G VAN (GMT 600)
Contents
1. 7 4 20 47 iss 30 12 10 eg 22580 7 768 0 30 24 CENTERLINE OF Ai 88 61 127 3 u FRONT AXLE 44 38 lae CENTERLINE OF REAR AXLE 241 3 332 8 9 50 13 10 re 72 9 IBE L igen 6 14 663 0 3347 7 2 53 85518 131 80 77 7 o 42 7 53 7 54 7 15 6 5260 3 06 3 62 1 68 2 11 2 15 1 80 b 5 f Se HI mS C H lt S i e LM 1 e 1 25 4 155 3 OUTSIDE OF 6 11 341 6 METAL NORMAL i 8 2 OF FRAME 13 45 3359 1 1 90 ih BE 132 25 201 5 160 8 mE 7 93 el 18 14 DIMENSIONS OF MOUNTING HOLES AND FRAME OUTLINE ARE SYMMETRICALLY OPPOSITE 22 87 ABOUT CENTERLINE OF VEHICLE G Rev 12 98 G Van GMT 600 G 217 317 05 06 Heavy Duty Crossmember Arrangement 155 Wheelbase2. 3937 0 WHEELBASE 1091 0 155 00 1115 3 42 95 43 79 mm 908 5 35 77 640 4 451 0 389 7 25 21 17 76 15 34 8 f fex E FA 668 D m d y i 550 0 26 30 21 66 Foy e s CENTERI T OF VEHICLE 630 7 A aH p 9 24 83 T 0 ZEW N 520 0 619 3 307 4 20 47 ines 24 38 12 10 55 45 768 0 aded s m 30 24 88 61 Nope 909 CENTERLINE OF CENTERL I NE OF un FRONT AXLE REAR AXL 241 3 332 8 9 50 13 10 72 9 63 9 2 87 4 ie 1 3348 3 77 4 6 13 B2 3 05 31 9 663 0 24 45 4 28 10 2 14 1 79 i 1 y AERE 2 o m f i OU 25 7 ll MET 1 01 13 45 3359 1 48 5 INCHE 132 25 201 5 160 8 1 91 7 93 18 14 DIMENSIONS OF MOUNTING HOLES AND FRAME 580 8 OUTLINE ARE SYMMETRICALLY OPPOSITE ABOUT CENTERLINE OF VEHICLE 22 87 G Rev 12 98 G Vau GM
3. S 4 884 3 099 34 811534 2 i 1800 1600 963 4 136 74 T 37 93 400 979 9 eo 1004 5 38 58 39 55 1000 988 7 m Goo 38 93 b 886 8 CT 600 34 91 ETM OF FER 1000 600 200 SECTION A A BACK OF CAB rm 2951 6 116 20 FOLDED 2422 0 95 35 2860 1 112 60 1499 1 FOLDED 59 02 lt SPARE TIRE MOUNTING f RPO BATTERY LOCATION SHIPPING ONLY 21 151 E93 4 59 58 LED OF RMAL lt 2011 6 RAME 79 19 OVERALL 139 159 139 159 177 139 159 2031 8 2539 8 2997 0 3770 8 4278 8 4736 0 gt 6129 8 6637 8 7095 0 80 00 100 00 118 00 148 1 68 45 1 186 45 2 6 1 8 27 9 S INCHES G Rev 12 98 G Van GMT 600 G 315 318 319 03 32 Cutaway Interior sS H POINTS FOR CUTAWAYS 68 82 5 SHOU
4. 201 4 749 329 9 12 99 MUFFLER CENTERLINE FRONT AXLE 1000 1000 76 8 3 02 rr esu RH 565 I lt 1 m 6599 3 27353 35 522 CONVERTER ASSEMBLY OPTION L 30 L35 CONVERTER ASSEMBLY OPTION LIGHT DUTY LIGHT DUTY B C 135 1262 6 48 0 1327 0 49 71 33 38 52 24 155 1770 6 1 35640 1835 0 69 71 53 38 72 24 INCHES G Rev 12 98 G Van GMT 600 G 217 317 05 06 Heavy Duty Converter Assembly Engine Options L31 California L35 CATALYTIC CONVERTER aoe 9 85 14203 5 60 A s ERI Y 13 09 MUFFLER 201 4 7 93 11 41 12 91 CENTERLINE OF VEHICLE 1000 CENTERLINE OF 1000 FRONT AXLE 967 7 38 09 52 1 634 5 2 05 es 9E f BA CNN
5. 3937 0 K WHEELBASE Sene 155 0 503 0 499 6 494 3 507 4 504 i 19 801 18 70 19 46 Sed leceo 1735 8 48 30 1 i 68 33 ue 1 483 3 p 15 41 522 3 ELE uS D SW 1 NG OUT SIDE CARGO DOORS SLIDING CARGO DOOR 497 4 20 84 19 58 ass 1 63 07 m aa INCHES DAYLIGHT OPENING Rev 12 98 20 G Van GMT 600 2959 116 5 1554 5 1440 2 61 2 1 1054 41 5 3429 0 lt WHEELBASE 135 0 BA 1 3467 1 us 136 5 1554 5 1440 2 61 2 56 7 1 l 3937 0 lt WHEELBASE 155 0 BAS G Rev 12 98 G Van GMT 600 G 315 318 319 03 32 Cutaway Exterior
6. 810 4 31 91 2000 593 04 E 881 9 6009 23 34 34 721 gt 4 L 1800 gea 138 711 600 37 91 JE 120 1004 5 38 58 1200 72 39 55 i 1009 SS EEE lt lt 988 7 B00 Y 38 93 eo 77 4 m 2011 9 34 54 BTM OF FLR 79 21 A Boo aoo o gt ECHO a IP 1000 600 200 V 140 27 SECTION A A 2 TYPICAL BODY CONTOUR L H SIDE 55 BOTH SIDES 1940 4 TYP 1791 8 76 39 70 54 1000 Mise SWING WIDTH 1 431 8 17 00 49 61 2673 5 297 4 FOLDED 195 43 11 71 A CENTERLINE OF 2042 5 87 MAX REAR AXLE 80 41 OPEN 75 PROP 1426 7 ROD POS 56 17 E 1242 0 1248 3 48 89 s RIM O ZS E _ AE 13 56 TOP OF 1 1269 1 g BODY MOUNT 49 96 33 1324 4 6065 9 82 14 238 81 BOTTOM OF FLOOR E 1 INCHE OVERALL Poo G Rev 12 98 G Van GMT 60 0 G 217 317 05 06 155 Wheelbase Interior 5 8 or 12 Passenger 1748 0 1465 0 144590 1749 0 68
7. H POINTS FOR 15 PASSENGER 155 W B DRIVER PASSENGER 1748 0 1465 0 1459 0 1452 0 1554 4 L 2115 0 L 2115 0 68 82 57 67 57 44 57 16 61 19 1160 0 1160 0 SHOULDER SHOULDER SHOULDER SHOULDER SHOULDER W 533 0 W 533 0 ROOM ROOM ROOM ROOM ROOM L 3003 L 3003 0 L 3003 0 1 SEAT ROW 1 H 1153 5 H 1153 5 H 1153 5 j T 3 PASS BENCH 5355 W 148 5 W 238 5 _ tameo 3 PASS BENCH W 535 5 W 148 5 W 238 5 4629 0 4629 0 4629 0 52 H 1153 5 H 1153 5 H 1152 5 w 5355 148 5 W 238 5 L 5420 5 5420 5 5420 5 5420 5 t 1 1153 5 H 1153 5 H 1153 5 H 1153 5 3950 W 81 0 W 156 5 W 546 0 Y NOTE CUTAWAY H POINTS FOR e DRIVER AND PASS SAME AS ABOVE 63 85 55 51 55 53 56 81 61 03 HIP ROOM HIP ROOM HIP ROOM HIP ROOM HIP ROOM H POINT 1045 9 41 17 EFFECTIVE LEG ROOM 995 6 987 5 970 6 89 19 38 87 38 21 EHR EHR EHR C 0 1032 0 992 0 40 63 89 05 EHR EHR a PASSENGER SEAT F H POINTS BOTTOM 740 J OR FLOOR 160 0 FORWARD 6 29 TRAVEL 980 0 920 5 38 58 36 24 7 44 60 0 REARWARD EFFECTIVE EFFECTIVE
8. i B Jina ol 4 d 1 2 4 T CENTERL 1 OF REFER TO FUEL TANK DRAWING di AXLE CENTERLINE OF MM S 7 RONT AXLE i BODY DRAWING Pd 1 INCHES UNLE A REFER TO TRAIL THERWISE SPECIFIED NSIONS ARE TO OUTSIDE OF META ER HITCH DRAWING G Rev 12 98 G Vau GMT 600 G 114 214 214 05 06 135 Wheelbase Exterior 5 8 or 12 Passenger USABLE OPENING 4 WITH SLID
9. B lt a A SECTION B ROTATED 90 MINIMUM GROUND CLEARANCE TO BE CALCULATED BY USING GROSS AXLE HEIGHT AND RECOMMENDED INCHE FIRE PRESSURE SERIES TIRE SLR REAR WHEEL GVW TRACK DIM DIM B DIM C DIM D DIM E G11405 5215 5 313 9 SINGLE 6100 718 0 0 0 944 0 482 0 5 166 1 172 P235 75RISXLS 325 9 SINGLE 7100 718 0 0 0 958 0 478 0 372 5 240 0 184 611406 P235 75RI5XLS 325 9 SINGLE 7100 718 0 0 0 958 0 478 0 372 5 240 0 184 521405 LT225 75R16D 344 9 SINGLE 7300 700 0 418 0 928 0 472 0 381 0 228 0 203 LT225 75R16E 345 9 SINGLE 8600 708 0 17 0 936 0 480 0 381 0 228 0 204 G21408 LT225 75RISE 345 9 SINGLE 8600 708 0 I70 936 0 480 0 381 0 228 0 204 621705 LT225 758180 344 9 SINGLE 7300 700 0 13 0 928 0 472 0 381 0 228 0 203 LT225 75R16E 345 9 SINGLE B600 708 0 17 0 936 0 480 0 381 0 228 0 204 G21706 LT225 758 160 344 9 SINGLE 8600 708 0 41720 936 0 480 0 381 0 228 0 203 031405 LT245 75RI6E 357 9 SINGLE 9500 708 0 17209 951 0 465 0 394 0 243 0 216 031406 LT245 75RI6E 357 9 SINGLE 9500 708 0 17 0 951 0 465 0 394 0 243 0 216 631705 LT245 75R16E 357 9 SINGLE 9500 708 0 17 0 951 0 465 0 394 0 24
10. ROOF BOW TYPICAL SECTION A A L ROOF BOW THIS ROOF BOW ONLY THIS ROOF BOW AVAILABLE WITH 155 INCH WHEELBASE ALSO COMMON TO ERON CUTAWAY FRON 454 0 17 87 783 1 30 83 28 71 m 119 9 4 69 1 i N 5 1351 2 M 53 201 cu SV a k 1357 0 oo 1 53 42 21 85 740 L 420 0 ee pE 16 53 8 T nes 1287 2 52 63 189 3 ACCEI BOTTOM OF FLOOR 50 87 SHEET 7 45 lt 262 4 BRAKE ie z pue Eu 8 50 04 CENTERLINE 50 3 INCHES FRONT AXLE CARPET G Rev 12 98 G Vau GMT 600 G 114 214 217 314 317 05 06 Exterior Glass 484 3 487 4 494 3 19 07 19 19 19 46 484 3 487 4 489 2 19 07 19 19 19 25 au A WME eee 602 7 1 l 602 7 23 7331 D538 8 1 e Ss 9 f eet
11. G Rev 12 98 G Van GMT 600 G 114 214 217 314 317 05 06 General Arrangement 135 155 Wheelbase 15 53 11 01 INE OF CENTERI FRONT AXLE 1000 pues CENTERLINE OF REAR AXLE i 183 9 7 24 OUTSIDE META OUTSIDE TOP OF NORMAL TOP OF FRAME FRAME TO BOTTOM OF SHIELD WB L55 155 DIM 1323 6 1831 6 Ez 72 1 INCHES G Rev 12 98 G Van GMT 600 G 315 318 319 03 32 General Arrangement 35 Gallon and 55 Gallon ENTERL IN 886 6 rm 1178 1 OO F VEHICLE 34 91 46 38 137 4 UU U U m NE eo al U U U U SS px o Ja ES GAL i 5RAW i CAPACITY PNE Li i i Mie MT LTU U 1 nij ol In IF o C CJ uua C CJ 45 34 eres 13 79 17 45 H I
12. G 319 03 32 Heavy Duty Cutaway Crossmember Arrangement 177 Wheelbase 1742 2 WHEELBASE 1495 8 68 59 177 00 640 4 21 00 25 21 d m U C J _ 260 3 768 9 10 25 30 27 1408 3 55 45 CENTERLINE OF FRONT SAREE ONU 2685 0 388 6 54 67 105 71 1000 CENTERLINE OF REAR AXLE al 91 2 40 2 40 DI Ei 163 53 2 01 4 41 B4 0 18 4 29 4 663 0 rm T o fave 1 18 26 10 16 55 ee RUE LS E 637 ILE Oe OUTSIDE 21 METAL NORMAL OP OF FRAME 1990 e 5 5 5 31 7 68 1 79 404 7 lt lt 1106 8 INCHES 161 69 15 93 1 123 3 DIMENSIONS OF MOUNTING HOLES AND FRAME 4 86 OUTLINE ARE SYMMETRICALLY OPPOSITE ABOUT CENTERLI
13. 35 GAL DRAW 11511 CAPACITY 912 7 11100 4 35 93 143 321 CENTERLINE OF 2 7 AXLE CENTERL INE REAR AXLE 7 TO EJ UT 9O RI T 314 1 12 37 2 6 SE OUTSIDE TOP OF FRAME TO BOTTOM OF FUE ANK G Rev 12 98 G Van GMT 600 G 114 214 217 314 317 05 06 Muffler Arrangement 135 155 Wheelbase 5 9 8 gt 11 93 22 82 Y 560 1 1672 33 86 ca 6 58 Lo 298 4 158 9 11 75 26 CENTERLINE OF REAR AXLE VEHICLE MUFFLER 267 2 215 6 10 52 OUTSIDE 8 50 META Ls 163 1468 9 US G Rev 12 98 G Van GMT 600 G 114 214 217 314 317 05 06 Light Duty Converter Assembly Engine Options L30 L31 135 CATA YT CONVER
14. 68 82 57 67 57 44 62 15 SHOULDER SHOULDER sHOULDER SHOULDER ROOM ROOM ROOM ROOM Ha 160 0 W 533 0 L 3003 0 L 3816 0 H 1153 5 H 1153 5 L 3003 0 L 3816 0 1153 5 H 1153 5 DRIVER W 148 5 W 148 5 L 2115 0 L 3003 0 L 3816 0 H 1160 0 H 1153 5 H 1153 5 W 533 0 W 535 5 W 535 5 B NOTE CUTAWAY H POINTS FOR DRIVER AND PASS SAME AS ABOVE EK 1620 1426 0 1410 0 L 1603 0 63 85 55 51 56 14 63 11 HIP ROOM HIP ROOM HIP ROOM HIP ROOM H POINT 1032 0 992 0 995 6 976 4 40 63 89 05 89 19 88 44 EHR EHR EHR EHR 1045 9 41 17 160 0 FORWARD EFFECTIVE 6 29 TRAVEL LEG ROOM 60 0 2 36 TRAVEL G Rev 12 98 REARWARD 980 0 38 58 EFFECTIVE LEG ROOM 1 740 DRIVER S SEAT H POINTS BOTTOM OR FLOOR 1066 0 41 96 PASSENGER SEAT 189 0 7 44 G Van GMT 600 G 217 317 05 06 155 Wheelbase Exterior
15. 55 45 68 0 30 24 1742 7 uh 4428 PS CENTERLINE OF 1000 FRONT AXLE llt 240 9 332 6 9 48 13 09 663 0 2845 5 gt 72 6 26 10 112 03 2 86 91 8 4 4 23 6 63 9 3 61 Sy 2 1 87 93 I2 52 1 67 6 11 H 1 565 XL E Pato i dem 222 152 7 io 77 4 46 4 6 05 OUTSIDE METAI 3 05 1 83 ORMAL TOP OF 2850 6 FRAME 112 23 202 1 342 0 7 96 13 46 INCHE 161 0 18 15 DIMENSIONS OF MOUNTING HOLES AND FRAME 0 OUTLINE ARE SYMMETRICALLY OPPOSITE T ABOUT CENTERLINE OF VEHICLE 22 87 G Rev 12 98 Van GMT 600 217 05 06 Light Duty Crossmember Assembly 155 Wheelbase 3937 0 WHEELBASE 1091 0 ISSO 1112 3 42 95 43 79 a 35 77 S40 d 451 0 389 7 25 21 17 76 15 34 9 fo o 668 1 26 30 reu 2 E lol es ENTERL INE 22 550 0 21 66 TO a E C Le N 619 3
16. 2 228 0 G31903 LT225 758160 344 9 2000 721 2 119 4 208 2 228 0 631932 11225 758160 344 9 2300 721 2 119 4 208 2 228 0 G Rev 12 98 G Van GMT 600 G 315 318 319 03 32 Rear Axle Tire Data Chart 1066 8 m 42 0 OUTSIDE FRAME gt Tr ji C futs my o eu TA EL gi Ran s TT una H Www B L E SLR n Li L 0 9 It 1 p 9 TTC G _ B A u i A SECTION ROTATED 90 INIMUM GROUND CLEARANCE O BE CALCULATED 1 INCHE BY USING GROSS AXLE WEIGHT AND RECOMM
17. 56 245 3 166 04 4 6 56 9 66 as 5 LU li nl p WD g CENTERLINE REAR AXLE MUFFLER 1000 8 39 213 0 NCHE G Rev 12 98 Van GMT 600 47 Ordering Information Electrical diagrams are available from Chevrolet and GMC through service publica tions They have contracted the following companies to handle the ordering and ship ping of the manuals Helm Inc P O Box 07130 Detroit Michigan 48207 1 313 865 5000 for information and inquiries 1 800 782 4356 for credit card orders G Rev 12 98 Routine orders will be shipped within 10 days of receipt Rush orders will be accom modated for an additional charge Order forms are available upon request and orders can be paid by check or money order made payable to the mentioned companies Credit Card orders can be made by phone on the listed toll free phone numbers G Vau GMT 600
18. Incomplete Vehicle Document Body insulation provided by General Motors should not be removed This includes any thermal or underbody heat shields This insulation is provided to protect the ve hicle 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 tailpipe shields and insulators Rear load floor interior insulation Front floor interior insulation Dash mat insulation Engine cowl insulation interior and exterior Engine cover insulation G Van GMT 600 Conversions Conversions which remove the roof bow above the front doors must provide equiva lent tie in between door pillars A minimum of 10 departure angle should be maintained if frame and or body is ex tended If body builder installs seating other than that supplied with vehicle it is the body build er 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 equip ment seats only Air Conditioning For additional information refer to Engine Section 6 NOTE Air conditioning systems using R 134A refrigerant are equipped with metric fittings to prevent interchange with R 12 r
19. does not occur There should be clearance at the insulated and grounded terminals so that wrenches can be used without accidental grounds or shorts occur 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 0 For installation or removal it should not be necessary to tip or tilt the battery in excess of 40 This is to prevent acid spillage For short duration vehicle shipment do not tilt the battery more than 19 from the horizontal 13 Temperature The temperature of the electrolyte should not exceed 52 Infrequent peak tem peratures to 75 C can be tolerated in soak situations only Shielding may be re quired to protect the battery from a source of excessive heat G Rev 12 98 14 Battery Storage Today s vehicles have several electronic devices which result in very small but con tinuous 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 20 F causing permanent damage To alleviate this condition check to make sure the green do
20. holes should be drilled in the frame using appropriate drilling practice and safety precautions Alterations If the wheelbase is modified the alterer must take responsibility for compliance with affected motor vehicle safety and emission standards and for warranty on items such as driveshafts universal joints center bearings and rear transmission tailshaft trans fer case and transmission case fractures output shaft bushings bearings brakes fuel systems and any other related component failures Additionally the customer G Rev 12 98 3 must be alerted in the modifier s owners 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 larg er than 20 mm 0 75 in in diameter Holes are to 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 a
21. ment or thermal exposure or may increase interior noise 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 affectthe function physical or mechanical properties environ ment 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 Vehicle Control Module VCM 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 drivers seat due to the Sensing and Diagnostic Module SDM The Sensing and Diagnostic Module SDM located under the driver seat and S I R sensor atthe lower radiator support can not under any circumstances be moved from their present mounting locations G Rev 12 98 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 ware points from moving parts or degradation from extreme environ ment or thermal exposure or may increase interior noise Any attachments must con sider chassis components for jounce and rebound motion at maximum GVW Welding CAUTION Fuel
22. not be obstructed by the addition of any acces sories that would impede the flow of air to the front brakes Itis mandatory that no change be made to the brake master cylinder location brake pedal push rod length or pedal position Ensure that hydraulic brake system is free of air and hydraulic leaks Bleed brakes if required following procedures as outlined in truck chassis service manual Ensure that vacuum booster system or hydroboost system is functional and free of leaks Check master cylinder fluid level and fill as necessary Use only DOT3 Fluid from sealed container Delco Supreme 11 is recommended Refer to Owner s Manual Check power steering fluid level for models equipped with hydroboost brake Refer to Owner s Manual Added floor covering or carpeting must not restrict service or parking brake pedal trav el from released position to full pedal travel No body part or chassis mounted component may be located within 2 0 in of brake hose routing in all wheel and axle positions All 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 re quired 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 operative The brake warning switc
23. the welding heat Apply protective coating to areas where coating was removed Service and service replacement parts 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 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 other label shall be installed on the same side of the sunvisor as the Inflatable Restraint Caution Air Bag Label SUNVISOR DOWN POSITION L INFLATABLE RESTRAINT SYSTEM CAUTION Print should be readable from Drivers Passenger position Note Sunvisor with vanity mirror shown Install label in same location on sunvisor without mirror 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 ve hicle to provide for proper load distribution on both axles and not to 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
24. to make use ofthe existing bat tery cables If the battery requires relocation and longer cables are required a propor G Van GMT 600 tionately larger gauge wire must be used If in relocating the battery the negative ground cable is attached to frame rail a cable of similar gauge must be provided be tween the frame rail and the engine This is required due to the heavy electrical 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 in Inches Copper 66 4 2 107 0 Battery Installation Cable Gauge 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 edge s in either the normal stored or slid maintenance position school bus application 2 he cables must not be bent in a radius of smaller than 10 times the cable diameter Insulation failure can occur if this happens 3 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 l
25. 1066 0 2 36 TRAVEL LEG ROOM LEG ROOM 41 96 EHR EFFECTIVE HEADROOM G Rev 12 98 G Van GMT 600 17 G 00000 Seat Riser Assembly Mounting 298 0 11 73 ra ni 1 E lee lee 326 0 12 83 oe LIN SEAT RISER ASSEMBLY MOUNT ING LA MIZ X 1278 4 PLAGES EACH SIDE 7 1392 0 54 80 7 07 4 326 0 C Le L 11 886 0 SEAT RISER ASSEMBLY MOUNT ING 42 2 INCHES G Rev 12 98 G Van GMT 600 G 114 214 217 314 317 05 06 Roof Bows Pedal Positions and Steering Wheel 601 0 23 66 745 29 34 Wr 685 0 26 97 13 4 K 0 761 _ 120 0 4 72
26. 3 0 216 631706 LT245 75RISE 357 9 SINGLE 9500 708 0 17 0 951 0 465 0 394 0 243 0 216 Rev 12 98 G Vau GMT 600 G 315 318 319 03 32 Front Axle Tire Data Chart MAX TIRE WIDTH TRACK SLR GROUND CLEARANCE MINIMUM GROUND CLEARANCE TO BE CALCULATED BY USING GROSS AXLE HEIGHT AND RECOMMENDED TIRE PRESSURE SERIES TIRE SLR GVW RANGE TRACK e 2 631503 LT225 758160 9 0000 721 2 119 4 208 2 228 0 LT225 75R16D 9 1000 721 2 119 4 208 2 228 0 LT225 75R16D 344 9 2000 721 2 119 4 208 2 228 0 LT245 75R16E 357 5 9500 721 2 17 0 221 2 228 0 631532 LT225 758160 9 1500 721 2 119 4 208 2 228 0 LT225 75R16D 9 2300 721 2 119 4 208 2 228 0 LT245 75RI6E 357 9 9500 721 2 17 0 221 2 228 0 631803 LT225 758160 344 9 0000 721 2 119 4 208 2 228 0 LT225 75R16D 344 9 1000 721 2 119 4 208 2 228 0 LT225 75RI6D 344 9 2000 721 2 119 4 208 2 228 0 631832 11225 758160 344 9 1500 721 2 119 4 208 2 228 0 LT225 75R16D 344 9 2300 721 2 119 4 208
27. 597 1777 Wheelbase Engine Option L29 L31 NS es 5 30 293 3 11 55 1395 0 1038 6 G31800 59 00 495 8 631900 77 00 G Rev 12 98 54 92 213 1 TYP m B 39 80 31 2939 3 m 115 72 1899 m _ We 610 0 24 02 ESO CENTERLINE REAR AX NATOR 2 8 0 642 4 10 94 25 29 508 0 p 20 00 1 INCHES NOTES G31800 631900 amp 129 131 G Van GMT 600 G 315 318 319 03 32 Heavy Duty Cutaway Converter Muffler Assembly 139 71597177 Wheelbase Engine Option L65 27 71 11 07 B MODEL 631500 G31800 G31900 DIM 139 159 177 2731 so 2939 3 3996 5 95 72 118 721 133 72 1688 6 346 0 66 48 13 621 CONVERTER m 191 8 7 55 A A D 830 5 m ot 1 32 701 u Q Very 8
28. 82 57 67 57 44 68 85 ut SHOULDER SHOULDER SHOULDER ROOM ROOM ROOM ROOM i F 8 1622 0 1410 0 1410 5 1740 0 63 85 55 51 55 53 68 50 HIP ROOM HIP ROOM HIP ROOM HIP ROOM H POINT 1032 0 992 0 9958 915 0 40 63 39 05 39 19 38 39 EHR EHR EHR EHR 1045 9 41 17 EFFECTIVE LEG ROOM 160 0 FORWARD 6 29 TRAVEL 60 0 REARWARD 2 36 TRAVEL G Rev 12 98 980 0 38 58 EFFECTIVE LEG ROOM 898 0 35 35 EFFECTIVE LEG ROOM H POINTS FOR 8 OR 12 PASSENGER 155 W B SEAT ROW 1 SEAT ROW 2 SEAT ROW 3 PASSENGER 3 PASS BENCH 8 PASS BENCH 4 PASS BENCH L 2115 0 L 4629 0 H 1160 0 H 1166 0 W 533 0 W 470 5 L 3003 0 L 3816 0 H 1153 5 1153 5 ES 2238 5 238 5 ins Wee W 156 5 L 3003 0 L 3816 0 L 4629 0 H 1153 5 H 1153 5 H 1166 0 W 148 5 W 148 5 W 156 5 DRIVER L 2115 0 L 3003 0 L 3816 0 L 4629 0 H 1160 0 H 1153 5 H 1153 5 H 1166 0 W 533 0 W 535 5 W 535 5 W 470 0 NOTE CUTAWAY H POINTS FOR DRIVER AND PASS SAME AS ABOVE DRIVER S SEAT H POINTS 740 BOTTOM OR FLOOR 1066 0 41 96 PASSENGER SEAT 189 0 7 44 G Van GMT 600 G 217 317 05 06 155 Wheelbase Interior 15 Passenger
29. DUS un 45 8 re 3 62 1 801 25 4 2 53 1 00 1 Lh Y X E Y 565 OUTSIDE 77 7 METAL NORMAL 54 3 08 0 OF FRAME 2 15 n 156 1 2851 1 6 15 INCHES 112 29 2015 341 6 7 93 13 45 DIMENSIONS OF MOUNTING HOLES AND FRAME 60 8 OUTLINE ARE SYMMETRICALLY OPPOSITE 18 14 F lt 580 8 ABOUT CENTERLINE OF VEHICLE G Rev 12 98 G Van GMT 600 G 214 314 05 06 Heavy Duty Crossmember Arrangement 135 Wheelbase 4 1091 0 42 95 3429 0 WHEELBASE 908 5 135 00 35 77 640 4 25 21 1 SE 15 34 3 O Y 4 1 668 1 d 1 550 0 26 30 SIL UBER 40 zee C 630 7 CENTERL INE fi 24 83 OF VEHICI Y N 9 e u d 71 T os 520 0 619 3 307 4 20 47 24 38 12 10 1408 3 1
30. ENDED 9 E PRESSURE SERIES RE SLR REAR WHEEI GVW TRACK a DI DIM B DIM C DIM DIDI EIDIM FIUIM GIDIM H 621503 EES SRIGE S5 9 SINGLE 9500 708 0 17 0 ISLE l465450 loos 220s3 3940 243 0 LT225 756160 DUAL 0000 852 4 127 0 2345 4 359 253 4 381 0 493 60 2 LT225 756160 oo DUAL 1000 852 4 3127 z345 4 OS s 6 3 253 4 381 0 493 60 2 LT225 75R16D ae DUAL 2000 852 4 127 0 2345 4 359 6 2 LS a 493 0 GO 2 521532 245 SRIGE 39749 SINGLE 9500 7080 ZO 19851 I46540 1 99 11 226 5 3940 243 0 22 75 160 3 aS DUAL 1500 852 4 127 0 2345 4 359 253 4 381 0 493 0 60 2 LT225 75 160 3 49 DUAL 2300 852 4 127 0 2345 4 359 O4 24 G O 493 0 GO 2 531803 LT225 75RI6D 3 552 DUAL 0000 852 4 2345 4 359 5 e3 4 389140 493 0 GO 2 LT225 7SRIGD a 55 DUAL 1000 852 4 127 0 2345 4 359 2554 Sel 493 0 60 2 LT225 5R1GD 3 409 DUAL 2000 652 4 127 0 2345 4 359 Bx 253 4 3614 0 26 GO 2 531852 LT225 75RIG6D 3 49 DUAL 1 500 852 4 12 0 2345 4 3569 642 259 4 381 0 493 0 GO 2 LT225 7SRI6D 3 DUAL 2300 Hose rns 2345 4 359 G 3 253 4 381 0 493 0 GO 2 631903 17225 75RIG6D 3 49 DUAL 2000 cles 2345 4 3259 63 3 253 4 Se lt 0 493 0 60 2 631932 122 75RI6D 3 409 DUAL 2300 852 4 127 0 2345 4 359 253 4 381 0 493 0 60 2
31. G 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 an complete incomplete vehicle No alter ation should be made to the incomplete vehicle which either directly or indirectly re sults in any component assembly or system being in nonconformance with any appli cable 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 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 and wear points from moving parts or degradation from extreme environ
32. H 179 0 7 04 B 29 2 52 B CONVERTER ASSEMBI Y s OPTION L3 CONVERTER ASSEMBLY OPTION L 35 HEAVY DUTY CAL HEAVY DUTY B C 135 995 4 1328 6 578 4 39 18 52 30 22 77 155 1503 4 1836 6 1086 4 59 18 72 30 42 77 INCHES G Rev 12 98 G Van GMT 600 G 217 317 05 06 Heavy Duty Converter Assembly Engine Options L31 129 INCHES EXHAUST RESONATOR 290 0 CATALYTIC 11 42 CONVERTER A 2 N rau B o LS i 4 AL 47 177 8 CENTERL INE OF 7 00 328 1 VEHICLE 12 92 135 2 5 32 1000 MUFFLER CENTERLINE CENTERLINE OF FRONT AXLE FROM AXLE be 5 1383 5 p 54 47 54 47 62 7 2 47 i lt lt S 1 TTL E S65 HH lt T iss L lt 1 208 0 208 0 8 11 8 11 CONVERTER ASSEMBLY OPTION CONVERTER ASSEMBLY OPTION L29 HEAVY DUTY A B HEAVY DUTY 577 6 576 9 g
33. Heavy Duty Cutaway Crossmember Arrangement 159 Wheelbase a 1739 4 1038 6 88 48 159 00 668 1 640 4 eb 26 30 m 8 O b JA lt qun i N o EB 4 21 00 ee MON PE 9 ni 1170 Lj o ee 771 7 ime maie 256 6 10 10 30 38 1408 3 a 1385 8 54 56 55 45 2482 5 97 74 CENTERLINE OF 1000 CENTERLINE OF FRONT AXLE AXLE 417 5 3693 7 16 44 145 42 114 9 4 52 B4 0 58 2 195 0 18 4 29 4 663 0 3 31 2 29 7 68 72 1 16 26 10 CN 1 1 637 TT li 51 0 OUTSIDE OF METAI 12 7 2 01 5 311 NORMAL TOP 3646 8 1 68 ri 143 58 126 1 4 97 a DIMENSIONS OF MOUNTING HOLES AND FRAME 5 OUTLINE ARE SYMMETRICALLY OPPOSITE 15 82 ABOUT CENTERLINE OF VEHICLE G Rev 12 98 G Vau GMT 600
34. ING CARGO DOOR 593 0 142 810 37 23 34 TYP Us gd 2000 881 9 34 721 932 4 1809 36 71 1 600 963 4 Cm EE 353 200 39 55 1009 2011 9 988 7 m 800 79 21 38 93 F 877 4 N pum BTM OF FLR 8ooK4ooIC O 000 600 200 1791 8 70 54 SECTION MAX WIDTH Y 55 TYPICAL BODY CONTOUR L H SIDE BOTH SIDES 100 ba 1940 4 431 8 76 39 1260 2 12720201 MAX SWING 49 61 297 4 11 71 CENTERLINE OF 97 A W FEAR AXLE OPEN y Y 7 I ROD POS 56 17 M 4 1242 0 8 48 89 4 J _ 607 8 749 1324 TOP OF 1 269 iE BODY MOUNT 49 96 5557 9 218 81 344 6 OVERALL BOTTOM OF FLOOR 13 56 78 517 Rev 12 98 G Van GMT 600 G 114 214 314 05 06 135 Wheelbase Interior 5 8 or 12 Passenger SEAT ROW 3 4 PASS BENCH L 4629 0 H 1153 5 W 546 0 L 4629 0 H 1153 5 W 232 0 L 4629 0 H 1153 5 W 81 0 L 4629 0 H 1153 5 W 395 0 H POINTS FOR 5 8 OR 12 PASSENGER 135 W B SEAT ROW 1 SEAT ROW 2 17480 1465 0 1459 0 1578 7 PASSENGER 3 PASS BENCH 3 PASS BENCH
35. LDER ROOM PASSENGER 1 2115 0 1160 0 8 W 533 0 U E ES DRIVER rr L 2115 0 H 1160 0 W 533 0 CENTERLINE OF VEHICLE 1622 0 63 85 HIP ROOM H POINT 1032 0 40 63 PASSENGER EHR SEAT DRIVER S SEAT TOP OF 1 BODY MOUNT H POINTS CD aime my i P 637 1045 9 41 17 160 0 FORWARD EFFECTIVE 6 29 TRAVEL OUTSIDE OF iM YOP OF TRAME 60 0 REARWARD 41 96 2 36 TRAVEL G Rev 12 98 G Van GMT 600 TYPICAL BOTTOM OF FLOOR 739 See OF FRAME 637 J G Rev 12 98 G Van GMT 600 G 114 214 05 06 Light Duty Crossmember Arrangement 135 Wheelbase m 3429 0 WHEELBAS 135 00 e a 908 5 668 1 520 0 20 47 1408 3 619 3 a 307 4 55 44 24 38 12 10 FRONT AXLE i NS 68 61 30 24 CENTER INE OF 1000 4429 REAR AXLE 241 3 332 8 9 50 13 10 26 10 MO
36. NE OF VEHICLE G Rev 12 98 G Vau GMT 600 31 G 114 214 217 314 317 05 06 Spare Tire Carrier 197 7 7 78 NN DANN C a ps CENTERL I NE 1 5 F M k S549 1 cup e 13 94 ENTERL INE OE EAR AXLE HOIST SHAFT QU qr S 138 7 5 46 20 OUTSIDE OF META P 45 75R16E W 6 5 R NORMAL TOP OF FRAME INCHES G Rev 12 98 G Van GMT 600 G 114 214 217 314 317 05 06 Trailer Hitch 135 155 Wheelbase 42 m 16 59 pa 3864 3 13 0 70 23 HOLES IN FRAME eo 1519 0 M O Aa t 1 4 47 52 0 2 05 REAR AXLE RAILER HITCH BRACKE 1223 5 48 17 INCHES G Rev 12 98 G Vau GMT 600 G 114 214 217 314 317 05 06 Front Axle Tire Data Chart FMAX TIRE WIDTH TRACK G
37. ROUND CLEARANCE MINIMUM GROUND CLEARANCE TO BE CALCULATED BY USING GROSS AXLE HEIGHT AND RECOMMENDED TIRE PRESSURE SERIES TIRE SLR GVW RANGE TRACK PE s G11405 P215 75815 313 9 6100 721 2 0 0 177 2 226 0 P235 y5RiEXLS 325 9 7100 721 2 0 0 189 2 240 0 511406 P235 75RI5xLS 9 7100 721 2 0 0 189 2 240 0 G21405 LT225 758160 344 9 7300 695 2 13 0 208 2 228 0 LT225 75RI6E 345 9 8600 721 2 17 0 209 2 228 0 G21406 LT225 758168 345 9 8600 721 2 17 0 209 2 228 0 621705 LT225 758160 344 9 7300 695 2 13 0 208 2 228 0 LT225 75RI6E 345 9 8600 28152 17 0 209 2 228 0 621706 LT225 758160 344 9 8600 721 2 17 0 208 2 228 0 631405 17245 75R16E 357 9 9500 7212 17 0 221 2 248 0 631406 LT245 75R16E 357 9 9500 Talaz 1760 221 2 248 0 631705 LT245 75RI6E 357 9 9500 SEIS 17 0 221 2 248 0 631706 LT245 75RI6E 357 9 9500 721 2 17 0 221 2 248 0 G Rev 12 98 G Vau GMT 600 G 114 214 217 314 317 05 06 Rear Axle Tire Data Chart 913 3 35 95 EM INSIDE FRAME m ut m zd P apo i SLR
38. T 600 G 315 03 32 Heavy Duty Cutaway Crossmember Arrangement 139 Wheelbase 3531 0 WHEELBASE 1739 4 139 00 68 48 640 3 25 21 8 a T U U py e I U 533 4 26 30 21 00 i o 1 FT TU HLH 5 CENTERLINE OF o VEHICLE 520 0 20 47 _ E 1408 4 772 0 10 09 55 45 30 39 CENTERLINE OF 1974 5 1385 4 FRONT AXLE 77 74 54 54 et E OF 1000 4531 REAR AXLE 3185 7 57 8 84 0 125 42 Ee Sus d 115 3 ma 4 54 663 0 18 4 417 1 72 16 42 ZEN n 1 637 i 3 Ep IW FE TN E 1 135 0 51 0 OUTSIDE 5 31 2 01 METAL NORMAL 7 68 OF FRAME INCHE 123 58 128 5 1 66 DIMENSIONS OF MOUNTING HOLES AND FRAME 14 98 401 5 OUTLINE ARE SYMMETRICALLY OPPOSITE ABOUT CENTERLINE OF VEHICLE Rev 12 98 G Van GMT 600 G 318 03 32
39. column must be locked or pinned to prevent rotation when the steering gear or column to gear intermediate shaftis disconnected Damage to the inflatable restraint control wire can result if this is not done See Service Manual Section 10 Tires Check wheel lug nuts for proper torque specifications are provided in the Owner s Manual Substitution of tires of greater 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 How ever the wheel offset and distance from centerline of rim to wheel mounting face must be the same as the replaced original equipment wheelto 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 J683 be adhered to in designing rear wheelhouse clearance Check tires and inflate to recommended tire pressure according to the tire pressure information provided in Owner s Manual and tire inflation label provided with 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
40. efrigerant components Do not interchange R 134A components refrigerant oil or service equipment with R 12 components refrigerant oil or service equipment Rear Air Conditioning This unit may be equipped with A C quick connect fittings on the liquid tube high pres sure 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 dis charge 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 modification 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 Service Manual for specifications e Refrigerant Add R 134 A 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 J639 This is important for servicing the A C system so that the technician knows the correct amo
41. eous 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 engi neering 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 gaseous fuel systems which could damage or reduce the longevity of those compo nents could cause the mechanical and emission performance warranty to be voided Exhaust System Particular care should be taken to prevent the possibility of exhaust exposure to ve hicle 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 G Rev 12 98 7 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 GVWR come under Federal noise re
42. event failure due to wear and fatigue Filler pipe and vent line must have a grav ity fuel flow to tank at all times no fuel traps are allowed Alterations of fuel line rout ings could affect the completed vehicle and are therefore not desirable The com plete fuel system must comply with FMVSS 301 as well as Federal and C A R B vapor emission requirements G Vau GMT 600 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 routing of the fuel fill will require evaporative emission validation by the final stage manufacturer Fuel Lines Fuel line routing precautions e 12in minimum clearance to exhaust system is required or a metal shield must be provided e Fuellines should be clipped to every 600 mm or less to prevent chafing Metal clips must have rubber or plastic liners e Usecorrosion 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 ru
43. 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 recommen dations on how to insulate or design components in the proximity of the exhaust sys tem Each manufacturer must make temperature checks of critical areas and adjust his de sign accordingly or provide shielding to ensure safe operation of body components The same can 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 insula tion 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 environ ment of the vehicle Do not modify the exhaust system in any way The tail pipes are made of 409 aluminized stainless steel 8 Heat shields are mounted to the chassis underbody and or exhaust system compo nents tailpipe 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 is not to be altered The steering
44. gula tions vehicles 10 000 lbs GVWR are regulated by various state and local regula tions 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 ware points from moving parts or degradation from extreme environ ment or thermal exposure or may increase interior noise Any attachments must con sider chassis components for jounce and rebound motion at maximum GVW Tail pipe outlet location must be tested statically and with the vehicle in motion to en sure that exhaust gases do not enter through side or rear windows or under body seams and holes Auxiliary power plants should also be tested under the same condi tions Tail pipe exit ahead of rear wheels is not recommended 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 Il 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 1600 F 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
45. h on models equipped with vacuum hydraulic brakes is located adja cent 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 See Service Manual The adjuster will wind in the cable until it can no longer be reconnected if not blocked pinned Section 6 Engine For additional information refer to Body Section 1 Air conditioning and auxiliary belt driven equipment installation recommendations G Rev 12 98 G Van GMT 600 No alterations or additions to the accessory drive belt system will be warranted on ei ther 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 recom mended The fan and fan clutch that come with the vehicles are matched to the equipment and conditions encountered in normal operation Substitution ofthe fan and or fan clutch may affect cooling performance A substitute fan may be subjected to excessive stresses and might break S
46. ill age or lead fatigue A rounded lip of adequate height to ensure stiffness and reten tion 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 more 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 recommenda tions noted above For other units the tray is supplied on the radiator support 9 Freedom Battery The hold down must be able to prevent the battery movement relative to the mount ing base or hold down Torque at the battery hold down shall be 15 20 133 177 lbs in at the base clamp or 2 3 4 5 Nem 20 40 Ibs in 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 build up 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
47. ination to be compatible with the rest of the electrical system 6 For further information refer to the instruction manual in the wiring repair kit ref erenced elsewhere in this section Accessory Power Supply Feeds For power requirements to service additional devices to be added by body builder up fitter the power supply source must be from the studs on the underhood electrical cen ter mounted on the left hand shear wall in the engine compartment A junction block has been provided behind the drivers side B pillar Both switched and unswitched power junction terminals are available See Owner s Manual for com patibility All additional loads should utilize these terminals NOTE ground stud has also been provided above the junction block G Van 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 radia tor 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 al tered 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 oper ate correctly and ma
48. ined 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 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 connec tions 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 G Rev 12 98 G Van GMT 600 and cracking The tray must provide firm continuous support of the battery and not amplify vibration levels There must be no protrusions or projections in the tray or mountings that would damage the battery Cantilevered mountings are not recom mended and the tray should be mounted flat so as not to aggravate electrolyte sp
49. ing 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 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 Fueltank 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 OF THE FUEL SYSTEM IS RECOMMENDED If the fuel system is received from the manufacturer in an incomplete condition certifi cation becomes the responsibility of the intermediate or final stage manufacturer Fuel Fill Fueltank filler pipe location should be so situated and constructed as to prevent gaso line vapor from emitting to vents of pilot flamed devices and to body and engine compartment air inlets Itis 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 pr
50. l 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 G Rev 12 98 5 b Accelerator to brake pedal relationship has been designed to provide mini mum 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 compo nents could void compliance and render the vehicle illegal Systems include e 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 e Exhaust system e Ignition system distributor and initial spark timing setting spark plugs and spark plug wires e Crankcase ventilation system The diesel engine induction and injector pump system is certified to be in compliance with the Federal Vehicle Emission Standards and or Noise Standards Any alter ations to the system or components could void compliance and render the vehicle ille gal Systems incl
51. n 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 Califor nia vehicle emission standards Alterations to fuel tank and metering unit lines can ister 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 opened 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 detrimen tal and affect tank durability G Rev 12 98 G Van GMT 600 The use of auxiliary fuel tanks is not recommended f an auxiliary fuel tank is add ed 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 at the top of the tank balance line between tank
52. ollowing conditions 1 Axle in full jounce against the metal to metal stop 2 Axle at 4 5 roll with one side of axle in full jounce at the metal to metal stop and 3 Axle at design position Allowance for the tire chain clearance shown on a maxi mum 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 calculat ing trim heights Section 5 Brakes See Truck Service Manual for brake specifications Due to the critical nature of brake systems anyone making modifications or alter ations must assume complete responsibility for system reliability performance and certification to FMVSS 105 G Van GMT 600 All G10 and some G20 models are equipped with front air dams below the front bum per as shown in the illustration These air dams are equipped with brake cooling open ings as shown These openings should
53. s 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 be within certain lim its 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 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 Truck Service Manual for complete alignment procedure specifications and measurement of the A dimension under Diagnosis and Front Alignment section 4 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 f
54. s 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 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 dis connected before starting any work on the fuel system 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 gas eous 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 ve hicles converted to gas
55. t 22 74 22 71 1085 7 1084 9 155 42 74 42 71 G Rev 12 98 G Van GMT 600 G 217 317 05 06 Heavy Duty Converter Assembly Engine Option L65 mI 346 0 9 56 13452 MUFFLER 1000 CENTERLINE OF FRONT AXLE om 6 2 03 CONVERTER ASSEMBLY OFTION L65 HEAVY DUTY 9 1259 4 135 49 58 1767 4 155 69 58 INCHES G Rev 12 98 G Vau GMT 600 G 315 03 32 Heavy Duty Cutaway Converter Mutfler Assembly Engine Option L29 L31 C EAR AXLE 134 6 TYP Ss 30 MUFFLER U U E E o E 2 lt pal D 836 0 m S 33 98 293 3 11 46 11 55 3530 6 139 00 ES G31500 amp L29 31 NCHES G Rev 12 98 G Van GMT 600 G 318 319 03 32 Heavy Duty Cutaway Converter Muffler Assembly 1
56. t is visible recharge as necessary then disconnect the negative battery cable on vehicles which are not go ing to be in service within a 30 day period If this is not 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 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 itis notfeasible for the O E M to take into account all potential revi sions Forthis reason any person modifying existing vehicle wiring must assume re sponsibility 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 ve hicle interfaces do not have their current load capabilities exceeded and that the re spective control devices are not overloaded Added wire size should be at least as large as the the wire to which it is attaching in order to maintain fuse protection A Packard electric wiring repair kit is available thro
57. tank and fuel lines must be drained and all vapors purged to ensure non combustible mixture before any welding brazing or soldering If arc welding is employed on the chassis or body parts or components which could be damaged by welding temperatures 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 drivers seat and 5 1 sen sor under radiator support To avoid electronic component damage disconnect bat tery batteries disconnect the negative cable first followed by the positive To recon nect 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 af fect 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
58. ubstitution is therefore not allowed The incorporation of an aftermarket air conditioning system could have the following consequences e Vehicle engine coolant overheating in certain geographical areas that normally experience high ambient temperatures e Restrictions to engine cooling fan airflow resulting in higher fan blade stress e 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 not to pinch inner cable Cable must not be loose in clip allowing sheath to move when accelerator pedal is applied and released e Cable must not be subjected to kinking or routing across any sharp edges e 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 the 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 e Caution must be taken so that the accelerator peda
59. ude e 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 e 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 a electronic fuel injection EFI engine it has an en gine control module ECM PCM TCM or VCM This ECM PCM TCM or VCM must be maintained at a temperature below 185 F at all times This is essential if the vehicle is put through a paint baking process The ECM PCM TCM or VCM will become inop erative if its temperature exceeds 185 F Therefore it is recommended that tempo rary insulation be placed around the ECM PCM TCM or during the time the ve hicle is in a paint oven or undergoing another high temperature process Section 7 Transmission This product is equipped with a neutral park start safety switch mounted on the trans mission which interfaces with the vehicle starter circuit The starter will only operate with the shift lever in the neutral or park position 6 Models equipped with brake transmission shift interlock BTSI require full applica tion of the regular brakes before shift
60. ugh Kent Moore GM P N 12085264 Kent Moore P N J38125 4 This kit contains instructions tools and com ponents 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 neces sary wiring additions by providing custom wiring stubs or jumpers to your specifica tions 10 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 sol der 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 term
61. unt to add to the modified system G Rev 12 98 G Van GMT 600 e Heater Defroster No modifications should be made to the heater defroster system or coolant supply which could affect compliance to FMVSS 103 Section 2 Frame Hole drilling welding modifications or alterations to the frame assembly are the re sponsibility 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 recommended 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 Flanges Do not drill holes in frame flanges e 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 e Closer to each other than twice the hole diameter Holes Holes to mount brackets supports and out riggers must be drilled in the vertical side web with the following restrictions e 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 e The minimum edge distance between any two 2 holes must be larger than twice the diameter of the larger hole e No holes should exceed 20 mm 0 75 in in diameter e All
62. y stay continuously never come on or cycle on and off ex cessively 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 engine to the heater connection on radiator or water pump in order to control transmission oil tem peratures during closed thermostat warm up operation Do not alter this flow as it may result in premature engine or transmission failure 6 If a 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 heating system it must be teed into the system in such a manner as to maintain con tinuous 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 coolant to system after adding capacity to system heaters The use of environmentally friendly long life coolant is required G Rev 12 98 G Van GMT 600 G 114 214 217 314 317 05 06 General Arrangement REFER TO FRAME DRAWING REFER TO EXHAUST DRAWING
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