BODY BUILDERS INSTRUCTIONS
Contents
1. 28 General Arrangement 139 WB G335 159 WB G338 177 WB G339 29 Sign Area 135 WB G H 134 234 334 Re 30 Sign Area 155 31 Window Opening 135 WB G H 134 234 334 J J J 12 32 Window Opening 155 WB G H 137 237 337 J J l 11 99 Glass Area 135 WB G H 134 234 S34 KR ERREUR 94 Glass Area 155 WB G H 137 2977 987 35 Mirrors so Lee Co de 36 G Cutaway Rear Flange Opening Dimensions U u J U J J 37 Rear CHMSL Location usu ua SS 38 Chevrolet Express Access and Access Plus GMC Savana Pro and Pro Plus Options PRP amp PCR U J J 39 BODY INTERIOR Seating Positio2. G H Van E BODY BUILDERS INSTRUG TIONS c 5 Section 0 General Instroctiofis 5 e b a a ta tdeo eerta 5 6 rep DEI HUE Tec DE 6 SECTION 1 BODY 7 ET 7 Rear Hedtars 8 ao Ra 8 mere M p etr IM m 8 Section 2 Frame asun 9 FlangeS M 10 po ce 10 Alterations 10 Shear Plate Attachments nn 11 RI IIo 11 Section 3 Front SUSpension a 11 Section 4 Rear Suspension 12 Section 5e Brakes uka tas 12 Section RC fter 19 Sectio 7 Iransmission ee 16 SECTION e Edi Le
3. 12 55 Rear Axle Tire Data Charts Sees ar ow oma ome omc omo ome ome omn 6134 3476 17210 310 19790 14630 1850 05 06 570817 1369 7900 125 7791 5760 7 28 H134 347 6 1721 0 310 19790 14630 1850 4276 3870 2480 2030 05 06 244970RT 700 678 412 77 91 57 60 728 1680 15 24 976 7 99 HN 120 0 4 72 U w 318 7 1969 0 77 52 1969 0 77 52 1977 0 77 83 1960 0 77 17 1977 0 77 83 1977 0 77 83 1960 0 77 17 2401 0 1395 0 164 1 427 6 94 53 54 92 646 16 80 1473 0 180 0 58 00 7 09 PAGE 69 427 6 387 0 248 0 203 0 16 80 15 24 976 7 99 427 6 16 80 482 0 2291 276 379 2 58 35 9 01 16 80 1493 386 0 258 0 203 0 15 20 10 14 7 99 1473 0 180 0 427 6 386 0 258 0 203 0 58 00 7 09 16 80 1520 10 14 7 99 SF SF SE SE 57 68 8 50 16 80 15 50 10 08 8 04 1482 0 229 1 427 6 379 2 239 0 58 35 9 01 16 80 1493 941 1465 0 229 1 427 6 379 2 239 0 5768 901 16 80 1493 941 SF T 57 68 8 50 16 80 15 50 10 08 8 04 EN 204 2 8 04 2042 8 04 239 0 2042 9 41 8 04 10 08 8 04 393 8 15 50 379 2 14 93 239 0 9 41 2172 8 55 503 0 19 80 2401 0 1395 0 164 1
4. 16 2010 Diesel Exhaust Systems Option LGH Duramax 6 6L Diesel 0004 4 inna 17 Section 9 Steeriht iiec iii eie 18 Section p an ah 18 Section 12 Electrical Battery and Battery Cables an a een 19 Battery Installations ass 19 Accessory Power Supply Feeds nn prr m pn nies oe ed od de esc vee 20 G H Van 2013 INO G H Van BODY BUILDERS INSTRUCTIONS Continued Section 13 Cooling 23 MODEL SYMBOL CHART a Led 24 GENERAL INFORMATIONN See Light Duty BBM General Information section See Light Duty On line Order Ref Guide Light Duty Trailering Specs MODEL amp OPTION WEIGHTS See Light Duty On line Order Ref Guide Model amp Opt Weights amp Weight Calculator BODY EXTERIOR General Arrangement 135 WB G H 134 234 334 and 155 WB G H 237 337
5. Fuel Tanks LPG 3 amp 4 Tanks Systems 159 Cutaway FRONT TANK 4 19 GGE LINCLUDED W 4 TANK 2065 04 82 093 112 79 4 441 o 11 000 215 04 NO CHANGE TO EXHAUST SYSTEM SAME AS 159 CUTAWAY 6 0L VB LSBI GAS GGE GAS GALLON EQUIVALENT CIKO GMT FUEL TANKS LPG a Tank SYSTEMS 633803 159 CUTAWAY 2JANZOI2 FM G H Van 2013 UPPER CROSSBAR LOWER CROSSBAR DETAIL ic CHASSIS STAC TURE REAR Pa REAR TANK 9 FEAR TANK REAR TANKS 31 GGE HINCLUDEO w 3 Tank SYSTENI 71 54 2 817 278 49 10 564 350 03 12 781 SHIELD REAR TANKS G H Van Fuel Tank Gas amp Diesel Fuel Sender Unit Asm FEED LINE FEED LINE VAPOR LINE VAPOR LINE RETURN LINE FUEL SENDER ASM FUEL SENDER ASM 57 GALLON GAS 57 GALLON DIESEL FEED LINE RETURN LINE FUEL SENDER ASM FUEL SENDER ASM 33 GALLON GAS 33 GALLON DIESEL GMT810 FUEL SENDER ASM 33 amp 57 GALLON FUEL TANKS 6335 338 339 03 2009 25AP2009 JF INCHES ANF60747 4 G H Van 2013 G H Van 78 PAGE Exhaust System 135 WB w Vortec 4 3L V6 LUS 000 CATALYTIC 801 1 CONVERTER 23 67 544 8 21 45 T 20 64 620 5 82 Lie 00 1262 4 126 4 49 70 FRONT AXLE 3429 0 WHEELBASE 135 00
6. SWING OUT SIDE CARGO DOORS EDGE OF GLASS 135 W B TD006054e G H Van 2013 35 PAGE G H VAN Glass Area 155 WB G H 137 237 337 558 0 562 7 547 9 21 97 22 15 21 57 3937 0 WHEELBASE 155 00 564 5 564 6 562 4 x 22 22 x 22 23 x 22 14 SLIDING CARGO DOOR INCHES EDGE OF GLASS 155 W B 00060541 G H Van 2013 G H Van 36 PAGE Mirrors Outside Rearview 2377 5 93 60 OPEN 2057 7 81 01 FOLDED OF VEHICLE MIRROR ASM RPO DE2 DE5 DE7 DRI FOR 20081 AND BEYOND GMT610 REAR VIEW MIRROR OPTIONS 20081 G H Van 2013 2966 5 116 79 OPEN 2219 5 87 38 FOLDED OF VEHICLE MIRROR ASM RPO DHC NOTE MIRROR SHIPPED LOOSE 20JLO7 1 INCHES ANE84273 3 G H Van 7 1809 1409 200 1009 OUTSIDE OF METAL NORMAL TOP OF FRAME REAR FLANGE CUTAWAY G Cutaway Rear Flange Opening Dimensions 6002 C400 lt 200 C o D gt 16 17 18 r19 20 126 5 4 98 152 1 5 99 168 5 6 63 193 1 7 6 184 3 7 26 SYMMETRICAL ABOUT GMT610 G335 338 339 03 2003 G H Van 2013 21 37 PAGE WIDTH HEIGHT LENGTH 963 4 37 93 1 972 3 38 28 616 1 25 67 995 7 39 20 800 0 31 50 1004 5 39 55 1 1000 0 139 37 1 979 8 38 57 1200 0 47 24 963 4 37 93 1 1400 0 55 12
7. 933 1 36 74 1600 0 162 99 B84 3 34 81 1800 0 70 87 807 4 31 79 2000 0 78 74 789 3 31 07 2030 4 179 94 749 4 29 50 2071 6 81 56 723 5 28 48 2084 0 182 05 704 8 1 27 75 2095 1 182 48 675 0 1 26 75 638 0 1 25 12 538 8 21 211 438 8 17 28 352 7 TD005979 3 G H Van G H Van 2013 38 PAGE Rear CHMSL Location SECTION A 881 3 34 ss j C740 BOTTOM OF FLOOR Hr REAR AXLE OF VEHICLE 4329 J INCHES TD006033a 99 G H Van Chevrolet Express Access and Access Plus GMC Savana Pro and Pro Plus Options PRP amp PCR 1273 8 1192 5 50 15 46 95 SECTION A A CHEVY GMC 135 W B 155 W B 1342 9 1852 1 DIM A 52 871 72 92 1334 3 1844 0 152 531 t 42 601 BOTTOM OF FLOOR 2886 9 113 66 t OF VEHICLE BOTTOM OF FLOOR SECTION B B GMT 610 2004 I G H 134234334 O5 GMC SHOWN G H 237337 05 CHEVY GMC INCHES ANC70879 G H Van 2013 G H Van Seating Positions and H Point Locations 2 5 8 12 135 WB GH134 234 05 06 G334 05 06 135 WHEELBASE G H Van 2013 FRONT AXLE H POINT H POINTS REAR AXLE 50 18 8 PASSENGER FORWARD TRAVEL REARW
8. 50 14 nd E 8 24 95 33 62 1573 2 81 94 FRONT AXLE REAR AXLE CO os CUTAWAY 2010 PURE en 1 INCHES ANFG620BB 4 G H Van 2013 86 G H Van Exhaust System 133903 177 WB w Vortec 6 0L V8 L96 G H Van 2013 G H Van G H Van 2013 Exhaust System 499405 135 WB w Duramax 6 6L V8 LGH gt Be PAGE 87 88 PAGE G H Van Exhaust System G33705 155 WB w Duramax 6 6L V8 LGH BASE WELDED EXHAUST 4 OPTION BUE SHIPPEO INSTALLATION INSTRUCTIONS 2206 0 8 11 AVAILABLE IN 2010 ap OXIDE CONVERTER PERMITTED B ENGINE AND THIS POINT 274 1 10 79 PARTICULATE TRAP 3937 0 WHEELBASE OUTSIDE OF METAL NORMAL TOP OF FRAME k OPTION LGH D FOR SP FIC INFO TION FOR MODIFYING TAILPIPE WHEN REQUIRED COOLER REQUIRED SECTION A A PLETE VEHICLE DOCUMENT 11 01 REVIEWED BY IONS 101 D FRONT AXLE BODY MOUNT INSTALLATI REAR AXLE G H Van 2013 G H Van 4 89 20101 Diesel Emission Compliant Opt LGH Exhaust Temperature Map on Cargo Vans w Full Body Shields Note These are typical exhaust skin and gas temperatures and the actual temperatures may vary based on specific operating and environmental conditions as well as the specific body
9. GMT610 EXHAUST SYSTEM LU3 4 3L GH134 05 06 G234 05 06 2010 G H Van 2013 REAR AXLE 1 INCHES 943 5 37 15 289 2 11 38 ANF62077 3 79 G H Van Exhaust System 135 WB w Vortec 5 3L V8 5300 LMF C100 CATALYTIC 3 sic Pa CONVERTER 10 22 igi m MUFFLER 23 79 21 45 315 2 11 00 JJ 943 5 11 90 ges 344 0 355 4 549 7 P 21 64 299 8 13 54 13 99 5 62 r 3429 0 WHEELBASE 135 00 GMT610 EXHAUST SYS LMF 5 3L GH134 05 06 6234 05 06 2010 1 INCHES ANF62077 4 G H Van 2013 80 G H Van Exhaust System 135 WB w Vortec 4 8L V8 1 20 6 0L V8 L96 CATALYTIC CONVERTER am Se 2 23 N 25 00 29 21 a WAK 3429 0 WHEELBASE 135 00 GMT610 EXHAUST SYS L20 4 8L L96 6 0L 6234 05706 63341057081 5257108 5937 05 06 2010 1 INCHES ANF62077 4 G H Van 2013 G H Van 81 PAGE Exhaust System Medium Duty Passenger Vehicle OF FRAME GMT610 EXHAUST SYSTEM L96 6 0L 6234 6237 05 2010 G H Van 2013 135 WBw Vortec 6 0L V8 L96 CATALYTIC CONVERTER LA 604 2 23 79 N ri q Mw 74
10. 1841 1 72 48 2162 1 B5 12 2350 92 52 2891 6 D I 3403 0 133 98 3937 0 155 00 WHEELBASE 1942 9 76 49 Y 3525 0 138 zi S gt BOTTOM OF FLOOR 697 2 27 45 859 7 33 84 lli 871 8 34 32 470 3 18 52 BOTTOM OF FLOOR 691 0 27 20 3403 5 134 00 859 9 33 85 3937 of 55 0 lt lt 9 STRAINERS BRACES RE INFORCEMENTS GMT610 2003 6237 337 06 1 INCHES 0006008 G H Van 2013 G H Van OF VEHICLE BOTTOM OF FLOOR G H Van 2013 PAGE 52 Floor Cross Sills Centerline Locations 42 20 1437 3 56 59 1841 0 72 48 2348 5 P 92 46 ee 2809 9 110 62 3248 4 127 89 qS i FRONT AXLE NOTE FOR 155 WB ONLY NOTE FOR 155 WB ONLY REAR AXLE INCHES TD006018a 53 G H Van Floor with Optional E26 135 WB G H 134 234 334 GMT610 2003 FLOOR DETAIL 135 W B 2968 5 WITH OPTION E26 116 87 _ 2726 2 107 33 1496 0 58 90 950 1 976 2 37 41 38 43 iol Ni eso 749 6 i 55 00 29 51 li SYMMETRICAL ABT OF VE 978 0 38 51 6 FRONT AXLE 6 REAR AXLE Pa H NORMAL TOP OF FLOOR 156 3 LH
11. 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 G H Van 2013 15 G H Van Section 6 continued from previous page 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 eng
12. 8 86 6 16 I 1 INCHES TD006077a G H Van 2013 G H Van 94 PAGE Floor without Optional E26 135 WB G H 134 234 334 GMT610 2003 FLOOR DETAIL 135 W B WITHOUT OPTION E26 917 0 36 10 Fg SYMMETRICAL ABT EXCEPT AS NOTED NORMAL TOP OF FLOOR G H Van 2013 798 1 912 0 869 5 741 181 42 35 91 34 23 NOTE SIDE ONLY 749 6 950 1 976 2 25 99 29 51 37 41 38 43 1 INCHES TD006077b 99 G H Van General Arrangement Full Body Van G H 100 200 300 05 06 4937 GH237 337 05 06 REFER 24292 6H134 234 334 05 061 REFER TO EXHAUST DRAWING FRAME DRAWING ER TO FUEL TANK DRAWING FRONT AXLE REAR AXLE gt o 1 REFER TO a a DRAWING GMT 610 2003 GH100 200 300 05 06 GENERAL ARRANGEMENT INCHES UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO OUTSIDE OF METAL TD005956a G H Van 2013 96 PAGE G H Van General Arrangement Cutaway G 335 338 339 03 REFER TO FRAME DRAWING REFER TO EXHAUST DRAWING A LY i vy g REFER TO FUEL TANK REFER TO SPARE TIRE DRAWING DRAWING 6 FRONT AXLE OF REAR AXLE GENERAL ARRANGEMENT G335 338 339 03 2003 INCHES TD005886a G H Van 2013 G H Van 57 Frame and Crossmember Arrangement 135 WB G 134 234
13. Opt Mtd Behind Rear Axle 1 0 1 J J 74 Fuel Tanks CNG 3 amp 4 Tank System 135 155 Full Body Van J U J U U Q 75 Fuel Tanks LPG 3 amp 4 Tanks Systems 159 Cutaway ee 76 Fuel Tanks Gas Diesel Fuel Sender Unit Assembl 77 EXHAUST SYSTEMS Exhaust System 135 WB w Vortec 4 3L V6 78 Exhaust System 135 WB w Vortec 5 3L 5300 V8 LMP J UU UU U U U Q 79 Exhaust System 135 WB w Vortec 4 8L V8 L20 amp 6 0L V8 196 80 Exhaust System Medium Duty Passenger Vehicle 135 WB w Vortec 6 0L V8 L96 81 Exhaust System 155 WB w Vortec 4 8L V8 120 amp 6 0L V8 196 82 Exhaust System Medium Duty Passenger Vehicle 155 WB w Vortec 6 0L V8 L96 83 Exhaust System G33503 139 WB w Vortec 4 8L V8 120 amp 6 0L V8 L96 J U J J nennt 84 Exhaust System G33803 159 WB
14. 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 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 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 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 amount to add to the modified system 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 al
15. locations in vehicles equipped with head curtain side impact air bags Optional The SDM may be relocated in incomplete vehicles with the VXT and options lice dos Section 0 continued on next page eo G H Van 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 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 and 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 coa
16. trim height dimensions See Van Service Manual for complete alignment procedure specifications and measurement of the 2 and D trim height dimensions under the Diagnosis and Wheel Alignment section G H Van 2013 12 G H Van 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 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 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 or tires 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
17. w Vortec 6 0L V8 LQG J U uu U U Q 85 Exhaust System G33903 177 WB w Vortec 6 0L V8 196 J U U U U Q Q 86 Exhaust System G33405 135 WB w Duramax 6 6L V8 1 J UU 87 Exhaust System G33705 155 WB w Duramax 6 6L V8 88 07 Diesel Emission Compliant LGH Exhaust Temperature Map on Cargo Vans w Full Body Shields 89 Exhaust System G33503 139 WB w Duramax 6 6L V8 U U uu U U l 90 Exhaust System G33803 159 WB w Duramax 6 6L V8 U uU u U Q 91 Exhaust System G33903 177 WB w Duramax 6 6L V8 LGH 4 4 4 12 2 92 G H Van 2013 G H Van 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
18. Battery Box Locations Dual req w Diesel Engine Full Body Cargo Vans G33505 amp 499705 OF VEHICLE 2021 38 C565 OUTSIDE OF METAL NORMAL TOP OF FRAME GMT810 633405 135 WB 633705 125 05 19JANO7 JF 1 INCHES ANE24667 4 ANE24667 4 G H Van 2013 66 G H Van Battery Box Locations Dual req w Diesel Engine Cutaway Vans G335 338 339 03 OF VEHICLE C637 OUTSIDE OF METAL NORMAL TOP OF FRAME GMT810 G33503 139 WB G33803 159 WB 19JANO7 JF 1 INCHES ANE24667 3 633903 177 WB ANE24667 3 G H Van 2013 67 G H Van Frt Axle Tire Data Charts MAX TIRE WIDTH GROUND CLEARANCE A MINIMUM GROUND CLEARANCE TO BE CALCULATED BY USING GROSS SLR AXLE HEIGHT REF AND RECOMMENDED 1 TIRE PRESSURE Max Tire Width 5124 08 16 248 0 576 H134 0506 21800078 5134 05 06 256 0 10 15 II H134 0506 17210675 25801015 224 05 06 172101678 2560 10 8 224 05 172101878 2000 787 2390 941 6237 05 340 3 13 40 1721 0 67 8 200 0 7 87 256 0 10 08 G335 357 0 14 06 1721 0 67 8 28 0 1 10 227 7 8 96 256 0 10 08 G335 172177675 SEN 17210675 0337 17210675 6335 336 3 13 24 1721 0 67 8 6335 325 5 12 81 1721 0 678 6336 3 17210675 G338 3 17210678 G338 3 17210678 G338 03 1721067 6339 03 LT225 75R16E 334 7 13 18 12300 1721 0 67 8
19. VEHICL TD005993b G H Van 2013 60 G H Van Frame and Crossmember Arrangement 155 WB 237 337 05 06 55 5937 0 WHEELBASE 1091 0 155 00 1112 3 42 95 25 21 451 0 43 79 908 5 35 77 17 76 6 OF VEHICLE OUTSIDE OF ji METAL NORMAL TOP OF FRAME 6 FRONT AXLE 7 59 REAR AXLE 2 52 og Loom DIMENSIONS OF MOUNTING HOLES AND UTLINE SYMMETRICALLY OPP GMT610 ae ARRANGEMENT ABOUT CENTERLINE OF VEHICLE WHEELBASE O2JUNEO4 JA 1 INCHES TD005994a G H Van 2013 61 G H Van Frame Crossmember Arrangement 139 159 177 WB Cutaway 03 GMT 610 PED 1409 1 DIMENSIONS OF MOUNTING HOLES AND FRAME FRAME ASM CUTAWAY A OUTLINE ARE SYMMETRICAL ABOUT W RPO BNC SOFT MOUNT ange 55 48 i CENTERLINE OF VEHICLE 47 97 645 9 20 47 25 43 J pe 668 1 r co uae H Bom Ld i 5 ED N x 492 5 19 39 s SOF TMOUNT 1 TORQUE SPEC D 70 10 5 F G FRONT AXLE WHEELBASE REAR AXLE 32 4 18 4 84 0 51 1 OUTSIDE OF METAL NORMAL TOP OF FRAME SECTION Z Z 5 om A omB G335037139 1630 8 1974 5 2245 3 3058 1 4010 5 4564 3 5181 5 778 3 250 8 1379 1 1732 7 L
20. a a 4 28 0 1 10 200 0 7 87 239 0 9 41 28 0 1 10 227 7 8 96 256 0 10 08 2227 8 77 256 0 10 08 196 0 7 72 239 0 9 41 120 0 4 72 185 2 7 20 239 0 9 41 1944 7 65 239 0 9 41 178 4 7 02 239 0 9 41 1784 7 02 239 0 9 41 1784 7 02 239 0 9 41 9 41 120 0 4 72 194 4 7 65 6 6 SS esi olo 4 gt i 3 i PEZ Paw S oj FSH HH gt 239 0 9 41 FRONT AXLE TIRE DATA CHART 2009 27MY2008 JF 1 INCHES ANF64684 3 G H Van 2013 G H Van Rear Axle Tire Data Illustration G H 100 200 300 OUTSIDE FRAME 43 31 1100 1 1066 8 G 335 338 339 OUTSIDE FRAME 142 0 GMT610 2007 RR AXLE TIRE DATA CHART G H Van 2013 MINIMUM GROUND CLEARANCE BE CALCULATED BY USING GROSS AXLE WEIGHT AND INFLATING TIRE PRESSURE TO 35 PSI A TRACK F TRACK F MAX GROWN TIRE RADIUS ON NARROWEST RIM MAX GROWN TIRE WIDTH ON WIDEST RIM TIRE CHAINS NOT INCLUDED OBAUO7 ML Iz INCHES PAGE 68 TD005980 3 rev 08AU07 ML G H Van 0134 05 06 H134 05 06 G234 05 06 G234 05 em O a o G335 6335 6334 05 06 G335 G335 03 0335 WD w 29 G338 G338 03 G338 G338 03 LT225 75R16E
21. 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 outlet 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 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 Section 8 continued on next page G H Van 2013 17 G H Van Section 8 continued from previous page Exhaust gas temperatures can exceed 1600 F under extreme operating conditions with pipe surface temperatures slightly less than this Extreme care m
22. applications LMM 2010i GMT610 Exhaust Surface Temperature Map w Normal Driving Severe Driving Temperature Locations ref below diagram Exhaust_skin_converter_inlet_pipe Exhaust_skin_converter_outlet_pipe Exhaust skin dpf front Exhaust skin dpf rear Exhaust_skin_middle_pipe 211 4 Exhaust_skin_before_kickup_pipe 201 7 All temperatures centigrade G H Van 2013 G H Van 90 PAGE Exhaust System G33503 139 WB w Duramax 6 6L V8 LGH ENGINE AND gt WHEELBASE COOLER REQUIRED OUTSIDE OF METAL NORMAL TOP OF FRAME THE BODY BUILDERS GENERAL INSTRUC G H VAN 8 EXHAUST UNDER EXHAUST lt 20101 DIESEL TIONS ON LGH INFO ION FOR 5 WHEN s ER J OP L DI FOR IK F IDIF Y ING L JT INGS RED INCOMPLETE D BE FRONT AXLE VEHICLE REVIEWED BY ICTIONS ON MS BEFORE JEM EXHAUST DOCUMENT UPFITTERS FOR 101 DIESEL EXHAUST ALTERING OR MODIFYING SYSTEM COMPONENTS 5 OR ACCES MODIF ICA TECNICIAN SERVICE SEL TICULA l P 27402010 INCHES G H Van 2013 91 G H Van Exhaust System G33803 159 WB w Duramax 6 6L V8 LGH GENERAL INSTRUCTIONS 8 EXHAUST IR SUB HEADER G H Van 2013 G H Van 92 PAGE Exha
23. 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 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 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 7 and D
24. 05 06 J J J Q Q T J J 50 Side Strainers Braces and Reinforcements 155 WB G237 G337 05 06 J J T J 51 Floor Cross Sills Genterline Lo6ations u a tte 52 Floor with Optional E26 135 WB G H 134 234 334 U UU U Uu u J J J J 53 Floor without Optional E26 135 WB G H 134 234 334 J UU U RAS RR RR Rss RR asas rra nr Q Q nana 54 CHASSIS General Arrangement Full Body Van G H 100 200 300 05 06 22202000nnnunnnunnnunnnnnnnnnnnnnnnnunnnunnnnnnnnnnnnnnnnnnnnnnnn 55 General Arrangement Cutaway G 335 338 339 03 J UU U U u u 56 Frame and Crossmember Arrangement 135 WB G 134 234 05 06 57 Frame Crossmember Arrangement 135 WB 134 234 05 06 J J J nnn Q 58 Frame Crossmember Arrangement 135 WB G 234 334 05 06 J u Q 59 Frame and Crossmember Arrangement 155
25. 05 06 3429 0 WHEELBASE 1091 0 640 4 135 00 42 95 25 21 451 0 389 7 OF VEHICLE 15 34 OUTSIDE METAL NORMAL TOP OF FRAME CROSSMEMBER ARRANGEMENT 135 WB 6134 234 05 06 amp G H Van 2013 148 0 1 99 5 83 6 REAR AXLE G42 DIMENSIONS OF MOUNTING HOLES AND Vee OUTLINE ARE SYMMETRICALLY OPPOS ABOUT CENTERLINE OF VEHICLE J INCHES TD005993a 98 PAGE G H Van Frame and Crossmember Arrangement 135 WB H 134 234 05 06 3429 0 WHEELBASE 135 00 640 4 25 21 fe m em IS 668 1 26 3 d A 6 I 4 1224 B Tg wa m Ar DE SEE VO OUTSIDE OF METAL NORMAL FRONT AXLE REAR AXLE 1 90 5 83 TOP OF FRAME OOD GMT610 CROSSMEMBER ARRANGEMENT 135 WB OUTLINE ARE SYMMETRICALLY OPPOSITE 134 234 05 0614 6 ABOUT CENTERLINE OF VEHICLE INCHES TD005993c G H Van 2013 59 G H Van Frame and Crossmember Arrangement 135 WB 234 334 05 06 3429 0 WHEELBASE 1091 0 135 00 42 95 640 4 OUTSIDE OF METAL p REAR AXLE 1 90 5 83 NORMAL TOP OF FRAME 4420 DIMENSIONS OF MOUNTING HOLES AND FRAME GMT610 CROSSMEMBER ARRANGEMENT 135 WB OUTLINE ARE SYWETRICALLY OPPOSITE L 1 INCHES 73341080818 ABOUT CENTERLINE OF
26. 19 G H Van 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 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 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 operative 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 installat
27. 2 1 25 00 29 21 3429 0 WHEELBASE 135 00 JF ANF62077 5 82 G H Van Exhaust System 155 WB w Vortec 4 8L V8 1 20 6 0L V8 L96 CATALYTIC CONVERTER REAR AXLE 289 2 11 38 NORMAL TOP OF FRAME 1 25 00 29 2 n R n 3937 0 WHEELBASE 155 00 JU EXHAUST SYSTEM V TEES T gd OL G237 G337 05 6337 06 O6MAY2010 L l INCHES 62077 6 G H Van 2013 93 G H Van Exhaust System Medium Duty Passenger Vehicle MDPV 155 WB w Vortec 6 0L V8 196 CATALYTIC CONVERTER 25 00 29 21 3937 0 WHEELBASE 155 00 GMT610 EXHAUST SYSTEM L96 6 01 G334 G337 05 2010 17 INCHES ANF62077 8 G H Van 2013 G H Van 84 PAGE Exhaust System G33503 139 WB w Vortec 4 8L V8 L20 amp 6 0L V8 L96 OF VEHICLE CATALYTIC CONVERTER E 330 8 lija 139 00 WHEELBASE 7 E NE Arme 3 H 1621 9 63 85 FRONT AXLE i REAR AXLE GMT610 EXHAUST SYSTEM L2014 8L1 amp L96 6 0L HD OBMAY2010 12 INCHES ANF62088 3 6335 03 CUTAWAY G H Van 2013 85 G H Van Exhaust System G33803 159 WB w Vortec 6 0L V8 1 96 559 CATALYTIC CONVERTER OF VEHICLE 12 ez TYP 29 8 25 9 1 17 1 02
28. 27 40 370 0 198 2 604 5 14 57 7 80 23 80 FRONT AXLE REAR AXLE IZ INCHES 46 PAGE 0006025 G H Van 47 PAGE Roof Bows 135 and 155 WB 05 06 2032 2 80 01 1430 9 56 33 THIS ROOF BOW ALSO COMMON TO CUTAWAY THIS ROOF BOW We ES Ze ros veru 2 TYPICAL AVAILABLE WIT OUTSIDE ROOF SHEET METAL i 80 155 WHEELBASE HICLE 2 76 120 0 4 72 ROOF BOW TYPICAL SECTION 322 5 12 70 WITH CARPET 11 83 W O CARPET 52 68 420 0 FRONT AXLE 16 54 RF BOWS GMT610 2003 G134 234 334 237 337 05 06 G H Van 2013 50 97 WITH CARPET 1349 5 53 13 1 INCHES W O CARPET 0006008 G H Van 2148 Side Strainers Braces and Reinforcements 135 WB G H134 G234 G334 05 06 BOTTOM OF FLOOR 3429 0 135 00 WHEELBASE L H SIDE VIEW amp E26 BOTTOM OF FLOOR 3429 0 135 00 WHEELBASE R H SIDE VIEW t amp E24 DESCRIPTION DR 51 RR HINGED DR SI RR LH HINGED DR SI RR SLIDING STRAINERS BRACES REINFORCEMENTS 6MT610 2003 G134 234 334 05 G H Van 2013 547 1 21 54 2892 7 113 89 3429 0 135 00 859 9 33 85 WHEELBASE L H SIDE VIEW E26 3404 0 134 02 BOTTOM OF FLOOR 3429 0 135 00 WHEELBASE R H SIDE VIEW amp YA2 1 INCHES TD006008b G H Van 49 PAGE Side Strainers Brace
29. 3706 i m o EZ EEE 8600 9 9 G33503 9600 C6Y Commercial Cutaway O0 FE tos 9900 4 G33503 w B3D 30 Series i 10050 9N2 139 10100 JFF 933803 12300 C7N 159 100 Commercial Cutaway 13980 C8V 14200 C71 G33803 w B3D 10050 9N2 459 400 Commercial Cutaway 12300 IN 10500 9N2 G33903 12300 E 177 118 Commercial Cutaway 13980 C8 14200 C71 G H Van 2013 G designates 2WD Model H designates AWD Model School Bus YF7 Upfitter Package YF1 Cutaway Upfitter 27 9 I gt 2 TRUCK Optional MODEL MODEL MODEL MERCHANDISING MERCHANDISING MERCHANDISING MERCHANDISING jp ie rix Vii Cu DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION 633503 w YF1 9900 CM4 ap Motor Home Cutaway 12300 C7N 30 Series G33803 w YF1 12300 C7N 159 100 Motor Home Cutaway 14200 C71 G33903 w YF1 12300 C7N 177 118 Motor Home Cutaway 14200 C71 G designates 2WD Model H designates AWD Model B3D School Bus YF7 Upfitter Package YF1 Cutaway Upfitter RV G H Van 2013 G H Van 28 General Arrangement 135 WB G H 134 234 334 155 WB G H 237 337 USABLE OPENING WITH SLIDING BOTH SIDES DOOR 884 3 34 81 933 1 36 74 963 4 37 83 979 9 38 58 1004 5 39 55 995 7 39 20 977 4 34 54 SECTIONA A TYPICAL B
30. 4276 379 2 239 0 2172 503 0 94 53 5492 646 16 80 1493 941 855 19 80 2401 0 1395 0 164 1 427 6 379 2 239 0 217 2 503 0 94 53 54 92 6 46 16 80 14 93 941 8 55 19 80 24010 13950 164 1 4276 379 2 239 0 225 7 503 0 94 53 54 92 6 46 16 80 14 93 941 8 89 19 80 24010 1395 0 164 1 427 6 3792 239 0 2162 503 0 94 53 5492 646 1680 1493 9 41 8 51 19 80 24010 1395 0 164 1 427 6 3792 239 0 2162 503 0 94 53 549 646 1680 1493 9 41 8 51 19 80 164 1 6 46 4275 16 80 3792 19 80 14 93 19 80 2013 70 G H Van Rear Axle Tire Data Charts 6339 3255 18980 1200 24010 13950 1641 42776 3792 2390 2172 3 1000 472 94 53 5492 646 1680 1493 941 855 G339 3255 18980 120 0 2401 0 13950 1641 4276 3792 2390 2172 9 L229 7SRI6E dzen 12300 7472 472 94 53 5492 646 1680 1493 941 855 G339 3255 18980 1200 2401 0 13950 1641 4276 3792 2390 2172 9 122575 6 424 13980 Tara 472 94 53 5492 646 1680 1493 941 855 6339 3255 18980 1200 2401 0 13950 1641 4276 3792 2390 2172 9 122575 6 595 14200 472 94 53 5492 646 1680 1493 941 855 GMTGIO R
31. 5 7 22 27 A 116 47 3429 0 WHEELBASE ed 135 00 1273 7 50 15 56 74 G H Van 2013 BODY EXTERIOR SIGN AREA 135 W B 1441 2 56 74 570 9 22 48 INCHES TD006054a 91 G H Van Sign Area 155 WB G H 137 237 337 3470 6 o To 22 4g 136 64 1544 0 80 79 895 8 35 27 3937 0 WHEELBASE 155 00 565 7 1272 6 22 27 50 10 56 74 SLIDING CARGO DOOR BODY EXTERIOR SIGN AREA 155 W B INCHES TD006054b G H Van 2013 G H Van 32 PAGE Window Opening 135 WB G H 134 234 334 516 8 519 6 500 9 20 35 20 46 19 72 3429 0 WHEELBASE 135 00 LE SWING OUT SIDE CARGO DOORS m Y Al SHEET METAL OPENING 135 W B 1 INCHES 0006054 G H Van 2013 33 G H Van Window Opening 155 WB G H 137 237 337 510 8 20 11 3937 0 WHEELBASE 155 00 513 2 518 3 20 21 20 41 SHEET METAL OPENING 155 W B TD006054d G H Van 2013 94 G H Van Glass Area 135 WB G H 134 234 334 567 7 570 5 558 0 579 0 22 35 22 46 1 97 x 22 80 3429 0 WHEELBASE 135 00 569 1 564 4 564 1 22 41 22 22 22 21
32. 6 G H Van 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 Exhaust Exhaust System CAUTION TO HELP AVOID PERSONAL INJURY SEAL THE INNER DOOR PANELS AND LIFTGATE IF EQUIPPED TO PREVENT INTRUSION OF CARBON MONOXIDE AND FOREIGN SUBSTANCES INTO THE PASSENGER COMPARTMENT 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 it is 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 210 000 lbs GVWR come under Federal noise regulations vehicles 10 000 Ibs GVWR are regulated by various state
33. 64 201 77 741 188 401 t 120 401 L 157 89 1 t 179 70 1 204 00 1 130 641 19 871 54 30 168 22 GO ieee 1768 0 2482 5 2753 3 3566 1 4518 6 5072 3 5689 5 783 5 245 6 1373 9 1727 5 69 611 97 741 108 401 1 140 40 1 1 177 96 1 t 199 70 1 1 224 00 1 30 851 9 671 54 091 168 011 33550371777 1768 0 2685 0 3213 3 4026 1 4978 5532 6149 5 253 7 1382 0 1735 89 61 1 L 105 71 126 51 r 158 51 1 196 01 1 1 217 81 1 t 242 11 1 30 531 19 991 154 41 68 33 GMT610 FRAME CROSSMEMBER ARR 6 CUTAWAY G335 338 339 03 2009 29SEPT2008 JF 1 INCHES TD005145 3 DME piM F G DIM J DIM K DIM L 3 G H Van 2013 G H Van 62 PAGE Platform Trailer Hitch i NENNEN L TIT 53 0 2 09 0 03 0 25 8 HOLES IN FRAME 24 1 95 TRAILER HITCH BRACKET 135 W BASE 155 W BASE 1 INCHES TD006052a G H Van 2013 63 G H Van Spare Tire Carrier 135 WB G H 134 234 05 06 334 05 06 O S OF METAL NORMAL TOP OF FRAME OF REAR AXLE P235 75R16 TD006017a G H Van 2013 G H Van Spare Tire Carrier 155 WB 237 337 05 06 OF VEHICLE HOIST SHAFT O S OF METAL NORMAL TOP OF FRAME LT225 75R16 OF REAR AXLE G H Van 2013 64 PAGE TD006017b 65 G H Van
34. ARD TRAVEL 461 1 18 15 12 PASSENGER C740 BOTTOM OF FLOOR H POINTS FOR 8 OR 12 PASSENGER 135 W B PASSENGER 1160 0 We 533 0 40 PAGE SEAT ROW SEAT ROW SEAT ROW 3 PASS BENCH 3 PASS BENCH 4 PASS BENCH NOTE CUTAWAY H POINTS FOR ORIVER AND PASS SAME AS ABOVE 300 5 11 83 649 4 25 57 26 1 OF VEHICLE 1 INCHES TD006025a 41 G H Van Seating Positions and H Point Locations 2 4 8 12 155 WB G237 05 06 G337 05 06 H POINTS FOR 12 PASSENGER 155 W B SEAT ROW 1 SEAT ROW 2 SEAT ROW 3 3 PASS BENCH 3 PASS 4 PASS BENCH RH 155 WHEELBASE PASSENGER L 2115 0 H 1160 0 W 533 0 REAR AXLE NOTE CUTAWAY H POINTS FOR DRIVER AND PASS SAME AS ABOVE BOTTOM OF FLOOR 160 0 FORWARD 300 5 c OF VEHICLE 6 30 TRAVEL 11 83 p 60 0 REARWARD 2 36 TRAVEL J INCHES TD006025b G H Van 2013 G H Van 42 PAGE Seating Positions and H Point Locations 2 4 8 12 15 155 WB G237 05 06 G337 05 06 155 WHEELBASE H POINTS FOR 15 PASSENGER 155 W B 3 PASS BENCH Tu PASS BENCH i PASS P 4 P 5 PASSENGER L 2115 0 H 1160 0 G H Van 2013 DRIVER NOTE CUTAWAY H POINTS FOR DRIVER AND PASS SAME AS ABOVE BOTTOM OF FLOOR 160 0 F
35. 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 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 It is the responsibility of the final stage manufacturer vehicle modifier or alterer to insure compliance of the completed modified or altered vehicle to all applicable Federal Motor Vehicle Safety Standards and regulations General Motors vehicles may contain systems that provide coverage beyond Federal Motor Vehicle Safety Standards and regulations It is the responsibility of the vehicle final stage manufacturer modifier or alterer to ensure these systems operate appropriately once the vehicle has been completed modified or altered For further assistance contact Upfitter Integration at 1 800 875 4742 or go to o
36. ODY CONTOUR L H SIDE 1904 5 MAX SWING 649 2 74 98 2379 0 MIRROR EXTENDED 25 56 617 8 93 66 24 32 2159 9 MIRROR FOLDED 18 13 HA B5 04 gt 1365 6 NN BLUR r L3 53 76 1424 98 ME iss el II eis gaa H A TRIM NO TRIM LZ ZI e E HN P KO ze 607 8 EN SN vr FAY STEP 144 7 1271 0 MIN HE I GHT FRT AXLE TOP OF 1 RR AXLE BODY MOUNT 1628 0 X WHEELBASE 1254 1 64 09 DOOR 2016 5 OAW 49 37 ORENING 79 39 5 70 50 04 OPENING 5691 3 224 07 OVERALL FOR 135 W B SHOWN 6199 4 244 07 OVERALL FOR 155 W B P TD005990a G H Van 2013 G H Van 29 PAGE General Arrangement 139 WB G335 159 WB G338 177 WB G339 OVERALL OF FRONT AXLE 4 OF REAR AXLE 1007 8 1499 1 39 68 59 02 139 WB A 2031 8 80 00 1 100 00 1 118 00 1 3770 8 4278 8 4736 0 148 46 11 168 46 11 186 461 6278 0 6786 0 7243 2 SPARE TIRE MOUNTING LOCATION SHIPPING ONLY CUTAWAY EXTER IOR GMT 810 G335 338 339 03 2003 1 INCHES G H Van 2013 26MYO4 JA 1513 6 59 59 TD005886b G H Van 570 9 22 48 22 27 90 Sign Area 135 WB G H 134 234 334 1268 8 1303 8 49 95 51 33 56
37. ORWARD OF VEHICLE 6 x 30 TRAVEL 60 0 REARWARD 2 3 36 TRAVEL J INCHES TD006025c G H Van 43 PAGE G H Van 2013 2 1392 0 54 80 KN Pe e 1st Row Driver and Passenger Seat Riser Mounting Locations X 1 75 WELD STUD 4 PLACES EACH SIDE SEAT RISER ASSEMBLY MOUNTING SEAT RISER ASSEMBLY MOUNTING 1 INCHES TD005989a 44 G H Van Seating Tie Down Locations 12 Passenger 135 WB GH134 234 05 06 G334 05 06 135 WHEELBASE 886 0 34 88 LL EI 7 80 23 80 FRONT AXLE REAR AXLE 1 INCHES TD006025d G H Van 2013 G H Van 45 PAGE G H Van 2013 Seating Tie Down Locations 12 Passenger 155 WB G237 05 06 G337 05 06 155 WHEELBASE 1 a An FRONT AXLE 198 2 7 8 3 CO 604 5 23 80 gt v REAR AXLE 428 0 16 85 p OF VEHICLE 1 INCHES TD006025e G H Van G H Van 2013 Seating Tie Down Locations 15 Passenger 155 WB G237 05 06 6337 05 06 4524 6 155 WHEELBASE 178 13 4250 1 167 33 3738 0 147 17 15 111 2649 2 104 30 prag 2453 12 34 21 a s C zb B 696 0
38. R AXLE TIRE DATA CHART 6H 05 06 G 03 2009 27MY2009 JF 1 INCHES ANF64872 4 G H Van 2013 G H Van G H Van 2013 Fuel Tank and Filler Location Full Body Vans PAGE 71 G H Van 72 Fuel Tank and Filler Location with L H Swing Out Doors Opt E26 Full Body Vans Silman ERIS Fe VW 16 72 926 9 36 49 VEHICLE P 3429 0 135 00 OUTSIDE METAL NORMAL TOP OF FRAME L FRONT AXLE REAR AXLE GMT 610 2003 INCHES GH134 234 334 05 08 FUEL TANK LOCATION OPTION E26 TD005956c G H Van 2013 73 G H Van Fuel Tanks G Cutaways 33 Gallon Mid Ship Tank C637 OUTSIDE TOP OF FRAME GMTGIO F GAS amp DI UEL TANKS 33 ESEL 33 6 57 GALLON 6335 33877 ec 339 03 2010 G H Van 2013 74 G H Van Fuel Tank Cutaways 57 Gallon Opt NE7 Mounted Behind Rear Axle C637 OUTSIDE GAS amp FUEL TANKS 33 6 57 GALLON DIESEL 6335 338 339 03 2010 G H Van 2013 75 G H Van Fuel Tanks CNG 3 amp 4 Tank System 135 155 Full Body Van 3429 00 135 000 4937 00 155 000 G H Van 2013 G H Van 76
39. The tailpipe should be 1 8 mm wall 3 5 diameter stainless steel 409 grade stainless steel Any extension to the system must minimize surface temperatures and the transfer of heat to the vehicleand surrounding environment The tailpipe must be oriented such that the exhaust gas exiting the tailpipe will not contact any downstream obstructions The tail pipemust be located at a height and with proper orientation such that there is a minimum of 25 inches of flow length straight line distance from the exit of the tailpipe in the direction of the exhaust flow from the exhaust tailpipe to the ground The exhaust cooling device must be reattached to the end of the tailpipe with the outlet positioned appropriately for the body installed by the body builder To maintain the Diesel Emission s Compliance Upfitter s modifying tailpipes can add up to a maximum of 8 linear feet and add no more than 180 degrees of combined bends Please consult the exhaust system schematics for each vehicle model and option combination for further clarification G H Van 2013 18 G H Van 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 Dam
40. WB G 237 337 05 06 J 60 Frame Crossmember Arrangement 139 159 177 WB G Cutaway 03 J J 61 Platform Trailer Fitch e 62 Spare Tire Carrier 135 WB G H 134 234 05 06 G 334 05 06 2 4 400002220 J J 63 Spare Tire Carrier 155 WB G 237 337 09 06 J J J 64 Battery Box Locations Dual req w Diesel Engine Full Body Cargo Vans 499505 amp 933705 65 Battery Box Locations Dual req w Diesel Engine Cutaway Vans G335 338 339 03 66 G H Van 2013 G H Van 4 AXLE TIRE DATA Fri Axie 67 Rear Axle Tire Data 68 Bear Axle Tire Data Charts ernannte 69 FUEL SYSTEMS Fuel Tank and Filler Location Full Body Vans ann une 71 Fuel Tank and Filler Location with L H Swing Out Doors Opt E26 Full Body Vans J J J 72 Fuel Tanks G Cutaways 33 Gallon Mid Ship Tank UU u sees J J 73 Fuel Tanks G Cutaways 57 Gallon
41. age 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 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 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 the Owner s Manual and tire inflation label provided with the vehicle Any substitution of tires may affect Soeedometer Odometer accuracy tire wear fuel economy ride and handling and stopping distances G H Van 2013 G H Van 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
42. an result in vehicle starting problems and loss of other key systems Section 12 continued on next page G H Van 2013 20 G H Van Section 12 continued from previous page 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 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 projections 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 aggr
43. 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 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 ee eee eee 19 PAGE 107 170 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 edge s 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 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 lined type not rubber dipped 5 Do not splice the battery cables Cable modifications c
44. arged batteries can freeze at temperatures as high as 20 F 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 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 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 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 w
45. avate 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 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 recommendations 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 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 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 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 hold down should be convenient for tools and hands so that persona
46. e Body structures interior and accessory arrangements must be designed into the vehicle 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 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 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 10 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 sys
47. environmentally friendly long life coolant is required G H Van 2013 24 I gt MODEL SYMBOL CHART TRUCK Optional MODEL MODEL MODEL EE MERCHANDISING MERCHANDISING MERCHANDISING MERCHANDISING pe iir dis S DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION G H13405 G H13405 GH13406 Passenger Van 20 Series G23406 Passenger Van G23405 w YF7 Cargo Van 6 designates 2WD Model H designates AWD Model B3D School Bus YF7 Upfitter Package YF1 Cutaway Upfitter RV 8600 6 135 8600 6 135 8600 6 135 W 2013 25 J I gt 2 TRUCK Optional MODEL MODEL MERCHANDISING MERCHANDISING MERCHANDISING MERCHANDISING CAB DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION G23705 20 Series 3 ME 23705 w YF7 5 6533405 6533405 w B3D 30 Series 33705 6533705 w B3D 6 designates 2WD Model designates AWD Model B3D School Bus YF7 Upfitter Package YF1 Cutaway Upfitter RV G H Van 2013 26 G H Van MODEL SYMBOL CHART continued Full Size Van amp SET Models TRUCK Optional he WS 2 WARE gt we MODEL MODEL MODEL MODEL T MERCHANDISING MERCHANDISING MERCHANDISING MERCHANDISING p Mir DN di am DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION 033406 8800 135 Passenger Van 9600 03
48. h 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 electrical system 6 For further 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 B 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 H Van 2013 23 G H Van 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 configurati
49. he exhaust systems have been specifically designed in conjunction with the engine hardware and software to meet the emissions certification requirements established by the U S Environmental Protection Agency For this reason modifications to any part of the exhaust system between the engine and exhaust particulate filter outlet are not permitted During normal vehicle operation and during the exhaust particulate filter regeneration process gas temperature inside the filter can reach levels as high as approximately 650 degrees C which is considerably higher than previous diesel exhaust systems Therefore materials and components installed near the exhaust system and exhaust gas stream should be shielded or designed to now withstand higher temperatures On all Diesel systems an exhaust cooling device has been designed for the end of the tailpipe to significantly reduce the exhaust gas exit temperature This device is required and is designed to draw in ambient air to cool the exhaust stream The exhaust and ambient air streams into the cooler assembly should remain unobstructed and free from foreign material When possible the tailpipe outlet location should not be modified because doing so could adversely affect noise and exhaust system back pressure and surface temperatures If it is necessary to modify the tailpipe the following restrictions apply and noise and exhaust system back pressure performance becomes the responsibility of the modifier
50. ine induction and injector pump system is certified 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 Systems include 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 an electronic fuel injection engine it has an engine 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 inoperative if its temperature exceeds 185 F 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 the under dash seat locations for control modules must be protected from moisture water when cleaning vehicle G H Van 2013 1
51. ing trim heights 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 All G10 and some G20 models are equipped with front air dams below the front bumperas shown in the illustration These air dams are 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 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 H Van 2013
52. ion 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 When additional alternators A C compressors and or other aftermarket accessory components are added to the OEM accessory drive system on the engine the Upfitter must be aware that these increased system loads may impact the components of the accessory drive system including the bearing life and durability of the OEM accessories drive belts water pump idler pulleys and belt tensioners The General Motors New Vehicle Limited warranty does not cover any damage or failure resulting from modification or alteration to the vehicle s original equipment as manufactured or assembled by GM Any issues resulting from body or equipment additions and any alterations to any of the parts components systems or assemblies installed by GM must be addressed by the special body company or equipment installer Section 6 continued on next page G H Van 2013 14 G H Van Section 6 continued from previous page The fan and fan clutch that come with the vehicles are matched to the equipment and conditi
53. ire 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 12085264 Kent Moore P N J38125 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 Section 12 continued on next page G H Van 2013 G H Van 22 PAGE Section 12 continued from previous page 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 wit
54. l injury does not occur There should be clearance at the insulated and grounded terminals so that wrenches can be used without accidental grounds 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 Section 12 continued on next page G H Van 2013 21 G H Van Section 12 continued from previous page 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 C Infrequent peak temperatures to 75 C 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 Disch
55. nd on the reference pages 38 40 in the Body Builders Manual 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 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 Alterations If the wheelbase is modified the alterer must take responsibility for compliance with affected motor vehicle safety and emission stan dards 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 Addi tionally 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 Section 2 continued on next page G H Van 2013 11 G H Van Section 2 continued from previous page 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 are to be drilled no closer than 63 5 mm 2 5 in apart For holes drilled forward
56. nents Do not interchange R 134A components refrigerant oil or service equipment with R 12 components refrigerant oil or service equipment Rear Air Conditioning A C system is designed to support a rear Evaporator Core heat rejection of 450 Btu min 27 000 Btu hr The system will not be properly balanced if a larger rear evaporator core is used without other system modifications This condition may lead to poor performance and or potential component failure Front Evaporator Core 28 200 Btu hr Rear Evaporator Core 27 000 Btu hr The A C and heater lines are usually routed between the vehicle floor and 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 Section 1 continued on next page G H Van 2013 co G H Van Section 1 continued from previous page NOTE It is imperative that the design of the HVAC lines and materials selected by the Conversion Companies upfitter or HVAC sup plier provide mechanical attachments to the vehicle to protect against abrasion engine oil 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
57. ns and H Point Locations 2 5 8 12 135 WB 40 Seating Positions and H Point Locations 2 4 8 12 155 WB 41 Seating Positions and H Point Locations 2 4 8 12 15 155 WB 42 1st Row Driver and Passenger Seat Riser Mounting Locations J J J J J 43 G H Van 2013 G H Van BODY INTERIOR Seating Tie Down Locations 12 Passenger 135 WB ecce eie 1 311 seas assa aa Rss u u 1 44 Seating Tie Down Locations 12 Passenger 155 WB neh 45 Seating Tie Down Locations 15 Passenger 155 WB UU U aa RR RR u U 46 BODY STRUCTURES Roof Bows 135 and 155 WB 47 Side Strainers Braces and Reinforcements 135 WB G H134 G234 G334 05 06 48 Side Strainers Braces and Reinforcements 135 WB G H134 G234 G334 05 06 49 Side Strainers Braces and Reinforcements 155 WB G237 G337
58. on and the external baffles provided should not be altered in any manner Any reduction in cooling ability may adversely affect engine transmission performance 3 Fanclutches not conforming to the original equipment specifications may not operate correctly and may stay on 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 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 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 coolant to system after adding capacity to system heaters The use of
59. ons encountered in normal operation Substitution of the fan and or fan clutch may affect cooling performance 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 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 Do not use 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 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 the dash fitting Flexible components hoses wires conduits etc
60. s and Reinforcements 135 WB G H134 G234 G334 05 06 1397 1 55 00 BOTTOM OF FLOOR 135 00 WHEELBASE L H SIDE VIEW amp E26 1435 0 56 50 871 8 34 32 96 0 3 78 3525 0 138 78 3429 0 135 00 547 1 21 54 WHEELBAS 859 7 33 85 L H SIDE VIEW t E261 1435 0 56 50 3429 0 135 00 WHEELBASE R H SIDE VIEW amp E24 RPO DESCRIPTION AO7 WINDOW BODY STRAINERS BRACES AND REINFORCEMENTS AOB WINDOW BODY RH GMT610 2003 6134 234 334 06 05 amp A07 A0B G H Van 2013 545 9 21 49 BOTTOM OF FLOOR 3429 0 135 00 WHEELBASE R H SIDE VIEW amp YA2 1 1 INCHES 0006008 G H Van 90 Side Strainers Braces and Reinforcements 155 WB G237 G337 05 06 3911 8 154 01 2348 8 92 47 j 1841 0 72 48 BOTTOM FLOOR 2893 7 I 3403 8 134 01 3937 0 155 00 WHEELBASE 3910 4 153 95 524 5 3402 4 133 95 20 65 4 475 7 18 73 697 2 27 45 859 7 33 84 859 9 33 85 WHEELBASE STRAINERS BRACES RE INFORCEMENTS GMT610 2003 G237 337 05 G H Van 2013 OF FLOOR INCHES TD006008d 91 PAGE G H Van Side Strainers Braces and Reinforcements 155 WB G237 G337 05 06 3395 8 133 69 3525 0 138 78 475 7 18 73
61. tems supplied with the vehicle were designed to accommodate the seating reference points and seat travel of the original equipment seats only e vendo Section 1 continued on next page G H Van Section 1 continued from previous page Rear Heater The heater system is designed to support a rear heater core heat rejection of 543 Btu min 32 580 Btu hr If additional heat is required a Fuel Operated Heater RPO K08 is offered on the GMT610 This option will provide an additional 17 500 Btu hr to the system cool ant The total of the rear auxiliary heater system supports 50 080 Btu Hr with a base engine plus the optional fuel operated heater GMT610 RPO Front Heater Core 37 020 Btu hr Rear Heater Core 32 580 Btu hr Fuel Operated Heater GMT 610 RPO K08 17 500 Btu hr directly to the coolant Diesel engines may set the Check Engine light if too large a rear heater core is installed The coolant temperature needs to be able to maintain a minimum of 70 degrees C 158 degrees F for regeneration of the particulate filter to occur Proper coolant flow to the EGR cooler must be maintained any modification or additions to the hose valves will require a coolant flow check 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 refrigerant compo
62. terations 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 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 New soft mount provisions for RV and Commercial bodies vehicles 03 32 Locations found on the reference pages 38 40 in the Bodv Builders Manual Section 2 continued on next page G H Van 2013 10 G H Van Section 2 continued from previous page 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 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 New soft mount provisions for RV and Commercial bodies vehicles 03 32 Locations fou
63. ting 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 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 All labels on the vehicle any message applied to the ea d 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 LABEL INFLATABLE RESTRAINT SYSTEM CAUTION the sunvisor as the Inflatable Restraint Caution Print should be readable from Drivers Passenger position Air Bag Label Note Sunvisor with vanity mirror shown Install label in same location on sunvisor without mirror G H Van 2013 PAGE 4 G H Van 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 flam
64. ur Web site at http www gmupfitter com Section O 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 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 frontal airbag sensor on the lower radiator support cannot under any circumstance be moved from the present mounting location The SDM side impact sensor SIS and rollover sensor ROS cannot under any circumstance be moved from their present mounting
65. ust System G33903 177 WB w Duramax 6 6L V8 LGH 8 11 VERTER WELDED AUST COOLER N BUE IFPED LOOSE WITH LLATION STRUCT IONS ABLE IN 2010 E OF VEHICLE OUTSIDE OF METAL NORMAL TOP OF FRAME GMT610 EXHAUST SYSTEM LGH DIESE G339 03 11 BI 10 G H Van 2013 4495 8 WH EELBASE t REAR AXLE COOLER REQUIRED SEE THE BODY BUILDERS GENERAL INSTRUCTIONS FOR G H VAN SECTION 8 EXHAUST UNDER EXHAUST L K FOR SUB HEADER 21 DIESEL EXHAUST SYSTEMS OPTION LGH 6L DIESEL FOR SPECIFIC INFO AND DIRE ION FOR MODIFYING TAILPIPES ROUTINGS WHEN REQUIRED THE INCOMPLETE VEHICLE DOCUMENT IVD SHOULD BE REVIEWED BY UPFITTERS FOR RESTRICTIONS 101 DIESEL EXHAUST 5 EMS BEFORE ALTERING OR MODIFYING OEM EXHAUST SYSTEM COMPONENTS BODY MOUNTINGS COMPONENTS OR ACCESSORIES INSTALLATIONS AND CHASSIS MODIFICATIONS SHOULD NOT IMPEDE SERVICE TECNICIAN S ABILITY TO REMOVE AND OR SERVICE DIESEL PARTICULATE FILTER DPF INCHES
66. ust 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 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 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 20101 Diesel Exhaust Systems option LGH Duramax 6 6L Diesel Beginning in 2007 vehicles with diesel engines have been equipped with exhaust particulate filters T
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