continued on next page G Van GMT 600 2001 11 GMT 600 Section 6 continued from previous page Systems include Fuel system Injection pump injector lines and injectors fuel return hoses and pipes air cleaner outside air hose fuel pump fuel filter fuel heater assembly and intake manifold Exhaust system e Crankcase pressure regulation system External engine components such as air cleaner crankcase pressure regulator valve alternator injection pipes fuel return hoses from injectors exhaust manifolds oil fill pipe etc must be provided with sufficient clearance for engine roll and torque When a vehicle is equipped with an electronic fuel injection EFI engine it has an engine control module ECM PCM TCM or VCM This ECM PCM TCM must be maintained at a temperature below 1859 at all times This is essential if the vehicle is put through a paint baking process The or VCM will become inoperative if its temperature exceeds 1859 Therefore it is recommended that temporary insulation be placed around the ECM PCM TCM or VCM during the time the vehicle is in a paint oven or undergoing another high temperature process Note To protect
42. ion provided by General Motors should not be removed This includes any thermal or underbody heat shields This insulation is provided to protect the vehicle body and occupants from excessive heat and or provide noise attenuation Any replacement material internal to the occupant compartment may have to be certified for MVSS 302 standard on flammability Some areas of specific interest are Underbody exhaust muffler and tail pipe shields and insulators Rear load floor interior insulation Front floor interior insulation Dash mat insulation Engine cowl insulation interior and exterior Engine cover insulation Conversions Conversions which remove the roof bow above the front doors must provide equivalent tie in between door pillars A minimum of 109 departure angle should be maintained if frame and or body is extended If body builder installs seating other than that supplied with vehicle it is the body builder s responsibility to ensure that the seating and restraint systems comply with FMVSS requirements The restraint systems supplied with the vehicle were designed to accommodate the seating reference points and seat travel of the original equipment seats only Section 1 continued on next page G Van GMT 600 2001 PAGE I GMT 600 Section 1 continued from previous page Air Conditioning For additional information refer to Engine Section 6 NOTE Air conditioning systems using
43. loads imposed by the starting circuit To ensure proper operation of the battery cables the following chart on length gauge and materials must be strictly adhered to Combined Length of Positive and Negative Cable Gauge Cable in Inches Copper x 5 m j Section 12 continued on next page G Van GMT 600 2001 17 PAGE GMT 600 Section 12 continued from previous page Battery Installation The battery and cable installation provided by the body upfitter must comply with the following guidelines Non compliance may result in a failure of the vehicle electrical component system the shutdown of the engine or the possibility of fire 1 The cables must not contact any sharp 5 in either the normal stored or slid maintenance position school bus application 2 The cables must not be bent in a radius of smaller than 10 times the cable diameter Insulation failure can occur if this happens The cable must be supported by clips spaced at a distance of not more than 250 mm In this clipping they shall not have a free movement that will allow rubbing on any vehicle component either fixed or moveable 4 All clips used must be of the rubber lined type not rubber dipped 5 Do not splice the battery cables Cable modifications can result in vehicle starting problems and loss of other key systems 6 The cables must be clipped to the battery tray such that the cable pull loads
44. me be said for the engine compartment Obviously there will be additional heat radiated from the engine How much is retained in the area will depend on how well the area is ventilated in your individual designs Here again temperature checks of interior areas surrounding the engine should be made to determine if your insulation is adequate This is the same engineering practice General Motors has followed on our complete vehicles incorporating these exhaust systems Exhaust system materials are selected and tested to withstand the operating environment of the vehicle Do not modify the exhaust system in any way The tail pipes are made of 409 aluminized stainless steel Heat shields are mounted to the chassis underbody and or exhaust system components tail pipe Section 9 Steering Check power steering fluid level and system operations Refer to Owner s Manual Steering wheel and horn pad must not be altered or replaced The steering column mast jacket must not be altered The steering column must be locked or pinned to prevent rotation when the steering gear or column to gear intermediate shaft is disconnected Damage to the inflatable restraint control wire can result if this is not done see Service Manual G Van GMT 600 2001 16 PAGE GMT 600 Section 10 Tires Check wheel lug nuts for proper torque specifications are provided in the Owner s Manual Substitution of tires of greater
45. n Allowance for the tire chain clearance shown on a maximum grown tire must allow for 1 66 in clearance to the sides of the tire and 2 5 in to the top of the tire Be sure sufficient clearance is provided for suspension axle and tire and wheel through full vertical travel up and down Pipes wiring conduits and any other related components must not be placed where they cross the path of motion of the rear axle driveshaft axle brake pipes hoses spring ortires Such crossing could result in rupture wear through or separation due to normal axle motion NOTE Notification to the consumer may be required in certain states if tire chains cannot be used See chassis data information for additional clearances and for assistance in calculating trim heights G Van GMT 600 2001 PAGE CO GMT 600 Section 5 Brakes See The G Van Service Manual for brake specifications Due to the critical nature of brake systems anyone making modifications or alterations must assume complete responsibility for system reliability performance and certification to FMVSS 105 G10 and some G20 models are equipped with front air dams below the front bumper as shown in the illustration These air dams equipped with brake cooling openings as shown These openings should not be obstructed by the addition of any accessories that would impede the flow of air to the front brakes It is mandatory that no change
46. re Carrier CENTERL INE SE OF VEHICLE 13 94 36 48 CENTERLINE j REAR AXLE HOIST SHAF T CE INCHES OUTSIDE OF METAL 245 75 16 W 6 5 RIM NORMAL TOP OF FRAME G Van GMT 600 2001 GMT 600 PAGE 114 214 217 314 317 05 06 Trailer Hitch 135 155 Wheelbase G Van GMT 600 2001 384 3 15 13 79 93 5 FRAME I CENTERLINE OF um REAR AXLE TRAILER HITCH BRACKET i Le 1223 5 48 17 1 INCHES PAGE GMT 600 114 214 217 314 317 05 06 Front Axle Tire Data Chart MAX TIRE WIDTH GROUND CLEARANCE MINIMUM GROUND CLEARANCE TO BE CALCULATED BY USING GROSS AXLE HEIGHT AND RECOMMENDED TIRE PRESSURE WHEEL ROUND MAX TIR SERIES TIRE SLR GVW RANGE TRACK OFFSET CLERAN WIDTH 511405 P215 75RIS 313 8 6100 1721 2 0 0 177 2 226 0 P235 75RISXLS 325 9 7100 1721 2 0 0 189 2 240 0 511406 235 75R15XLS 7100 1721 2 0 0 189 2 521405 17225 758160 344 9 7300 1695 2 13 0 208 2 LT225 75816 345 9 8600 1721 2 17 0 209 2 228 0 G21406 LT225 75816 345 9 8600 1721 2 17 0 209 2 228 0 228 0 521705 1225 758160 344 9 7300 1695 2 13 0 208 2 LT225 75 18 1721 2 17 0 209 2 228 0 G21706 LT225 75R16D 8600 1721 2 17 0 208 2 228 0 631405 1245 75816 357 9 9500 1721 2 17 0 221 2 248 0 631406 124
47. rformance A substitute fan may be subjected to excessive stresses and might break Substitution is therefore not allowed The incorporation of an aftermarket air conditioning system could have the following consequences Vehicle engine coolant overheating in certain geographical areas that normally experience high ambient temperatures Restrictions to engine cooling fan airflow resulting in higher fan blade stress Section 6 continued on next page G Van GMT 600 2001 10 PAGE GMT 600 Section 6 continued from previous page Inadequate air conditioning performance unless system capacity is enough to cool the interior space of the completed vehicle Due to the critical nature of the accelerator system anyone making modifications or alterations assumes complete responsibility for system reliability performance and compliance to FMVSS 124 Caution must be exercised so that the accelerator cable routing is unchanged e Donotuse accelerator cable or clips to route wires harnesses or other cables Cable sheath must be clipped so as to pinch inner cable Cable must not be loose in clip allowing sheath to move when accelerator pedal is applied and released Cable must not be subjected to kinking or routing across any sharp edges Cable routing must be perpendicular to the surface of the front of dash at the dash fitting No objects or routings should force cable to have a bend at t
48. s fuel systems which could damage or reduce the longevity of those components could cause the mechanical and emission performance warranty to be voided Exhaust System Particular care should be taken to prevent the possibility of exhaust fumes and carbon monoxide exposure to vehicle occupants in units completed by body builders Holes and openings through the floor and all other parts of the body must be permanently and adequately sealed by the body builder to avoid exhaust intrusion into any occupant area If itis necessary to change the exhaust outlet location the exhaust discharge must be unobstructed and directed away from occupant areas Alteration of the exhaust outlet or its position may increase exhaust noise and render the vehicle illegal in those areas with pass by noise regulations All vehicles gt 10 000 Ibs GVWR come under Federal noise regulations vehicles 10 000 Ibs GVWR are regulated by various state and local regulations of the Environmental Protection Agency see those regulations for rules test procedure and noise levels permitted Check for proper clearance between body members and chassis components which may in any way affect the reliability and performance of the vehicle by developing abrasion and wear points from moving parts or degradation from extreme environment or thermal exposure or may increase interior noise Any attachments must consider chassis components for jounce and rebound motion at maximum GVW Tail pipe o
49. soldering If arc welding is employed on the chassis or body parts or components which could be damaged by welding temperatures these parts must be removed or adequately shielded Some examples are brake lines fuel lines and fuel tank assembly electrical wiring electronic modules sensing and diagnostic module under the drivers seat S I R sensor under radiator support To avoid electronic component damage disconnect battery batteries disconnect the negative cable first followed by the positive To reconnect cables connect the positive first then the negative When welding low carbon steel side rails crossmembers and brackets emphasis is placed upon weld application techniques to avoid stress risers that may adversely affect frame operating stresses Note that some of the frame sections are made of high strength low alloy steel that could be adversely affected by heating due to welding Also prior to welding the area to be welded and surrounding area must be cleaned of all frame protective coating After welding when parts are cool carefully inspect wiring and electrical components for shorts or other damage which could draw excessive currents and possibly cause an electrical system short when the battery is reconnected Also assure that the fuel systems and especially the fuel lines are not damaged or distorted from the welding heat Apply protective coating to areas where coating was removed Service and service replacement p
50. t possible batteries should be periodically recharged every 30 60 days until the green dot is visible NOTE The ignition switch must be off when connecting or disconnecting battery cables or hangers jumper cables Failure to do so may overstress or damage the ECM PCM TCM VCM or other electronic components Modifications add on wiring must be carefully reviewed to ensure compatibility with the base vehicle wiring by reviewing system schematics wire routing paths harness connections etc Due to the wide range of modifications that may be required for vocational needs it is not feasible for the O E M to take into account all potential revisions For this reason any person modifying existing vehicle wiring must assume responsibility that the revisions have not degraded the electrical system performance Any add on wiring must be properly fused and routed to prevent cut pinch chafe problems and exposure to excessive heat Care must be exercised that existing Section 12 continued on next page G Van GMT 600 2001 Van GMT 600 19 Section 12 continued from previous page PAGE vehicle interfaces do not have their current load capabilities exceeded and that the respective control devices are not overloaded Added wire size should be at least as large as the wire to which it is attaching in order to maintain fuse protection A Packard electric wiring repair kit is available through Kent Moore GM P N 1208
51. unds or shorts occuring Terminal polarity markings warning labels and test hydrometer should be visible The battery ground connection must be readily accessible for disconnection as required for vehicle electrical service requirements 12 Tilt Angles For normal vehicle operation at GVW the battery should not be tilted 09 For installation or removal it should not be necessary to tip ortilt the battery in excess of 409 This is to prevent acid spillage For short duration vehicle shipment do not tilt the battery more than 199 from the horizontal 13 Temperature The temperature of the electrolyte should not exceed 529C Infrequent peak temperatures to 759C can be tolerated in soak situations only Shielding may be required to protect the battery from a source of excessive heat 14 Battery Storage Today s vehicles have several electronic devices which result in very small but continuous current drains on their batteries commonly referred to as parasitic loads Vehicles that are not used for an extended period of time may develop extremely discharged and or permanently damaged batteries resulting from these parasitic loads Discharged batteries can freeze at temperatures as high as 209F causing permanent damage To alleviate this condition check to make sure the green dot is visible recharge as necessary then disconnect the negative battery cable on vehicles which are not going to be in service within a 30 day period If this is no
52. utlet location must be tested statically and with the vehicle in motion to ensure that exhaust gases do not enter through side or rear windows or underbody seams and holes Auxiliary power plants should also be tested under the same conditions Tail pipe exit ahead of rear wheels is not recommended Section 8 continued on next page G Van GMT 600 2001 PAGE GMT 600 Section 8 continued from previous page Check for leaks in exhaust systems and repair as required NOTE The manifold joint take down pipe and converter assembly incorporating oxygen sensors is designed to suit OBD II requirements which are dependent upon specific gas leakage rates at the joints Ideally this assembly should not be disturbed during the body manufacturing process Exhaust gas temperatures can exceed 16009F under extreme operating conditions with pipe surface temperatures slightly less than this Extreme care must be used when placing body components in the proximity of the exhaust system so as not to exceed the rated temperature limits of the components Due to variants in underbody configurations of the vehicles General Motors is not in a position to make recommendations on how to insulate or design components in the proximity of the exhaust system Each manufacturer must make temperature checks of critical areas and adjust his design accordingly or provide shielding to ensure safe operation of body components The sa
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