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P32/42 CHASSIS

1. MODELS CP308 10 CP314 18 TP308 TP310 TP314 TP318 A 105 0 115 7 E 705 705 782 632 2200 45 57 1 TRANS SUPT FUEL 8 BRAKE LINE _ N ROUTING RIGHT SIDE m 46 86 2 RAIL 77 SECTION 94 00 FUEL EMISSION CANNISTER 91 96 28 07 BATTERY x 36 40 12 31 amp RETAINER 5155 45 98 42 42 56 00 26 30 2SPRING 1 ig Mt EL p 5 29 P n 22 21 Hh d 17 00 1 34 00 s a H 1 7 viu T EE 12 93 tore 41 56 1 ACCEL 00 15 60 5 62 2 78 y STRG COL JA 2000 v N 48 4000 N BRAKE PEDAL ZSPRING 29 39 E 26 16 69 90 40 GAL TANK 84 84 36 53 CAUTION ENGINE CONTROL MODULE MUST BE PROTECTED FROM TEMPERATURES ABOVE 185 F FLOOR TO BE POSITIONED SO THAT IT WILL NOT INTERFER WITH PEDALS IN DEPRESSED POSITION PICTURE BASED ON P31442 amp L35 amp FL6 AND DUAL 8R19 5 TIRE SIZE FOR ADDITIONAL INFORMATION SEE CH
2. DIM BODY MOUNTING HOLES 7 750 000 ese 42 AN 16 60 TOL out 0 40 0 238 40 03 5 P308 P310 P314 P318 ee V id A 11 97 11 97 11 97 11 97 11 97 cL E B 22 85 22 85 22 85 22 85 22 85 on 47 47 47 4 C 69 69 69 ENGINE 8 5 16 69 62 69 16 58 E VEHICLE VEHICLE E 32 62 32 62 32 62 32 62 32 62 REF F md 2 42 7875 78 75 78 75 1 1 gt G 8842 8812 10412 10412 105 00 Z a H 89 84 89 84 105 84 105 84 126 84 f FRT AXLE 2 38 pou DE 4 REF E 33 88 Soe UE NORMAL TOP NORMAL TOP OF FRAME OF FRAME PEN PE 20 20 80 24 80 9 86 0 SECOND uc 2 1 E 6 14 0 J 40 20 40 15 00 MD 5 FIRST SUPPORT ASM FLOOR amp DASH SUPPORT ASM FLOOR amp DASH FRT BATTERY amp FKA FK5 amp FL5 FL6 FL7 6 14 E pi BODY MTG _ ENGINE amp D VEHICLE G BODY MTG BODY MTG 4 DATUM 100 00 GAGE HOLE B H i UNLESS OTHERWISE SPECIFIED P BODY MTG gar 365 HOD ue ALL DIMENSIONS AFT OF THIS BODY MTG TYP LINE ARE TAKEN FROM GAGE HOLE B B BODY MTG BODY MTG FOR ADD
3. HOLE 2 CAM MUST BE HORIZONTAL 8 HOLE 2 _ MUST 12 O CLOCK POSITION 4 2 89 R TYP 4 _ s zi 0 96 E31 N WA 1 1 gt 4 IH 3 23 M W 1 TENES 23 54 BASE 28 00 E73 SS 29 85 74 0 48 A 5 50 08 T VIEW IN DIRECTION OF ARROW S FILLER NECK OPENING FOR E32 E33 BODY PANEL VERTICAL OR POSITIVE SEE GENERAL ARRANGEMENT DRAWING FOR ANGET RELATIVE TO ROUND ENEAS FILLER NECK LOCATION FOR B3D B3M REQUIRED TO SATISFY CALIFORNIA VAPOR RECOVERY REQUIREMENTS 46 39 FURNISHED WITH CHASSIS 9 FOR INSTALLATION 18 28 7 32 MODEL DIM A d 1 P311 32 63 82 14 32 67 38 18 32 106 00 319 32 106 00 20 32 106 00 TE P321 32 106 00 A 880 P308 42 53 82 10 42 69 82 14 42 69 82 18 42 90 82 GAGE HOLE B P32 42 Rev 12 98 P32 42 CHassis P 30000 Fuel Tank Arrangement REMOVE FROM THE PERMANENT TANK THE SNAP RING AND SHIPPING PROTECTOR INSTALL O RING AND SENDER ASM INTO FUEL TANK LINE UP TAB ON FUEL SENDER WITH SLOT IN TANK SECURE THE PARTS WITH THE SNAP RING REMOVE THE U SHAPED STEEL TUBE FROM THE REAR F
4. 3 8847757 REF UPC 9C DIM 311 314 318 319 320 321 STEERING COLUMN SUPT BRKT A 13700 15850 17800 190 00 20800 228 00 ki 7 93 50 105 00 93 50 9350 93 50 11700 135 00 135 00 11070 132 20 15170 16370 181 70 150 00 173 00 23428 25934 317 46 329 46 34746 367 46 DRIVER S ISLAND lt SEE ENGINE DRAWING VIEW IN DIRECTION 2 AUTO APPLY PARK ACTUATOR FOR RADIATOR 8 OF ARROW B WA P318 319 320 321 ES RADIATOR SUPPORT FOR ADDITIONAL FUEL INFORMATION N 52 93 INCLUDING TEMPORARY TANK N SEE FUEL TANK DRAWINGS 9 1590 BATTERIES 4 N RETAINERS A i y 74 33 00 PE c Li Z 6 02 see 8 78 FLAT c 66 00 13 55 M 1 4 1 34 00 m 3 78 i NN 1 56 H d AUXFUEL PICK UP 26 00 Si Y 3 94 2 77 COL PEDAL SHIELD 2 45 57 W 188 41 75 W JF9 B Bo ee me 70 50 26 10 46 25 FOR ADDITIONAL INFORMATION WHEELBASE e 5 R n SEE ENGINE PAGE CHASSIS DATA PAGE AND INSTRUCTION PAGE G OVERALL PICTURE BASED ON P31432 W L65 ENG amp MT1 TRANS P32 42 Rev 12 98 P32 42 Cnassis 30032 General Arrangement Di
5. REAR FACE ENGINE BLOCK 27 96 ds FACE OF TRANSMISSION CASE AT danh OF CRANKSHAFT 21 19 12 05 20 I 7 49 2 48 AIR INDUCTION TRANSMISSION OIL SEE NOTE 10 99 COOLER AG DRYER 2 HEATER SUPPLY RADIATOR SURGE FRONT VIEW 34 97 OF FRONT WHEELS TANK 3224 GENERATOR NE 9021 e ry OILFILLER EE TRANS OIL LEVEL o Deg at 30 68 INDICATOR gt L 27 68 REAR FACE OF y ENGINE BLOCK M 76 59 18 91 i 38 48 93 1 56 1 T y y T TURBOCHARGER 7 p CRANKSHAFT Q4 PISPUMP d 15 d RAD OUTLET 48 J 2 34 2 0 Nm 13 92 x qu un es FRONTFACEOF 7 POINTE z AT ENGINE BLOCK 1548 STARTER lt 35 22 26 58 f TRANS OIL 93 44 ENGINE COOLER 34 84 CRANKSHAFT amp VEHICLE 1 48 53 20 NORMAL aN OF FRAME 40 P32 42 Rev 12 98 32 42 CuHassis P 30042 Diesel Engine 6 5L HO Option L57 HEATER RETURN NOTE 1 25 MINIMUM CLEARANCE REQUIRED TO ANY PART OF ENGINE FOR ENGINE ROLL 2 00 MINIMUM CLEARANCE REQUIRED IN VERTICAL MOVEMENT FOR ANY PA
6. SPRING gr y CAUTION 2 EE NN FLOOR TO BE POSITIONED SO THAT IT WILL NOT INTERFERE WITH pe PEDALS IN DEPRESSED POSITION ENGINE CONTROL MODULE MUST BE PROTECTED FROM TEMPERATURES ABOVE 185 MODELS CP308 CP310 CP314 CP318 10 14 TP318 104 98 105 0 70 5 70 5 78 2 63 2 PICTURE BASED ON 1442 WITH 135 amp 4 AND DUAL 8R19 5 TIRES P32 42 Rev 12 98 32 42 CuHassis 30042 General Arrangement Gas Engine Option L35 4 3L V6 w FK4 Front Suspension 2 t TIRE SIZE WHEEL W Y 7 NORMAL OF FRAME Pal AXLE POSITION 2 WHEEL Loe LT215 85R16 DUAL 1040 436 2350 8272 ETATO M L 8819 5 DUAL 10 83 5 92 2448 85 60 1229 LT235 85R16 SINGLE 1116 978 1456 7540 x a NORMAL SIDE VIEW DASH AND TOE PANEL STEERING COLUMN AND BRAKE PEDAL BRACKET MUST BE FIRMLY SUPPORTED IN ITS ORIGINAL LOCATION BY BODY STRUCTURE SO THAT STEERING WHEEL MOVEMENT IS LESS THAN 50 INCH WITH 100 LBS LOAD APPLIED IN THE PLANE 715 24 lt 4
7. 3 38 21 80 48 68 16 98 5 93 38 41 22 06 63 75 _ 23 00 ACCEL cee 59 90 W JB8 Se 5 25 13 06 ES i 25 4 64 2 76 95 rc 6 67 z La 1 1 ACCEL L UPR E Pa N 2 96 2 50 DRUM m 20 REMOVAL 420 NORMAL 4 9 ONLY OF FRAME 80 21 00 GAGE HOLE ABS MODULE 2234 m 25 38 MODULE PROTECTOR 32 78 SHIELD 2630 Ls 55 40 51 55 W JB8 32 42 12 98 P32 42 CHassis P 30042 General Arrangement Diesel Engine Option L57 6 5L HO w FL6 Independent Front Suspension FUEL amp BRAKE LINE MODELS ROUTING RIGHT SIDE RAIL CP308 10 14 18 TP308 TP310 14 18 4 705 705 7820 63 20 1 105 0 1157 BATTERY
8. FUEL BRAKE LINE ROUTING 41 75 MW3 RIGHT SIDE RAIL 1 22 _ 45 57 ee Ties 7 41 75 MW3 W JF9 3 46 86 41 75 MT1 W JF9 SECTION A A 2 00 9400 gt BATTERY 5 amp RETAINER 52 93 51 55 49 09 MT1 amp JF9 49 09 8 JF9 i i dd 2SPRING 28 07 69 90 1 i 2 78 91 90 20 00 NI 40 00 41 56 2143 Z 4 STRG COL 21 pA 5 12 93 29 39 348 26 08 ES ACCEL BRAKE PEDAL 40 GAL TANK 2SPRING CAUTION E k 46 25 FLOOR TO BE POSITIONED SO THAT i IT WILL NOT INTERFERE WITH A A PEDALS IN DEPRESSED POSITION ENGINE CONTROL MODULE MUST BE PROTECTED FROM TEMPERATURES ABOVE 185 MODELS 3 34 CP308 CP310 14 CP318 2 25 TP308 TP310 TP314 18 i1 A 104 98 105 0 718 705 705 782 632 Ta II TRANS SHIFT LEVER BOOT TO VIEW IN CIRCLE
9. POINT LOCATION 20 0 STRG WHL TILT 215 24 ro 25 44 of LA Wu POINT LOCATION FRONT AXLE x 40 80 30042 FK4 FK5 32 42 Rev 12 98 P32 42 Cnassis P 30042 General Arrangement School Bus Application Option B3D B3M 1 r 1 SECTION A A SPRNG Ti EE EE EET el roy cane 4 2 HH 1 18 i I OO A 1 m D LESE i SPRNG 2 Y i3 TRE SZE WHEEL F 6425 105 1 4 B3M 11215 85RI6 DUAL IO 800 95 DUAL 0 TIRE IN FULL JOUNCE POSITION F 105 m PEO EW SOOO 40126225 pere 905401246 8560 Qui PROP SHAFT GUARD GENERATOR BLACK WHEELS 4 FRONT BUMPER l4 HIGH NOTE HORN IOO AMP BODY CONNECTOR 0 6800 8900 9300 E 6950 89 501 93 50 AMP BODY CONNECTOR L57 TEMPORARY FUEL TANK NORMAL TOP OF FRAME 310 314 ONLY 7L 651
10. 45 57 1 VIEW CIRCLE R EE S SU 1 WITH ARTICULATION 4 20 74 dota SECTION A A amp RETAINER 91 96 FUEL EMISSION CANNISTER 36 40 42 42 56 00 rm 51 55 26 30 2 7 19 45 98 5 29 14 07 A IA d 1 TR 1 1 1 1 WA 28 14 12 93 ACCEL 878 31 20 20 00 S 41 56 2143 21 15 60 STRG COL ILL LA 21 43 40 00 S 3 48 PEDAL SPRING 29 39 26 16 7050 40 84 84 36 53 ENGINE CONTROL MODULE MUST BE PROTECTED FROM TEMPERATURES ABOVE 185 F L CAUTION FLOOR TO BE POSITIONED SO THAT IT WILL NOT INTERFER WITH PEDALS IN DEPRESSED POSITION PICTURE BASED ON P30542 amp 135 4 FL5 AND SINGLE LT225 75R16 TIRE SIZE FOR ADDITIONAL INFORMATION SEE CHASSIS DATA PAGE NOTE CLEARANCE SHOULD BE PROVIDED FOR THE TIRE IN FULL UPWARD TRAVEL AND FULL LH amp RH TURN TIRE ENVELOPES WILL BE PROVIDED UPON REQU WHEN VEHICLE IS STORED FOR LONG PERIODS CLUTCH PEDAL LEVER MUST BE BLOCKED DISENGAGED P32 42 Rev 12 98 P32 42 Cnassis P 30042 General Arrangement Gas Engine Option L35 4 3L V6 w FL5 FL6 Independent Front Suspension 3100 22 7 1 2221604 SIDE VIEW DASH AND TOE PANEL STEERING COLUMN AND BRAKE PEDAL BRACKET MUST BE FIRMLY SUPPORTED IN IT
11. 2906 SHIPPING 35 60 18 68 3 75 ONLY 491 30 09 9 24 7 44 20 d E de ZUM 1 11 70 8 16 1 75 1 4 70 amp JF9 POWER BRAKES RPO JB7 JB8 amp JF9 PARKING BRAKE RPO JF9 NORMAL TOP 1 00 DIA 2 HOLE 38 00 40 GAL ABS MODULE ow A WHEELBASE C amp MODULE PROTECTOR FRONT AXLE 53 4 OVERALL ues 40 P32 42 Rev 12 98 P32 42 CuHassis 30042 General Arrangement Gas Engine Option 131 5 7L V8 w FK4 Front Suspension 41 75 MW3 FUEL 8 BRAKE 22 22 45 57 LINE ROUTING RIGHT Seem 77 41 75 MW3 W JF9 j SIDERAIL 22 00 94 00 56 00 20 74 51 55 49 09 MT1 amp
12. 30 0 FRONT CROSS MEMBER EXTENSION Deaeration Cooling System Diesel Tank Inlet Connection Crossover Pipe DEAERATION TANK Vent Line Heater Water Pump Body Builder Installed Radiator P32 42 Rev 12 98 P32 42 Cnassis P 30042 Air Conditioning Fittings 19 00 0 76 x45 28 75 2 PLACES 28 50 i 19 00 4 32 7 40 406 7 11 494 0 99 52455752 WASHER 1 94 0 41 45 QE SEALING 1 68 2210 80 10 67 2 15 95 15 80 076 45 2 PLACES 0 99 041 9 7 35 5 34 5 728 75 28 50 7 40 B2455752 WASHER SEALING 2213 59 13 34 2215 95 15 80 ALL SEALING SURFACES MUST FREE FROM SCRATCHES AND 5 DISCHARGE FITTING L29 L31 L35 L57 L65 P32 42 Rev 12 98 SUCTION FITTING L29 L31 L35 L57 L65 SUPPLIED BY BODY BUILDER 44 P32 42 5 5 6 53 2177 SUCTION DISCHARGE A DISCHARGE SUCTION 7 SUCTION 90 44 L31 H a imc 16 04 135 1 18 27 32 42 Rev 12 98 P32 42 Cnassis 45 P 300 32 42 Fuel Filler Neck NOTE AFTER FILLER NECK 15 ASSEMBLED TO BODY SHEET METAL FLAT PORTION OF MAX DIM ESTABLISHED BY WIDTH OF BODY
13. 32 42 Rev 12 98 P32 42 CuHassis 30042 General Arrangement Gas Engine Option 135 4 3L V6 w FK4 Front Suspension FUEL amp BRAKE LINE ROUTING RIGHT SIDE RAIL 25 90 lt 45 57 MTI I TRANS SUPT 46 86 SECTION 2200 94 00 2 7 BATTERY amp 2 0 FUEL EMISSION CANNISTER SPRING 51 55 69 90 28 07 26 30 IM uec MN ERR 5 18 5 62 se 2 78 91 90 7740 I 36 40 Ih i 66 00 33 00 I N i aS 31 20 8 78 1 Ha ds i g Hi 2610 B 1 15 60 40 00 1 M 2143 2 pA gt i m9 5 20 TRG COL NJ 7 19 4 2616 E 29 39 348 2 me a PEDAL
14. POWER BRAKES 2590 TERT APPROX TRAVEL 6 84 POWER BRAKES Eius ES 1524 lt 8 95 HYDROBOOST 488 AC 2 1742 POWER BRAKES ES X 18 30 HYDROBOOST JB8 S 19 39 ACCEL gt T AUXILIARY SPRING BRACKET 17 37 ACCEL IDEL i RPO G60 HA3 HD1 15 36 ACCEL MAX GAGE 31 00 F 29 06 5 21 08 1 3 75 zia 4 64 I Iez 18 08 lt 27 T 11 70 800 38 40 GAL 3 69 2134 N ma D NORMALTOP __ 80 OF FRAME 34 78 552 1 00 GAGE HOLE MODELS ABS MODULE 3600 B WHEELBASE CP308 CP310 CP314 CP318 amp MODULE PROTECTOR DIM TP308 10 14 18 40 C OVERALL FRONT AXLE lt B 125 0 133 01 157 0 178 0 2148 2388 2628 3048 538 698 698 90 8 32 42 Rev 12 98 P32 42 CHassis P 30042 General Arrangement Gas Engine Option L35 4 3L V6 w FL5 FL6 Independent Front Suspension FUEL amp BRAKE LINE ROUTING TRANS SHIFT LEVER RIGHT SIDE RAIL 66 FLOOR BOLT PATTERN 2200
15. The following statement applies to models with B3D school bus option only Hydroboost systems are equipped with a brake fluid flow indicator Alarm system must be completed by the body builder Shipped in a loose parts box are a buzzer module time delay module and wire harness which must be installed per instructions shipped with the loose parts box Floorboard and toe pan position cannot be altered as it will interfere with brake and ac celerator pedal movement or cause driver discomfort The floor may be covered with normal pad and carpeting only except P30032 42 models No floor covering should be under the accelerator pedal area it will interfere with accelerator control movement Carpeting musthave 1 minimum clearance to the accelerator pedal and should be cut pile only Carpeting must be properly secured to prevent any movement P32 42 Rev 12 98 Parking brake installation and adjustment procedure 1 Secure vehicle in place with hoist or wheel chocks and place vehicle transmis sion in park position 2 Front cable routing throughout body must have a minimum radius of 6 in and be protected from all moving components and sharp edges 3 For transmission mounted parking brake The following applies to all P 30042 models with the exception of P 31842 amp MT9 Hand lever 1 Release parking brake handle and remove cotter pin washer and clevis pin inserted from outboard side of vehicle Mount handle convenient to driver
16. MOTOR HOME BRAKE SWITCH MTG COMMERICAL BRAKE SWITCH MOUNTING P32 42 Rev 12 98 P32 42 Cnassis P 300 32 42 Lamp Mounting P 30042 P 30032 4 32 SPRING LOCATING SLOT HEAD LAMP NOT DIA 2 HOLES E ALL DIM S SHOWN ARE FOR 16508077 THRU 080 DIMENSIONS MARKED THUS ARE SYMMETRICALLY OPPOSITE FOR 16508077 079 CAPSULE ASSEMBLY HEADLAMP 32 RPO HPR P32 42 Rev 12 98 50 P32 42 CHaAssis INSTRUMENT CLUSTER OPENING ENING 3 37 1 37 Th RE 70 bacs 56 1 06 OPTIONAL TRIM LINE 05 45 25 x 45 2 PLACES 25 R 1 12 2 PLACES 25 R TYP 73 13 PLACES 13 V 3 38 2 50 IN 1 50 001 01A HOLES J 2 17 PLACES 31 1 16 62 134 7 29 DIA HOLES T 17 PLACES 12 R 4 PLACES R TEE 4 60 1 84 38 t STEERING COLUMN P32 42 Rev 12 98 P32 42 CuHassis 51 Electrical diagramsare available from Chevroletand GMC through service publications Routine orders will be shipped within 10 days of receipt Rush orders will be accommo They have contracted the following companies to handle the ordering and shipping of dated for an additional charge the manuals Order forms available upon requestand orders can be paid
17. SYSTEM 5 X REQUIRE APPLICATION OF A LUBRICANT TO PREVENT 13 80 a POSSIBLE CONTAMINATION OF TENET THE FUEL SYSTEM ONLY ENGINE OIL Im ENGINE amp CRANKSHAFT PART NUMBER 9985784 a d REED TE LUBRICANT USED y EIER _ HEATER RETURN AIC COMP REAR FACE OF MASS AIR ENGINE BLOCK SENSOR CRANKSHAFT 25 74 GENERATOR 7 lt 23 83 POWER STEERING _ 20 7 e 13 29 WATERPOMP NORMAL TOP OF FRAME 5 23332330216 ENGINE BLOCK P32 42 Rev 12 98 P32 42 Cnassis P 30032 Gas Engine 7 4L V8 Option 29 OF ENGINE ANDVEHICLE RADIATOR FILL B HEATER RETURN AIR INDUCTION CRANKSHAFT MAT 1 y EVAPORATIVE EMISSION CANISTER MAY d CU 5 BE RELOCATED IF NECESSARY EXISTING AIR CLEANER HOSE ASSEMBLY MUST NOT BE ALTERED N TO MAINTAIN SYSTEM CERTIFICATION os BESCNATOR FRONT VIEW 9 MASS AIR SENSOR 39 38 36 88 TRUE TO ENGINE OIL FILLER ENGINE OIL LEVEL INDICATOR s T 13 86 HEATER SUPPLY 726 03 _ 11 11 85 N H 14 27 P S PUMP NOTE 1 25 MINIMUM CLEARANCE REQUIRED TO ANY PART OF ENGINE F
18. ZONE WHEEL BUMP OF THE WHEEL IN ANY DIECTION j METAL TO METAL E Z AUXILIARY SPRING CLEARANCE SHOULD APPROX TRAVEL BRACKET RPO G60 PROVIDED FOR THE FULL 2 VER OBODS 4 6 84 POWER BRAKES HA3 HD1 amp eo 895 HYDROBOOST ENVELOPES WILL wa gt gt RPO JB8 PROVIDED UPON REQUEST 19 39 ACCEL PIVOT 50 A UE WHEN VEHICLE IS STORED 17 37 ACCEL IDEL T 31 00 29 06 15 36 sZ FOR LONG PERIODS CLUTCH C 45 88 18 68 PEDAL LEVER MUST BLOCKED 1 DISENGAGED T 17 42 POWER BRAKES 18 30 HYDROBOOST JB8 FOR ADDITIONAL 214 qtd INFORMATION SEE ESSEN 4 64 CHASSIS DATA PAGE VY 1 1 A 1 2 1 74 1 THR i 5 9 HJ d 3 90 14 36 20 51 13 28 13 03 30 20 4 88 5 _ 11 70 PA 1 63 1 00 DIA 21 08 E UO 2 50 DIA 6 40 q GAGE HOLE i 21 94 2 3 18 FROM TOP 38 00 40 GAL 2480 10 33 50 30 37 MODELS ABS MODULE La ogg ig CP308 CP310 CP314 18 S WHEELBASE TP308 TP310 14 18 1250 1330 1570 178 0 20 C OVERALL ee 2157 2397 2637 3057 D 538 698 698 908 32 42 Rev 12 98 P32 42 CuHassis P 30042 General Arrangement Gas Engine Option 135 4 3L V6 w FL6 Independent Front Suspension
19. amp RETAINER 94 00 46 86 41 37 MTI 86 06 1 18 81 MW3 W JF9 33 07 37 55 1 W JF9 5155 m 1 12 31 5 5 26 30 52 93 5 18 1 20 00 40 00 17 00 49 09 224122 2 78 56 00 1 E 45 98 i s 31 20 1 91 96 1 1 11 1 1 1 84 84 15 60 5 62 I zi 26 08 E S 2 amp e S 40GAL N F lt 46 25 CAUTION PICTURE BASED ON P31442 amp L57 amp FL6 S s s A AND DUAL 8R19 5 TIRE SIZE PEDALS IN DEPRESSED POSITION FOR ADDITIONAL INFORMATION 3 34 SEE CHASSIS DATA PAGE i NOTE CLEARANCE SHOULD BE PROVIDED FOR I ge is THE TIRE IN FULL UPWARD TRAVEL AND FULL e A 5 74 2 38 LH amp RH TURN TIRE ENVELOPES WILL BE 7 18 exa PROVIDED UPON REQUEST 4 SOS i WHEN VEHICLE IS STORED FOR LONG PERIODS i3 PEE 66 CLUTCH PEDAL LEVER MUST BE BLOCKED DISENGAGED TRANS SHIFT LEVER BOOT TO VIEW IN CIRCLE R CAB FLOOR BOLT PATTERN WITH ARTICULATION PATTERN P32 42 Rev 12 98 32 42 CuHassis 30042 General Arrangement Diesel Engine Option L57 6 5L HO w FL6 Independent Front Suspension 7 92 re 14 88 AXLE POSITION 2 WHEEL METAL TO METAL NORMAL TOP OF FRAME TREAD SEE CHASSIS 3 DATA CHART 7 ONE WHEEL METAL TO MET
20. JF9 49 09 8 JF9 26 30 2SPRING 69 90 28 07 BATTERY 8 RETAINER 2 M 5 _ _ _ 518 k 7 B 91 90 66 00 PY 411 5 17 00 34 00 1 1 4 i X 40 00 20 00 4156 43 2 1 A Z gt J 4 _ i STRG CO W j c 5 20 N 7 19 ACCEL 72 BRAKE PEDAL 40 GAL TANK gi ZSPRING CAUTION 2 4605 FLOOR TO BE POSITIONED SO THAT IT WILL NOT INTERFERE WITH PEDALS DEPRESSED POSITION XE A ENGINE CONTROL MODULE MUST BE PROTECTED MODELS 3 34 FROM TEMPERATURES ABOVE 185 CP308 10 14 18 2 25 TP308 10 14 TP318 104 98 105 0 705 70 5 78 2 63 2 8 66 PICTURE BASED ON 1442 WITH 131 8 4 AND DUAL 8R19 5 TIRES VIEW IN CIRCLE R TRANS SHIFT LEVER BOOT TO WITH ARTICULATION PATTERN FLOOR BOLT PATTERN P32 42 Rev 12 98 P32 42 Cnassis P 30042 General Arrangement Gas Engine Option L31 5 7L V8 w FK4 I Beam Front Suspension Option FK4 TIRE SIZE WHEEL W x Y 7 NORMAL AXLE POSITION 2 WHEEL LT235 85R16 SINGLE 11 16 9 78 14 56 75 40 METAL METAL LT215 85R16 DUAL 10 40 4 36 2350 82 72 31 00 8R19 5 DUAL 10 83 5 92 24 48 85 60 ar NORMAL TOP
21. OF FRAME SIDE VIEW DASH AND TOE PANEL STEERING COLUMN AND BRAKE PEDAL BRACKET MUST BE FIRMLY SUPPORTED IN ITS ORIGINAL LOCATION BY BODY STRUCTURE SO THAT STEERING WHEEL MOVEMENT IS LESS THAN 50 INCH WITH 732 100 LBS LOAD APPLIED IN THE PLANE WHEEL BUMP THE WHEEL DIRECTION ETAL O ETT 25 37 AUXILIARY SPRING CLEARANCE SHOULD BE 5 70 POWER BRAKES BRACKET G60 PROVIDED FOR THE FULL 7 50 HYDROBOOST RPO JB8 sa DOWERBRAKES HA3 HD1 LH amp RH TURN TIRE 7 62 HYDROBOOST RPO JF9 7 E ES ENVELOPES WILL BE 1524 1 8 95 HYDROBOOST PROVIDED UPON REQUEST 1939 ACCELPIVOT 50 x 4 RPO JB8 amp JF9 17 37 ACCEL 2 IDEL 2 d 31 00 29 06 WHEN VEHICLE IS STORED 30 20 15 36 ACCEL 26 19 PARKING Er FOR LONG PERIODS CLUTCH MAX RPO JF9 18 68 PEDAL LEVER MUST BLOCKED __75 1 amp 9 DISENGAGER SIRS FOR ADDITIONAL E INFORMATION SEE 4 5515 DATA PAGE W y 1 P IT T 3 75 13 90 aoe ABS MODULE 12 48 15 87 6 40 1 00 DIA MEOS 3 00 DIA GAGE HOLE 24 80 0 3 18 38 00 40
22. Thisis the same engineering practice we have 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 stainless steel or aluminized 409 stainless steel Heatshields are mountedtothe underbody and or exhaustsystem components catalyt ic converter and muffler Shields for the propshaft hanger bearings are also provided in some vehicles 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 following statement applies to motorhome chassis only Steering wheel and shaft must be located and supported as shown on the body builders drawing Section 10 Tires Wheels 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 ve hicle 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 component
23. above The Builder must use all appropriate data NOTE Failure to keep body and payload CG at least 26 forward of centerline of rear axle will result in degradation of trailer towing capacity Consult with your Body Builder Final Stage Manufacturer to determine maximum tongue load for your vehicle Section 3 Front Suspension See chassis data information for clearances and assistance in calculating trim heights Clearanceshouldbeprovidedforthetireusedwhileinfulljounce upwardtravel against metal stops and at full left hand and right hand turn The envelopes will be provided upon request See Section 5 Brakes Allowance for the tire chain clearance shown on a maximum grown tire must allow for 1 66in clearancetothe sides of the tire and 2 5in to the top of the tire Be sure suffi cient clearance is provided for suspension axle and tire and wheel in full vertical travel up and down NOTE Notification to the consumer may be required in certain states if tire chains cannot be used Vehicles equipped with 3650 Ibs low height independent front suspension IFS The urethane air cylinders must be maintained at 70 psi Ifthe vehicle is also equipped with option 9Q6 right side air cylinder should be set at 50 psi instead of 70 psi Vehicles equipped with 4500 and 5000 Ibs independent frontsuspension IFS urethane air cylin ders must be maintained at 50 PSI with 5500 Ibs independent front suspension air cyl inders
24. as fusible link Fusible link cable is not the same as normal vehicle wiring 4 Terminate fusible link harness wire with a suitable compression splice clip and solder with an electrical grade rosin core solder Wrap splice area with tape to provide electrical insulation as well as mechanical strain relief at the splice 5 Strip terminate solder and insulate remaining end of fusible link with ap propriate 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 P32 42 Rev 12 98 P32 42 CuHassis provide satisfactory engine cooling the following conditions must e The minimum frontal area for the Chevrolet GMC is 360 square inches to be directly in front of the radiator If the vehicle grille area is not directly in line with the radiator face filler panels between the radiator and grille must be used to directthe air through the radiator Any area outside of a 45 angle from the edge of the radiator should not be considered as grille open area for cooling e The grille opening should be open in configuration Small holes for the grille openingtendto restrictairflow morethan large holes although both may havethe same frontal area e Cooling canbe improved by inserting filler panels between the outer vertical side edges of the radiator and grille In addition a filler pane
25. comfort range 2 Feed cable through body and reattach to handle with clevis pin inserted from outboard side of vehicle 3 Readjust parking lever knob to give a definite snap over feel approx 60 105 when the lever is applied With the lever in the applied position the forward edge of the clevis pin head should be approximately 5 8 in from the end of the adjusting slot on the bracket 4 Do not alter the drum or cable adjustment at transmission unless routine ser vice is required in order to obtain the desired setting above No drag should be present after parking brake handle is released The following applies to all P 30032 models and P 30042 amp MT9 Foot pedal 1 Release foot pedal and remove cotter pin washer and clevis pin inserted from outboard side of vehicle Mount pedal coinvent to driver comfort range 2 Feed cable through body and reattach to handle with clevis pin inserted from outboard side of vehicle 3 Readjust parking brake pedal to give a firm pedal at 2 5 clicks P 30032 and at 8 16 clicks P 30042 amp MT9 when the pedal is applied With the pedal in the applied position the forward edge of the clevis pin head should be approxi mately 5 8 in from the end of the adjusting slot on the bracket 4 Do not alter the drum or cable adjustment at transmission unless routine ser vice is required in order to obtain the desired setting above No drag should be present after Parking brake is released 6 F
26. cut pinch and chafe problems as well as avoid exposure to excessive heat Care mustbe exercised that existing vehicle inter faces do not have their current load capabilities exceeded and that the respective con trol devices are not overloaded Added wire size should be at least as large as the the wire to which it is attaching in order for fuse protection to be maintained A Packard electric wiring repair kitis 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 ac complishing necessary add on wiring such as body marker lamps so that system reli ability 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 assistin making necessary wiring addi tions by providing custom wiring stubs or jumpers to your specifications Fusible Link Repair Procedure 1 Cut damaged fusible link from wiring harness assembly splice 2 Strip insulation from harness wire as required to splice on new fusible link 3 Fabricate a new fusible link wire approximately 6 to 8 in long from the same wire size as the original link Acceptable fusible link material will be imprinted with the wire size and the wording to identify it
27. hydraulic clutch actuator Check fluid level as outlined in the vehicle owners manual Attach manual transmission shift lever boot to floor using four 11514843 screws or equivalent It is mandatory that no change be made to the clutch master cylinder location clutch master cylinder push rod length or pedal position After installation of the body vehicles with automatic transmissions should have the shift linkage checked and adjusted if necessary as outlined in the Truck Service Manual 8 Shift Cables e Controlcablesshouldbe supportedoranchoredto preventsag when suspended overhead and to prevent movement where the routing bends e Onlong control runs the conduit should be clamped to supporting structure at least every 48 inches e Supports should be placed at the end of the straight runs and not in the middle of a bend e Care must be taken that the clamps do not collapse the conduit and increase control friction e Controls should be routed so that they will avoid rubbing pinching and extreme heat cold or vibration e Bendradius to be 6 0 in minimum Section 8 Fuel and Exhaust Fuel Systems Any body installed must be mounted securely to absorb loads and prevent movement relative to the frame whichcould cause any fuel system componentto be punctured sep arated or otherwise damaged when tested to the applicable procedures of FMVSS 301 No other installed components or modifications are allowed which could impin
28. standard models is connected to the regular fuel tank The fuel system for option B3D gasoline and diesel school bus models is also equipped this way A fusible plug is included in the loose parts box This must be installed into the tagged hole in the tank to replace a plastic shipping plug Fuel Fill Fueltank filler pipe location should beso situated and constructed as to prevent gasoline vapor from emitting to vents of pilot flamed devices and to body and engine compartment air inlets P32 42 Rev 12 98 P32 42 CuHassis It is recommended that when mounting the fuel filler pipe assembly and vent hose that a minimum of 3 clearance be provided to any body component to prevent contact be tween hoses and or mating parts and that retention be provided to ensure routing and prevent failure due to wear and fatigue Filler pipe and ventline must have a gravity fuel flow to tank at all times no fuel traps are allowed Alterations of fuel routings could affectthe ability ofthe completed vehicle andare therefore notdesirable The complete fuel system must comply with FMVSS 301 If additional new hose is required when installing fuel tank filler neck this hose must be suitable for use with unleaded fuels or diesel fuel respectively and mustallowthe vehicle to meet enhanced evaporative emissions requirements The fuel fillinlet pipe assembly attached to the body must be groundedto the frame struc ture with the ground strap and fasteners p
29. vehicle This allows any proportioning of the rear brakes to be communicated to the auxiliary brakes This tap in should not require more than 02 cu in of fluid and be capable of withstanding pressures up to 3000 psi Auxiliary brakes must be capable of taking the proportion of the braking load for which they are designed to provide for the overall vehicle combination irrespective of fade or other operating effects Section 6 Engine For additional information refer to Section 1 Body Air conditioning and auxiliary belt driven equipment installation recommendations No alterations or additions to the accessory drive belt system will be warranted on ser pentine belt systems Theserpentinebelttypeofdriveisdesignedasatotalsystem incorporatinga single poly V belt and an automatic tensioner In this type of system degrees of pulley wrap belt tension and pulley alignmentare very criticalfactors Modification is not recommended P32 42 CuHassis Due to the critical nature of the accelerator system anyone making modifications or al terations assumes complete responsibility for system reliability performance and com pliance to FMVSS 124 Caution must be exercised so that the accelerator cable is prop erly routed Specifications are as follows e Route cable to maximize bend radii In no case should bend radii be less than 76 mm Minimum distance from exhaust manifold to be 6 0 in 150 mm unless a heat shiel
30. 0 PROP SHAFT GUARD 55 NOISE SHIELD ES SHOWN FS3 4 BEAM OPTIONAL FRONT WHEELS P32 42 Rev 12 98 D B WHEELBASE E MAX C OVERALL REAR OF FUEL TANK FOR ADDITIONAL INFORMATION x SEE CHASSIS DATA PAGE NOT FOR USE WITH FS3 REMOVE PLASTIC THREADED CLOSURE INSTALL 14019007 FUSIBLE BUSHING TORQUE TO 19 27 NOTE IF SHORTER FILLER PIPE IS REQUIR ED USE SUBURBAN FILLER PIPE GAS 14071917 DESEL lorem VEW S SEE FUEL FILLER NECK DRAWING MUST MAINTAIN CLEARANCE TO VENT PIPE AS SHOWN DIMENSIONS MARKED THUS ARE pea ed BOL G8wxo aH FOR FILLER NECK AS SHPPED BAT TER YRBS EUAN ESOC CRISES RPO B3D SCHOOL BUS EQUIPMENT NOT SHOWN ON DRAWING 1 4500 LB FRONT SUSPENSION 14 500 GVWR ONLY MODEL 50042 11500 LB 14500 18 GVW 3 5 1LXZ OWx8 BATTERYBASEUA 465 2 4 5 LIN AGH IMPORTANT BODY BUILDER MUST LOCATE REAR BUMPER TO DIMS AGE TO ASSURE COMPLIANCE WITH FMVSS 301 STANDARD REAR BUMPER AND BRACES ARE NOT PROVIDED PICTURE BASED ON P 31442 RPO B3D 32 P32 42 CHaAssis CLIP PART OF AUTO gt 55 N LK SCR HX HD GROUND FOR AUTO APPLY PART O
31. 9 09 SPRING i BATTERY 8 RETAINER J T 7 19 5 62 45 98 5 29 id 17 00 I 224 1 NL M 1 L E 41 56 31 20 20 00 243 2143 c 15 60 STRG COL 21 43 40 00 348 2 1 BRAKE PEDAL SPRING __ 26 16 a 88 90 I 40 GAL TANK 84 84 46 25 2 CAUTION ENGINE CONTROL MODULE FLOOR TO BE POSITIONED SO THAT MUST SE PROTECTED FROW l T WL NOT INTERFER Wt PICTURE BASED ON LO amp FLS 185 PEDALS IN DEPRESSED POSITION FOR ADDITIONAL INFORMATION SEE CHASSIS DATA PAGE NOTE CLEARANCE SHOULD BE PROVIDED FOR THE TIRE IN FULL UPWARD TRAVEL AND FULL LH amp RH TURN TIRE ENVELOPES WILL BE PROVIDED UPON REQUEST WHEN VEHICLE IS STORED FOR LONG PERIODS CLUTCH PEDAL LEVER MUST BE BLOCKED DISENGAGED P32 42 Rev 12 98 32 42 CuHassis P 30042 General Arrangement Gas Engine Option 131 5 7L V8 w FL6 Independent Front Suspension TIRE SIZE WHEEL Ww x Y 7 LT225 75R16 SINGLE 941 975 1463 75 00 NORMAL OF FRAME LT235 85R16 SINGLE 11 16 9 78 14 56 175 40 AXLE POSITION 2 WHEEL 31 00 LT215 85R16 DUAL 10 40 4 36 23 50 82 72 METAL TO METAL 2 8819 5 DUAL 1083 5 92 2448 85 60 22 76 1 T SIDE VIEW NORMAL DASH AND TOE PANEL OF FRAME STEERING COLUMN AND BRAKE PEDAL BRACKET MUST BE FIRMLY SUPPORTED IN I
32. AL TIRE SIZE WHEEL w Y 7 a 13 80 LT235 85R16 SINGLE 11 16 9 78 14 56 75 40 31 00 o 11 90 LT215 85R16 DUAL 10 40 4 36 23 50 82 72 rh Soto d 8819 5 DUAL 10 83 592 2448 8560 1 1 1 aj 16 04 MODELS NORMAL OF FRAME CP308 310 CP314 CP318 SIDE VIEW DASH AND TOE PANEL 16906 TP310 TP314 TP318 1250 133 0 157 0 1780 B 2148 2388 2628 3048 538 69 8 698 908 STEERING COLUMN AND BRAKE PEDAL POET TS BRACKET MUST BE FIRMLY SUPPORTED 44222 lite os 2522 7522 IN ITS ORIGINAL LOCATION BODY INSTRUMENT PANEL STRUCTURE SO a LESS THAN 50 IN WITH 100 LBS LOAD APPLIED IN THE PLANE OF THE WHEEL IN ANY DIRECTION 2590 25 27 25 60 APPROX TRAVEL 6 84 POWER BRAKES 8 95 HYDROBOOST RPO JB8 amp JF9 31 00 17 42 POWER BRAKES 18 30 HYDROBOOST 488 AUXILIARY SPRING i 5 70 POWER BRAKES 18 38 HYDROBOOST RPO JF9 j BRACKET RPO G60 7 50 HYDROBOOST RPO JB7 8 JB8 GAGE 244 HA3 HD1 D 7 62 HYDROBOOST RPO JF9 HOLE B W FOR 6 22
33. ASSIS DATA PAGE NOTE CLEARANCE SHOULD BE PROVIDED FOR THE TIRE IN FULL UPWARD TRAVEL AND FULL LH amp RH TURN TIRE ENVELOPES WILL BE PROVIDED UPON REQUEST WHEN VEHICLE IS STORED FOR LONG PERIODS CLUTCH PEDAL LEVER MUST BE BLOCKED DISENGAGED P32 42 Rev 12 98 32 42 CuHassis P 30042 General Arrangement Gas Engine Option 135 4 3L V6 w FL6 Independent Front Suspension 13 80 TIRE SIZE WHEEL W X Y 2 14 88 LT215 85R16 DUAL 1040 436 23 50 82 72 NORAD TOP 2 11 90 8R19 5 DUAL 10 83 5 92 24 60 85 60 AXLE POSITION 2 WHEEL ENT LT235 85R16 SINGLE 11 16 9 78 14 56 175 40 METAL TO METAL EN 1 8 10 SIDE VIEW NORMAL DASH TOE PANEL OF FRAME STEERING COLUMN AND BRAKE PEDAL BRACKET MUST BE FIRMLY SUPPORTED IN ITS ORIGINAL LOCATION BY BODY INSTRUMENT PANEL STRUCTURE SO STEERING WHEEL MOVEMENT 15 1 LESS THAN 50 WITH 100 LBS LOAD APPLIED IN THE PLANE OF THE WHEEL TREAD SEE CHASSIS IN ANY DIRECTION 5 70 POWER BRAKES 7 7 50 HYDROBOOST 488 2 ONE WHEEL BUMP METAL TO METAL
34. BOOST ENVELOPES WILL BE gt 4 RPO JB8 amp JF9 PROVIDED UPON REQUEST 19 39 ACCEL PIVOT 17 37 ACCEL IDEL PARKING 3100 2906 TOR LONG PERIODS CLUTCH EL 15 36 9 NP RD PEDAL LEVER MUST BE puc BLOCKED DISENGAGED MW3 amp FOR ADDITIONAL 2 14 INFORMATION SEE 4 64 CHASSIS DATA PAGE I S 744 M 1 3 75 13 90 7 14 36 0 51 2 2 E 12 48 13 28 30 20 69 11 70 1 63 100 DIA 8 00 DIA 2 6 40 GAGE HOLE 7 21 34 25 3 18 38 00 40 GAL a 24 80 80 m 33 50 30 37 MODELS ABS MODULE fagga s CP308 CP310 CP314 18 17 42 POWER BRAKES WHEELBASE TP308 10 TP314 18 18 30 HYDROBOOST JB8 5 2 1250 1330 1570 1780 18 38 HYDROBOOST RPO 9 20 2157 2397 2637 3057 D 53 8 69 8 69 8 90 8 P32 42 Rev 12 98 P32 42 CuHassis P 30042 General Arrangement H Point Locations Front Suspension Options FK4 FK5 without Front Suspension Options FL5 FL6 FL7 20 02 STRG WHL 25 60 A 75 244 FRONT AXLE 40 30042 amp FL5 FL6 FL7
35. Check power steering fluid level for models equipped with hydroboost brake Referto Owner s Manual Added floor covering or carpeting must not restrict service or parking brake pedal travel from released position to full pedal travel The body builder must provide access to brake master cylinder to enable fluid level check and the ability to add fluid as required Clearance to master cylinder should be provided to enable its easy removal and replacementif ever required Visual access to warnings printed on master cylinder reservoir must be provided per FMVSS 105 The body builder must also provide access to auto apply parking brake actuator switch on all 16 500 Ib GVW chassis Opening for service in brake shield on chassis below drivers island must remain clear No body part or chassis mounted component including wheel house shields may be lo cated within 2 0 in of brake hose routing and or wheel speed sensor wire in all wheel and axle positions All exhaust system components must also have a minimum of 2 0 clearance to brake hoses in closest positions Be sure to account for brake hose and sensor wire travel with suspension Body builder is to verify that the brake light switch and brake warning switch is operative This includes both the brake system differential pressure and parking brake actuator switch Any ABS system codes that may have been set due to the body build process must be checked and cleared prior to customer delivery
36. EL TANK REAR SHIELDS PROVIDE PROTECTION FOR THE DEPARTURE ANGLE SHOWN ABOVE ANY ALTERATION TO THESE SHIELDS REQUIRES THAT AN EQUIVALENT ANGLE AND DEPTH OF PROTECTION BE PROVIDED BY THE COMPLETED VEHICLE P32 42 Rev 12 98 P32 42 Cnassis 47 30000 Temporary Fuel Tank Arrangement gt 21 s DISCONNECT ALL FUEL LINES AND THE ELECTRICAL CONNECTOR FROM THE TEMPORARY TANK FUEL SENDER ASSEMBLY DISASSEMBLE SNAP RING amp REMOVE FUEL SENDER ASM AND O RING amp FUEL CAP REMOVE AND DISCARD TEMPORARY FUEL TANK CONNECT VAPOR LINE FUEL FEED AND FUEL RETURN LINES TO FRAME RAIL LOCATED PIPES AS SHOWN IN VIEW REFER TO FUEL TANK FILL PIPE INSTRUCTION SHEET FOR PROPER REMOVAL amp INSTALLATION OF QUICK CONNECT FITTINGS FUEL RETURN LINE FUEL FEED LINE FUEL VAPOR LINE 41 75 m A VIEW A TEMP FUEL TANK P32 42 Rev 12 98 2 42 CuHassis P 30000 Center High Mounted Stop Lamp CHMSL S 280 SERIES METRI PACK TERMINAL 2 ROLL CRIMP TERMINAL P N 12034046 18 GA LEAD CHMSL FEED WIRE 12015857 14 16 GA LEAD RELEASE LOCK HINGE FULLY SEAT TERMINATED LEAD THEN SNAP LOCK HINGE CLOSED TYPICAL EXISTING JUMPER CONNECTOR OPPOSITE YELLOW LEAD BRAKE SWITCH CONNECTOR
37. F THE FUEL SYSTEM ONLY GM PART NUMBER 9985784 LUBRICANT MAY BE USED 55 SV CMPR 2 ET ES AREE OF AIR CLEANER ELBOW COOLER POINT B 1 OF DISTRIBUTOR 659 22 47 99 13 12 GENERATOR EE EN y WATER PUMP pede ons gt ape X POWER STEERING 5 23332330216C PUMP P d 2 1 56 NORMAL 2 42 Rev 12 98 P32 42 CHassis P 30042 Gas Engine 4 3L V6 Option L35 Tea 22 8380 2 EU SM 1 25 MINIMUM CLEARANCE XN 6 62 REQUIRED PART m gt EVAPORATIVE EMISSION CANISTER MAY ENGINE FOR ENGINE ROLL RELOCATED NECESSARY EXISTING p HOSE ASSEMBLY MUST NOT BE ALTERED CLEARANCE MUST BE SYSTEM CERTIFICATION PROVIDED VERTICLE MOVEMENT FOR PART ON TOP AERA OF ENGINE FOR SERVICEABILITY POINT B REAR FACE OF TRANSMISSION COOLER ENGINE BLOCK amp FRONT N FACE OF TRANSMISSION 4 5 OF CRANKSHAFT CASE AT CENTERLINE OF amp CRANKSHAFT MASS AIR SENSOR MUST REMAIN IN INSTALLED POSITION RELATIVE TO AIR VIEW IN DIRECTION OF ARROW Z CLEANER 2 OF FRONT WHEELS 40 2 2 ASSEMBLY FUEL gt
38. F AUTO APPLY HARNESS BODY BUILDER TO REAPPLY WITH GMTB 9985086 RUST INHIBITOR OR GMTB ENGINEERING APPROVED V EQUIVALENT APPROX 25 CC REQUIRED FOR Me COMPLETE COVERAGE VIEW IN DIRECTION OF ARROW A NOTE THIS VIEW APPLIES FOR THE ELECTRIC AUTO PARK HARNESS GROUNDING PROCEDURE WHEN THE AHT Aj BODY BUILDER REMOVES THE BATTERY NEGATIVE GROUND CABLE P32 42 Rev 12 98 P32 42 CuHassis 33 M E N 40 40 80 I BEAM SUSPENSION INDEPENDENT SUSPENSION P300 42 amp FM5 FN6 P300 42 amp FN3 FN5 FN6 NOTE ALLINSTRUMENT CLUSTERS ARE CENTERED ABOUT STEERING COLUMN 29 19 i 6 60 40 80 INDEPENDENT SUSPENSION P300 32 amp 8 P32 42 Rev 12 98 P32 42 CHassis P 30042 Body Mounting Hole Location P 30000 Battery Mounting Hole Location
39. GAL 3350 2134 5 me D 36 93 30 37 MODELS CP308 CP310 CP314 CP318 17 42 POWER BRAKES B WHEELBASE TP308 TP310 14 TP318 18 30 HYDROBOOST RPO JB8 u A B 125 0 1330 1570 178 0 18 38 HYDROBOOST RPO JF9 40 a C OVERALL isi C 2157 2397 2637 3057 D 538 698 698 908 P32 42 Rev 12 98 P32 42 CuHassis P 30042 General Arrangement Gas Engine Option L31 5 7L V8 w FL6 Independent Front Suspension MODELS CP308 CP310 14 18 TP308 10 TP314 TP318 EU A 1050 115 7 TRANS SHIFT LEVER BOOT TO E 705 705 782 632 DIM 22 00 TRANS SUPT CAB FLOOR BOLT PATTERN VIEW IN CIRCLE R 41 75 MW3 FUEL amp BRAKE LINE WITH ARTICULATION PATTERN SIDE RAIL TE 41 75 MT1 W JF9 94 00 SECTION A A 28 07 91 96 gt 36 40 12 31 n 51 55 1242 56 00 EMISSION 26 30 ANNISTER 4
40. INCHES Conversions Added bodies must be securely fastened to the basic vehicle structure Do not attach through side rails but bolt securely through rail flange at floor and added reinforcing plates A minimum of 10 departure angle should be maintained if frame and or body is extended P32 42 CHassis Chassis Asshownonthechassis drawings the relationship of the dash panel brake pedal clutch bracket and steering column must be maintained to ensure proper operation of brakes and steering Body structure must be provided to firmly support the steering column and brake pedal brace inthe fore and aft direction and laterally so that the angular dimensional geometry shown on the chassis drawing is preserved On all P truck single axle models provi sions are incorporated in the dash toe and frame assembly for body assembly attach ments It is imperative that the body assembly structure be integrated to the chassis through the above parts to ensure vehicle structural integrity Ifthis design is not adhered to by the body builders General Motors Corporation cannot be responsible or liable for chassis warranty resulting from inadequate attachment of the body or the chas sis Body underside must include inner fenders so that engine compartment is adequately shielded from wheel splash The following statement applies to P 30032 model only The front crossmember extension must not be used as a bumper Body Builder s b
41. ITIONAL INFORMATION SEE CHASSIS DATA PAGE PICTURE BASED ON P31842 P32 42 Rev 12 98 P32 42 Cnassis P 30000 Chassis Data d E TE TON Y WHEEL OFFSET MINIMUM TIRE FOR GVWR MINIMUM MAX REAR WHEEL FRONT FRONT REAR MODEL GVW TIRE WIDTH RADIUS SLR WHEEL OFFSET SUSP TRACK TRACK P30542 8600 LT225 75R16E E 8 98 14 65 13 70 SINGLE 67 IND 66 44 65 54 P30842 P31042 9400 LT235 85R16E E 9 25 15 87 14 61 SINGLE 67 IND 66 44 65 54 P31442 P30842 42 IND 65 34 10000 LT215 85R16D D 8 50 15 20 14 09 DUAL 5 00 63 41 P31042 THRU L31 amp JF9 P31132 P31432 42 11000 COMMERCIAL LT215 85R16D D 8 50 15 20 14 09 32 IND 69 70 12300 MOTOR 7 50R16LTD D 8 20 15 90 14 70 42 BEAM 72 64 P31842 P30842 12000 8R19 5E E 8 40 17 05 16 00 I 1042 THRU EUST EN I EPA 65 73 1442 14100 COMMERCIAL 8R19 5E E 8 40 17 05 16 00 P31842 14500 SCHOOL BUS 8R19 5E E 8 40 17 05 16 00 BEAM 7264 31432 1832 66 75 14800 225 70R19 5F 8 90 16 10 14 90 DUAL 5 00 IND 69 70 P31932 72 95 P32032 P31832 P31932 66 75 16500 225 70R19 5F 8 90 16 10 14 DUAL iors 90 5 00 IND 69 70 s P32132 P32 42 Rev 12 98 ALL P MODELS ARE 6 00 RIM WIDTH FOR
42. OR ENGINE ROLL 2 00 MINIMUM CLEARANCE REQUIRED IN VERTICAL MOVEMENT FOR ANY PART ON TOP AREA OF ENGINE FOR SERVICEABILITY POINT B REAR FACE OF ENGINE BLOCK amp FRONT FACE OF TRANSMISSION CASE AT OF CRANKSHAFT MASS AIR SENSOR MUST REMAIN IN INSTALLED POSITION RELATIVE TO AIR CLEANER ASSEMBLY OF ANY FUEL SYSTEM COMPONENTS MAY REQUIRE APPLICATION OF A LUBRICANT TO PREVENT POSSIBLE CONTAMINATION OF THE FUEL SYSTEM ONLY GM PART NUMBER 9985784 LUBRICANT MAY BE USED FRONT WHEELS TOP OF DISTRIBUTOR CCR SHF 40 WATER PUMP NORMALTOP OFFRAME E 5 52 OF ENGINE 25 SEENE EVAP CANISTER 662 774 NORMAL REF 0 MARK L TO TIME ENGINE FROM THIS POINT USE 5 CYLINDER P32 42 Rev 12 98 P32 42 CuHassis P 30032 Diesel Engine 6 5L Turbo Ho Option 165 OF ENGINE amp VEHICLE NOTES TRANS OIL LEVEL A 1 25 MINIMUM CLEARANCE REQUIRED TO INDICATOR ANY PART OF ENGINE FOR ENGINE ROLL HEATER RETURN 2 00 MINIMUM CLEARANCE REQUIRED IN VERTICAL MOVEMENT FOR ANY PART ON
43. P32 42 CuHassis The Incomplete Vehicle Document is supplied with each incomplete vehicle and provides information that should be used by intermediate andfinal stage manufacturers in determining conformity to applicable Federal Motor Vehicle Safety Standards FMVSS The IVD also includes information which must followed in order to ensure that Environmental Protection Agency EPA and California emissions certification re quirements and NHTSA Fuel Regulations are met The Body Builders Book contains information that may be used in addition to the for any manufacturer making alterations to an complete incomplete vehicle No alteration should be made to the incomplete vehicle which either directly or indirectly results in any component assembly or system being in nonconformance with any applicable Federal Motor Vehicle Safety Standard or Emission Regulation Intermediate and final stage manufacturers should be familiar with all Federal Motor Vehicle Safety Standards and Emission Regulations and aware of their specific responsibilities as manufacturers For further assistance contact SVIE at 1 800 875 4742 All notes are applicable to all models except where specifically stated other wise Section 0 General Instructions Check for proper clearance between body members and chassis components which way affectthe reliabilityand performance ofthe vehicle by developing abra sion and wear points from mov
44. R CAB FLOOR BOLT PATTERN WITH ARTICULATION PATTERN PICTURE BASED ON P31442 WITH L57 amp FK4 AND DUAL 8819 5 TIRES P32 42 Rev 12 98 32 42 CuHassis 30042 General Arrangement Diesel Engine Option 157 6 5L w FK4 FK5 Front Suspension TIRE SIZE WHEEL Y 7 NORMAL OF FRAME AXLE POSITION 2 WHEEL LT215 85R16 DUAL 10 40 4 36 23 50 82 72 METAL TO METAL 8R19 5 DUAL 10 83 5 92 2448 85 60 LT235 85R16 SINGLE 11 16 9 78 14 56 75 40 pu c Ye 11 90 NORMAL OF FRAME SIDE VIEW DASH AND TOE PANEL STEERING COLUMN AND BRAKE PEDAL BRACKET MUST BE FIRMLY SUPPORTED IN ITS ORIGINAL LOCATION BY BODY STRUCTURE SO THAT STEERING WHEEL MOVEMENT IS LESS THAN 50 INCH WITH 100 LBS LOAD APPLIED IN THE PLANE 15 24 2 gt 219 4 ZONE WHEEL BUMP OF THE WHEEL IN ANY DIECTION METAL TO METAL 2 CLEARANCE SHOULD BE 25 37 AUXILIARY SPRING 5 70 POWER BRAKES APPROX TRAVEL BRACKET RPO G60 PROVIDED FOR THE FULL 7 50 HYDROBOOST RPO JB8 y 4 6 84 POWER BRAKES HA3 HD1 LH amp RH TURN TIRE 7 62 HYDROBOOST RPO JF9 7 8 95 HYDRO
45. RT ON TOP AREA OF ENGINE FOR SERVICEABILITY POINT B REAR FACE OF ENGINE BLOCK amp FRONT FACE OF TRANSMISSION CASE AT C QF CRANKSHAFT ICOF FRONT WHEELS PA 7 OIL LEVEL INDICATOR lt OILFILLER REAR FACE OF ENGINE BLOCK 250 RADIATOR SURGE TRANS COOLER b AIR INDUCTION ae 12 76 18 78 r AND VEHICLE 1 45 T UN 2 61 N CRANKSHAFT TRUE TO ENGINE HEATER SUPPLY 0 y amp VEHICLE D fm N A 216 75 d INTAKE QN Pu 976 J GENERATOR N 1 1341 RADIATOR SURGE N OIL FILLER NS j be e ou s RAD INLET 2337 WATER JAF DUMP d VACUUM PUMP Pe US Fs lt P S PUMP POINT B P 4 use OUTLET 1 VACUUM PUMP 1337 le 5 63 CRANKSHAFT po SE 29 55 NORMAL FRONTFACEOF ENGINE BLOCK ICCRANKSHAFT P32 42 Rev 12 98 P32 42 CHassis P 300 32 42 Engine Removal Space Requirements and Deaeration Cooling System Engine Removal Space Requirements BODY BUILDER SUPPLIED 19 7 SHEET METAL ENGINE WIDTH 26 5 MANIFOLDS GAS 4 27 0 INJECTOR APES DIESEL 27 6 EDGE OF DASH TOE
46. S ORIGINAL LOCATION BY BODY INSTRUMENT PANEL STRUCTURE SO THAT STEERING WHEEL MOVEMENT IS LESS THAN 50 IN WITH 100 LBS LOAD APPLIED IN THE PLANE OF THE WHEEL IN ANY DIRECTION 5 70 POWER BRAKES 7 50 HYDROBOOST RPO JB8 25 90 NORMAL TOP OF FRAME TIRE SIZE W X Y Z LT225 75R16 9 34 10 00 14 38 74 52 LT235 85R16 9 51 9 86 14 13 74 79 19 39 ACCEL PIVOT 1737 ACCEL IDEL 15 36 ACCEL MAX POWER BRAKES RPO JB7 JB8 3 75 491 L NORMALTOP 3 69 OF FRAME 3478 86 00 ABS MODULE amp MODULE PROTECTOR AXLE 32 42 12 98 POSITION 2 WHEEL NORMAL OF METAL APPROX TRAVEL 6 84 5 8 95 HYDROBOOST RPO JB8 17 42 POWER BRAKES 18 30 HYDROBOOST RPO JB8 TREAD SEE CHASSIS P ex DATA CHART 2 2 ONE WHEEL BUMP METAL TO METAL B WHEELBASE 1 00 DIA GAGE HOLE 53 8 C OVERALL MODELS CP305 CP308 TP305 110 0 125 0 199 8 214 8 P32 42 CuHassis P 30042 General Arrangement Diesel Engine Option L57 6 5L HO w FK4 FK5 I Beam Front Suspension
47. TS ORIGINAL LOCATION BY BODY INSTRUMENT PANEL STRUCTURE SO 8 THAT STEERING WHEEL MOVEMENT IS TREAD SEE CHASSIS LESS THAN 50 IN WITH 100 LBS LOAD DATA CHART APPLIED IN THE PLANE OF THE WHEEL _ ANY DIRECTION T 2 ONE WHEEL BUMP 5 70 POWER BRAKES _ METAL TO METAL 7 50 HYDROBOOST RPO JB8 7 62 HYDROBOOST RPO JF9 APPROX TRAVEL 6 84 POWER BRAKES 2590 25 27 8 95 HYDROBOOST RPO JB8 amp JF9 gt 17 42 POWER BRAKES 18 30 HYDROBOOST RPO JB8 18 38 HYDROBOOST RPO JF9 1939 ACCEL PIVOT 17 37 ACCEL IDEL AUXILIARY SPRING BRACKET 15 36 ACCEL MAX RPO G60 HA3 HD1 POWER BRAKES RPO JB8 amp JF9 GAGE HOLE B _ 3 75 4 64 LG 7 44 i 6 22 15 80 1411 924 dE 14 34 8 16 1 11 70 75 MTI amp JF9 70 MW3 amp JF9 38 40 GAL PARKING BRAKE RPO JF9 NORMALTOP 3 69 21 34 3478 3037 60 1 00 DIA GAGE HOLE MODELS 366 B WHEELBASE pim 10 14 18 ABS MODULE amp TP308 TP310 TP314 18 MODULE PROTECTOR 2 DENN C OVERALL C 214 8 238 8 262 8 304 8 2 FRONT AXLE 40 538 698 698 908
48. UEL LINES AND DISCARD PIPE CONNECT VAPOR LINE FUEL FEED AND FUEL RETURN LINES TO FUEL SENDER AS SHOWN IN VIEW FUEL FEED FUEL VAPOR N AN FUEL RETURN VIEW TANK WITH FUEL SENDER PUMP INSTALLED IS TO BE PRESSURE CHECKED BY BODY BUILDER AT A PRESSURE NOT GREATER THAN 3 PSIG THIS CHECK MUST OCCUR PRIOR TO REMOVAL OF PLUGS FOR VAPOR VENT OR AUXILIARY FUEL PICK UP SYSTEM REMOVE VENT SHIPPING PLUG WITH TAG INSTALL 15676369 STEEL PLUG TORQUE TO 19 27 Nm 80 GALLON TANK RPO NJ9 THE 80 GALLON TANK WILL BE AVAILABLE IN A CONFIGURATION THAT ALLOWS IT TO BE FUELED FROM EITHER THE LEFT OR THE RIGHT SIDE OF THE VEHICLE TO ACCOMODATE THIS FEATURE THE TANK HAS FILL AND VENT TUBES ON BOTH SIDES THE BODY BUILDER IS TO CHOOSE WHICH SIDE HE WILL BE USING FOR FUEL FILL AND REMOVE AND DISCARD ONLY THE CAPS TO BE REPLACED BY THE FUEL FILL HOSES THAT ARE SHIPPED LOOSE ONE SET OF CAPS SHIPPED ON THE FUEL TANK WILL REMAIN IN PLACE ON THE COMPLETED VEHICLE 37 30 53 06 _ 60 GAL FUEL TANK P314 318 319 320 321 P314 SHOWN ex P300 32 42 lt 45 55 8 69 50 80 FUEL c P318 319 320 321 318 SHOWN 0032 B 63 86 60 GAL 80 30 80 GAL Ty lt ZELLE 14 12 60 GAL 15 08 80 GAL FU
49. 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 green dot is visible recharge as necessary then disconnect the negative battery cable on vehicles which are not goingtobeinservice within a 30 day period Ifthisis notpossible batteries should be recharged periodically every 30 60 days until the green dot is visible P32 42 Cnassis 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 ABS or other electronic components Modifications add on wiring must be carefully reviewed to ensure compatibility with the base vehicle wiring by reviewing the vehicle electrical system mechanization prints de tailed harness prints and Delphi Packard electric division connection system design quality guidelines Duetothe wide range of modifications that may be required for voca tional needs itis notfeasible for the O E M to take into account all potential revisions Forthisreason any person modifying existing vehicle wiringmustassumeresponsibility thatthe revisions have notdegradedthe electrical system performance Any add onwir ing must be properly fused and routed to prevent
50. WIDE TRACK AXLE APPLICATION 36 P32 42 CHassis P 30032 Taperleaf Suspension 55 38 26 50 SIZE Y 2 NORMAL OF FRAME FOR BUMP STOP BRACKET FOR BUMP STOP BOLT y FAL 60 TAPERLEAF SUSPENSION WITH P30032 52 ONLY P32 42 Rev 12 98 P32 42 Cnassis P 30042 Gas Engine 5 7L V8 Option L31 TRANSMISSION OIL COOLER 0 29 26 r EVAPORATIVE EMISSION CANISTER MAY RELOCATED IF NECESSARY EXISTING HOSE ASSEMBLY MUST NOT BE ALTERED TO MAINTAIN SYSTEM CERTIFICATION AIR INDUCTION NOTE 1 25 MINIMUM CLEARANCE REQUIRED TO ANY PART OF ENGINE FOR ENGINE ROLL 3 ENGINE amp CRANKSHAFT CLEARANCE MUST BE PROVIDED 0 gt OF ENGINE IN VERTICAL MOVEMENT FOR 3374 VEHICLE EB ONT VEW ENGINE FOR SERVICEABILITY TRUE TO ENGINE MASS AIR SENSOR MUST 2 REMAIN IN INSTALLED 40 POSITION RELATIVE TO AIR __ es CLEANER sv ASSEMBLY OF ANY FUEL ENGINE OIL FILLER 1171 DL 12 03 29 52 SYSTEM COMPONENTS Hee REQUIRE APPLICATION OF lal TRANS OIL 2867 LEVEL INDICATOR A LUBRICANT TO PREVENT MASS AIR SENSOR 2749 ENGINE OIL LEVEL INDICATOR 12 81 ____ HEATER RETURN POSSIBLE CONTAMINATION O
51. aintained at a temperature below 185 F at all times This is most essentialifthevehicleis putthroughapaintbakingprocess The ECM PCM TCM or will become inoperative if its temperature exceeds 185 F Therefore it isrecommendedthattemporary insulationbe placed aroundthe ECM PCM TCM or VOM during the time the vehicle is in a paint oven or undergoing another high temperature process Engine starting instruction label location Label should be installed 2 in above driver s sunvisor bracket and 2 1 2 in to the left of the right hand bracket The following statement applies to models with remote mounted air cleaners The Body Builder must install the air inlet duct such that it provides cool dry airto the air cleaner Radiator baffling must be provided to prevent recirculation of air through the radiator The air inlet must be shielded from water and snow that may come from the road tires and through the grille The air cleaner position and ducting between the air cleaner and engine should not be modified The following applies to P models with L29 L31 L35 engines Therelationship of the air cleaner assembly to the Mass Air Flow sensor MAF as posi tionedbytheaircleanerelbowcannotbe altered The MAF sensor black electronic mod ule must remain 30 forward of vertical The following statement applies to P 30032 models with a 6 5L turbo diesel engine P32 42 Rev 12 98 7 CAUTION Donotrun the engine with the cleaner
52. bbing on any vehicle component either fixed or moveable All clips used must be of the rubber lined type not rubber dipped Donotsplicethe battery cables Cable modifications can resultin vehicle starting problems and loss of other key systems 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 and battery failure Battery acid leakage could result around posts not properly relieved of strain The cable attachments at the battery terminal must not cause undue strain at these connections There should be no sharp bends in the cables adjacentto 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 N M freedom 14 20 N M linehaul Mounting Base Tray Thetray should be of substantial material minimum 1 75 mm thick or sufficiently reinforced to resistflexing and cracking Thetray must provide firm continuous support of the battery and not amplify vibration levels There must be no protrusions or projections inthe tray or mountings that would damagethe battery Cantilevered mountings are not recommended and the t
53. by check or money order Helm Inc made payable to the mentioned companies Credit Card orders can be made by phone P O Box 07130 on the listed toll free phone numbers Detroit Michigan 48207 1 313 865 5000 for information and inquiries 1 800 782 4356 for credit card orders P32 42 Rev 12 98
54. d is provided e 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 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 Caution must be taken so that the accelerator pedal remains properly located Guidelines for accelerator pedal locations are as follows 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 No floor covering should be installed under pedal area Accelerator to brake pedal relationship has been designed to provide mini mum driver movement and should not be altered in any way Gasoline engine induction and or ignition system is certified in compliance with the Fed eral Vehic
55. dd 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 Section 1 Body Accessory items such 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 interiorand accessory arrangements mustbedesignedintothe vehicle to provide for proper load capacity and distribution on both axles and not to exceed any gross axle weight ratings Lateralload equalization mustalso be maintained The resul tant 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 thermalorunderbody heatshields This insulationis providedto protectthe vehicle body and occupants from excessive heat and or provide noise attenuation Any replacement material internal to the occupant compartment must be certified for MVSS standard on flammability Areas of specific concern but not limited to 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 The following statement applies to P 30042 school bus model only The fuel
56. ducting to the turbo removed Serious personal injury or damage to the engine could result Apply a Caution label on the turbo inlet ducting Apply Starting Fluid Warning label in a visible area near air intake duct inlet Refer to information in the Loose Parts Box for labeling and air inlet duct part numbers Section 7 Transmission Lightdutymodels equippedwithmanualtransmissionhaveaclutch operatedstartsafe ty switch Starter should operate whenever the ignition is turned to start and the clutch isfully depressed Theclutch operated startsafety switchisintegral with the clutch mas ter cylinder push rod It is not adjustable Models equipped with automatictransmissions and columnshift control have asteering column mounted neutral park start safety mechanical lockout feature which interfaces with the steering column ignition switch Starter will only operate when gear shift lever is in the neutral or park position Re adjust the shift linkage if necessary as outlined in the Truck Service Manual Transmission shift cable must be routed and clipped properly to avoid contact with hot surfaces such as exhaust manifold or EGR pipe NOTE Remove the shift cable clearance tag from the EGR tube after shift cable routing Models equipped withbrake transmission shiftinterlock BTSI mustfully apply theregu lar brakes before you can shift from park when the ignition key is in the run position Models equipped with manualtransmission use a
57. e 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 in the frame side rails Manufacturing holes normally 16 mm diameter are consistently placed along the frame side member in the center of the web on each frame 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 ofthe 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 Forframe holes drilled rearward ofthe rear axle hole centers are to be nocloser than 51 mm 2 0 from the top or bottom flange and no closer than 89 mm 3 5 in from suspension attachments No additional holes or notching of either top or bottom frame flanges is allowed 4 tie down holes should only be drilled in top flange no larger than 0 76 in diameter centerline of holes should be 1 0 to 1 12in fromthe web side ofthe frame rail Minimum distance between edges of the holes should be approximately 2 0 in Trailer Towing The Incomplete Vehicle Document also specifies that the CG location be within certain limits for proper brake balance and may be more restrictive than the data mentioned
58. e reasons NO ALTERATION OF THE FUEL SYSTEM IS RECOMMENDED Temporary Tank The temporary fuel container must be replaced with a permanent fuel tank prior to plac ing the vehicle into use The replacement tank supplier and or body builder is responsi ble for certifying evaporative emissions The following statement applies to motorhome chassis only The unit is fueled during shipping gas engines only from a temporary fuel tank which contains the tank unit for the main tank The temporary tank is to be removed and scrapped Transfer the tank unit with O ring seal to the main tank The fuel cap for the main tank filler neck is the same as on the temporary tank Remove the tank unit hole cover and lock ring Discard only the tank unit hole cover and the lock ring Reinstall the seal lock ring and the tank unit assembly The 75 gallon fuel tank RPO NJ9 as received has a vented plug marked For Shipping Purposes Only This plug is to be removed and a solid steel plug shipped in the ship loose box must be installed in place of the plug removed The 75 gallon fuel tank RPO 9 is provided with rear shields to provide protection for the departure angle shown onthe fuel tank arrangementdrawing Any alteration or dele tion of these shields requires that an equivalent departure angle of protection be pro vided by the completed vehicle The following statement applies to commercial models with option B3D only The CPI fuel system for
59. ed The use of auxiliary fuel tanks is not recommended f an auxiliary fuel tank is added the alterer must take responsibility for compliance with affected motor vehicle safety 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 tanks is not permitted Gasoline fueled vehicles are now equipped with a fuel pump return line auxiliary tank is added the tank selector valve must include a return port which returns fuel to the tank from which the fuel is being drawn In gasoline engines the fuel pumpis located in the fuel tank The battery must be discon nected before starting any work on the fuel system In the use of dual fuel systems the vehicle operator should strictly adhere to the manufacturer s procedures for switching from gasoline to gaseous fuel operation Im proper switching procedures may result in overheating and damage to the exhaust sys tem andthe vehicle The gaseous fuel tank should not be mounted in an enclosed area ofthe vehicle such as the passenger compartment truck etc and the system should be ventedto the outside of the vehicle In addition vehicles converted to gaseous fuels should notbe storedin enclosed places such as garages Further General Motors cau 10 tions purchasers that the design location and installation of any type of fuel storage sys tem involves significant technical and
60. engineering considerations and that these state ments 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 ofemission control components orthe addition of gas eous fuel systems which could damage or reduce the longevity of those components and could also cause the mechanical and emission performance warranty to be voided Exhaust System Particular care should be taken to prevent the possibility of exhaust fumes and carbon monoxide exposure to vehicle occupantsin units completed by body builders Holes and openings through the floor and all other parts of the body must be permanently and ade quately 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 gt 10 000 lbs GVWR come under Federal noise regulations vehicles lt 10 000 lbs GVWR are regulated by various state and local regulations ofthe Environmental Protection Agency see those regulations forrules test procedure and noise levels permitted Tail pipe out
61. esel Engine Option L65 6 5L Turbo BRAKE SYS TIRE SIZE WHEEL T w x Y z JF9 225 70R19 5 DUAL 46 1166 640 23 56 85 04 MUST BE FIRMLY SUPPORTED IN ITS ORIGINAL JF9 225 70R19 5 DUAL 46 1188 9 50 26 66 91 24 LOCATION BY BODY INSTRUMENT PANEL JB8 7 50R16 DUAL 38 11 50 410 2378 83 00 STRUCTURE SO THAT STEERING WHEEL MOVEMENT IS LESS THAN 50 IN WITH 100 LBS LOAD APPLIED IN THE PLANE OF THE WHEEL IN ANY DIRECTION AXLE POSITION 2 WHEEL NORMAL OF FRAME METAL TO METAL 13 89 91 98 WIDE TRACK AXLE APPLICATION 30 38 22 42 BRAKE PIVOT 21 32 N 14 20 BRAKE PEDAL 13 14 E 277 4 RU TE REF FOR 1 5 4 Fes x txt SHIPPING ONLY ZONE WHEEL BUMP CHASSIS ol 2 19 54 23 ACCEL IDLE 30 STRG WHL TILT 1
62. esel powered vehicles incorporate water drain provisions in the fuel system These valves are only to be opened when siphoning water and contaminants from the fuel sys tem P32 42 Rev 12 98 Fuel Tank For vehicles with full frames the tank musthave a minimum clearance of 2 in top front rear and sides to body and other supports Tank may be pressurized with nitrogen Do not use air with fuel in the system to 1 25 PSI maximum to check for final line leakage or for forcing fuel through the system Pres sures greater than this amount may be detrimental and affect tank durability The following statement applies to commercial models only Tapping into the main fuel supply line to get fuel for a powered motor generator is not recommendedsincethis couldresultinfuelstarvation vaporlock problems and running the fuel tank dry Itis not permissible to draw fuel from a fuel return line The fuel meter assembly has a anti siphon feature in the return line that prevents fuel from being drawn out The following statement applies to motorhome models only The 40 60 amp 75 gallon gasoline tanks will include a fuel draw tube in the top of the tank assembly This is provided for body builders to use for generators The body builder should remove the pipe plug in this fitting and plumb system to the generator from this pickup point Added auxiliary power unit must use the same fuel as the chassis engine or a separate fuel system will be requir
63. ge on or cause distortion to the fuel system with sufficient energy to puncture separate or other wise damage the fuel system when tested to the applicable procedures of FMVSS 301 Due to the critical nature of the fuel system anyone making modifications or alterations to the existing system except as specified in the Incomplete Vehicle Documentor inthis manual must assume complete responsibility for the systems reliability performance and compliance to FMVSS 301 Assembly of any fuel system components may require application of a lubricant to pre vent contamination of the fuel system only GM lubricant 9985784 may be used The fuel evaporative emission control equipmentis certified to be in compliance withthe Federal and California Vehicle Emission Standards Metal fuel lines and fuel tanks have a surface coating to reduce corrosion oninside and outside surfaces to comply with use ful life requirements All fuel hoses are made of alow permeation multilayer material to comply with enhanced evaporative emission requirements Any alterations to systems orcomponents including materials hose lengths and their location except as described in the fuel fill system modifications section could void compliance The system includes P32 42 CHassis e Fueltank fuellevel sender fuel filland venthoses and pipes emission canisters fuel feed fuel return and vapor lines purge control solenoids fuel fill cap and canister vent solenoid For thes
64. ing parts or degradation from extreme environment or thermalexposureormayincreaseinterior noise Any attachments must consider chas sis components for jounce and rebound motion at Maximum GVW Checkheadlamp aim and all vehicle illumination systems for proper operation whenthe vehicle has been completed Re aim headlamps when necessary Check for proper op eration of windshield washer wipers and defroster system Extreme care must be taken when working on vehicles equipped with Engine Control Module ECM Powertrain Control Module PCM Transmission Control Module TCM Vehicle Control Module VCM Anti lock Braking System Model ABS or any electronic unit associated with an inflatable restraint system See Owner s Manual If arc welding is employed on the chassis precautions must be taken to protect all ve hicle components especially brake fuel lines front suspension air cylinders and fuel tank assembly electrical wiring and ECM PCM TCM or ABS To avoid electronic component damage disconnect battery batteries disconnectthe negative cable first P32 42 Rev 12 98 followed by the positive To reconnect cables connectthe positive first then the nega tive All labels on the vehicle any message applied to the vehicle or vehicle component that informs instructs or warns must appear on the completed vehicle so the user can read them easily and without obstruction Service and service replacement parts for your a
65. ket and rework as required for proper mounting P32 42 Rev 12 98 13 2 Hose may be cut to proper length as required to reach from the radiator over flow tube just under the radiator cap to the larger diameter nipple on the cool ant recovery bottle cap Retain the hose by using two 5 8 in hose clamps 3 For the initial fill of the coolant recovery bottle fill to the hot mark on the bottle This allows the system to initially purge itself and maintain the proper coolant level Refer to the Owner s Manual for proper mixture The following statement applies to P 30042 models only Radiator support assembly is not a structural member No body mounting supports or other attachments used for structural purposes are to be fastened to radiator support assembly Example Horns should not be mounted on the radiator support assembly The following statement applies to P 30032 42 diesel models only For diesel engines a de aeration tank is added to the cooling system This system will pass normal combustion gases out of the cooling system The de aeration cooling sys tem includes a de aeration tank radiator fitting and hoses Heater Be sure to add coolant to system after adding capacity to system heaters If a heater is installed on the vehicle bleeder valve must be added to the heater return line at the heater in the return line to the engine valve must be atthis point since it is the highest point in the system The
66. l should be fitted horizontally from the bottom ofthe radiator out to the bottom ofthe grille This will preventairfromby passingthe radiator and exitingthroughthefrontwheelhouse area or under the radiator These panels will force the air through the radiator e Aflexibleair tightseal mustbe provided between the upper radiator support and the body to aid idle cooling and prevent hot air recirculation The seal assures that incoming ram air must go through the radiator core rather than by passing the radiator core going up and over the core e Bug screens should be avoided if at all possible If conditions require a bug screen motor home owners are advised to be alert to possible engine overheating problems as well as temperature changes The screen s mesh should be at most half as dense as that of standard household screening Household screening will create an overheating condition The bug screen should be removed immediately upon leaving the bug infested area Do not install any internal flow restrictors The 3 way or H valve is not required in the heater system for port fuel injected engines Coolant Recovery Bottle 1 Mount the coolant recovery bottle in an easily accessible area with the top approximately the same height as the radiator fill cap The bottle must be sup ported by the two attaching embossments at the top and also by the rib at the bottom of the bottle to prevent failure of the unit You may use the supplied brac
67. le Emission Standards Any alterations to the systems or components could void compliance and render the vehicle illegal System includes e Fuelsystem Sequential port fuel Injection SPFI central portinjector and associated tubes hoses and pipes air cleaner outside air hose fuel pump and inlet manifold and fuel vapor canister e Exhaust system e Ignitionsystem distributor and initial spark timing setting spark plugs spark plug wires P32 42 Rev 12 98 P32 42 Cnassis e Crankcase ventilation system Diesel engine induction and injector pump system is certified to be in compliance with the Federal Vehicle Emission Standards and or Noise Standards Any alterationstothe system or components could void compliance and render the vehicle illegal System in cludes e Fuelsystem Injection pump injector lines and injectors fuel return hoses and pipes aircleaner outside airhose fuel pump fuelfilter fuel heaterassembly and intake manifold e Exhaust system e Crankcase pressure regulation system e 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 e Whenavehicle is equipped with a electronic fuel injection EFI engine it has an engine control module ECM PCM TCM VCM This ECM PCM TCM must be m
68. let location must be tested statically and with the vehicle in motion to ensure that exhaust gases do not penetrate side or rear windows or under body seams and holes Auxiliary power plants should also be tested under same conditions Tail pipe extension must extend 2 0 to 2 5 in outboard of body side panels Tail pipe exit ahead of rear wheels is not recommended Check for leaks in exhaust systems and repair as required Exhaust temperatures can exceed 1600 F under extreme operating conditions with pipe surface temperatures slightly less than this Extreme care mustbe used when plac ing body components inthe proximity ofthe exhaustsystem so notto exceed the rated temperature limits of the components Due to variants in underbody configurations of the vehicles we are 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 of his vehicle and adjust his design accordingly or provide shielding to ensure safe operation of his body components The same can be said for the engine compartment Obviously there will be additional heatradiated from engine How muchis retainedin the area will depend on how well thisareaisventilatedin yourindividual designs Here again temperature checks of inte rior areas surrounding the engine should be made to determine if your insulation is ade P32 42 Cnassis quate
69. low 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 in full vertical travel up and down NOTE Notification to the consumer may be required in certain states if tire chains cannot be used Pipes wiring conduits andany other related components mustnotbe 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 See chassis data information for additional clearances and for assistance in calculating trim heights Section 5 Brakes See Truck Service Manual for brake specifications Due to the critical nature of brake systems anyone making modifications or alterations mustassumecompleteresponsibility forsystem reliability pberformanceandcertification to FMVSS 105 or FMVSS 121 P32 42 Rev 12 98 P32 42 CuHassis Itis mandatory that no change be made to the brake main 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 Refer to Owner s Manual
70. must be maintained at 90 psi Air cylinders when provided must be shielded dur ing welding operations Since there is a large variation in completed vehicle front weight due to differences in body weight and equipment the front suspension alignment caster camber and toe must be checked and reset if necessary after the vehicle is completed The suspension must be reset by the Body Builder if it is found that the setting s do not conform to the specifications as outlined in the Chassis Service Manual On 30042 trucks with P32 42 Cnassis l beams camber and caster is designed into axle suspension and cannot ad justed See Truck Service Manual for complete alignment procedure specifications under Diagnosis and Front Alignment section The following statement applies to P 30042 models with front axle The front crossmember steering gear attachment is a weldment Under no conditions may the flanges be cut or notched out in any manner Any alteration would severely af fect steering attachment capabilities Section 4 Rear Suspension Clearance to body should be provided for the suspension axle driveshaft and tires un der 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 atthe metal to metal stop and 3 Axle at design position Allowance for the tire chain clearance shown on a maximum grown tire must al
71. or axle mounted parking 30800 31100 P 31432 with 9 1 Release parking brake handle and remove connector between front and inter mediate parking brake cables Remove front cable from frame bracket and floor pan assembly 2 Feed cable and handle assembly through body and re attach handle to body convenient to driver s comfort range 3 Feed cable back into frame bracket and making sure tangs lock into position Place connector back on front and intermediate brake cables 4 With lever in the applied position turn adjusting knob to give 5 8 in clearance from forward edge of clevis pin head to end of adjusting slot in bracket 5 Do not alter rear brake drum adjustment or cable equalizer unless routine ser vice is required in order to obtain the desired settings above Auxiliary Braking Systems If add on braking systems are installed to control either tag axle or trailer braking sys tems the body builder is responsible for the integrity of the system This may require running FMVSScertificationtests Any changetothe GVWR necessitate recertification to FMVSS Care must be taken to assure that flow rate of the brake fluid is not affected by the modification as this could reduce the effectiveness of the ABS system Therec ommendations of the auxiliary brake device manufacture should be followed in making the modifications For most systems that require a tap in is best done near the rear axle ofthe
72. or tools and hands so that personal injury does not occur There should be clearance at the insulated and grounded terminals so that wrenches can be used so that accidental grounds or shorts will notoccur Terminal polarity markings warning labels andtesthydrometer should be visible The battery ground connection must be readily accessible for disconnection as required for vehicle electrical service requirements Tilt Angles For normal vehicle operation at GVW the battery should not be tilted 0 For installation or removal itshould necessary to tip or tiltthe 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 Temperature The temperature of the electrolyte should not exceed 52 Infrequent peak temperatures to 75 C can be tolerated in soaksituations only Shielding may be required to protect the battery from a source of excessive heat Battery Trays Battery trays are supplied with the chassis Inthe case of motorhomes anddiesel school busses the trays are secured to the frame rail for shipping only The trays shipped on the rails may be relocated to other areas on the vehicle keeping in mind the recommendations noted above 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
73. ositive and Negative Cable Gauge Cable in Inches Copper 4 66 2110 01 2 21 If the battery requires relocation in the engine compartment the OEM supplied genera tor with flat compensated regulator must replaced with a generator with temperature compensated regulator to regulate system voltage compatible with underhood battery temperatures Underhood Battery Location OEM Part No Substitute Part No 10480170 105 A 10480168 105 A 10480267 124 A 10480255 124 A If the battery is relocated in the engine compartment without replacing generator as stated above it will effect the battery life and will be reduced by 50 of the average bat tery life Battery Installation The battery and cable installation provided by the body upfitter must comply with the followingguidelines Non compliance may resultinafailureofthe vehicle electrical com ponent system the shutdown of the engine loss of backup brake system loss of ABS braking control and the possibility of fire P32 42 Rev 12 98 11 The cables must not contact any sharp edge s in either the normal stored or slid maintenance position school bus application The cables must not be bent in a radius of smaller than 10 times the cable diameter Insulation failure can occur if this happens The cable must be supported by clips spaced at a distance of not more than 450 mm In this clipping they shall not have a free movement that will allow ru
74. purpose forthe bleederis to bleed air from the system after the heater and lines are installed Failing to do so can cause water pump seal dam age Proper bleed procedure are as follows 1 Open bleeder valve and fill cooling system with coolant until coolant exits valve 2 Close valve and continue filling system until full 3 With radiator cap off start engine and run for approximately two minutes at medium RPM 4 Shut engine off open bleeder valve and fill system as above and run again for two minutes Shut engine off top off coolant and install radiator 6 Check for leaks at connections P32 42 CHassis P 30032 General Arrangement Diesel Engine Option L65 6 5L Turbo HO STEERING COLUMN r USE EXISTING FASTENER
75. rameassemblyreliability performanceafteralterationsandcom pliance to applicable FMVSS requirements Thefollowing 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 rail web with the following restrictions e Materialbetweenedgeofholeandinside of upper or lower flange mustnotbeless than 37 mm 1 50 in for low carbon steel 36 000 PSI yield e Theminimum edge distance between any two 2 holes must be larger than twice the diameter of the larger hole No holes should exceed 20 mm 0 75 in in diameter e All holes should be drilled in the frame using appropriate drilling practice and safety precautions 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 P32 42 Rev 12 98 3 When welding low carbon steel side rails crossmembers and brackets 32 000 or 36 000 PSI yield strength emphasis is placed upon weld application techniques to a
76. ray should be mounted flat so as not to aggravate electrolyte spillage or lead fatigue A rounded lip of adequate heightto 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 Freedom Battery The hold down must be able to prevent the battery movement relative to the mounting base or hold down Torque battery hold down shall be 15 20 N m 133 177 lbs in at the base clamp or 2 3 4 5 N m 20 40 Ibs in at the top bar A bottom hold down centrally located at the sides of the battery is recommended Linehaul Battery A tight secure hold down is essential Hold down brackets must retain the battery ata 226 3 millisecond shock loading Atop hold down should be spaced 12 minimum of 15 mm from terminal posts to avoid possible ground paths If atop hold down is used a non corrosive non conductive coating is desirable Location The battery should be located in a well ventilated area where a temperature build up does notoccur Thelocation shouldalso provide protectiontothe battery to prevent damage from foreign objects The ends of the battery in the area of the vent ports should be free of obstructions sothatthe gasses generated during charging can be freely dissipated into the atmosphere Accessibility The hold down should be convenient f
77. rovided in the shipped loose box Fuel Lines Fuel line routing precautions e 12in minimum clearance to exhaust system is required or a metal shield must be provided Fuellines should be clipped to chassis to prevent chafing Metal clips must have rubber or plastic liners e Use corrosion resistant steel tubing with short sections of approved hose to connect components Hose to tube connections should be clamped for diesel systems Steel tube ends should be beaded for hose retention Fuel supply is pressurized by an in tank pump for CPI systems Coupled hose or nylon quick connects must be used Clamped hose is not acceptable for CPI systems All engines require a fuel return system which returns excess fuel from the injection pump and injector nozzles back to fuel tanks Care should be taken that these lines are not blocked nor their hoses pinched The engine may run poorly or stall if these lines are restricted or blocked Allgasoline engine vehicles are equipped with fuel evaporative emission control equip ment which is certified to be in compliance with the Federal or applicable California ve hicle emission standards Alterations to fuel tank and metering unit lines canister or canisters canister filters canister purge control valves relay switches tank auxiliary ventvalve enginespeedcontroller orotherdevices systems aretherefore notallowable since vehicle adherence to C A R B and Federal regulations may be affected Di
78. s Increasing tire and wheel capacity does not necessarily increase vehicle GVW ratings recommended thattire chain clearance guideline J683 from the Society of Automo tive Engineers be adhered to in designing rear wheelhouse clearance Checktires andinflate to recommendedtire pressure according tothe tire pressure infor mation displayed onthe certification tire label provided with the vehicle before shipment of vehicle from Body builder Any substitution of tires may affect Soeedometer Odometer accuracy P32 42 Rev 12 98 P32 42 CuHassis Ifthe body builderinstalls wheel coversonthe vehicle vented covers used The minimum vent area is to be the greater of 34 in 2 or 9096 of the original vehicle s wheel vent zone Air flow through the wheel vent and cover vent must be direct Section 12 Electrical Battery and Battery Cables The vehicle battery should be located and positioned to make use ofthe existing battery cables Ifthebattery requiresrelocationandlongercablesarerequired aproportionate ly larger gauge wire must be used If in relocating the battery the negative ground cable is attachedto frame rail a cable of similar gauge 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 P
79. system for the school bus chassis is certified to FMVSS 301 Barrier Perfor mance requirements based on abody floor height not exceed 3 above the top of frame The 3 maximum dimension is to be measured from the bottom surface of the interior body floorto the top of the frame The height of any cross supports and spacers between the bottom of the floor surface and the top of frame are not to exceed this 3 dimension 2 body support brackets that project more than 1 125 outside ofthe frame to attached to the frame rail adjacent to the area of the fuel tank 1 Any body installed by a subsequent manufacturer is mounted securely to ab sorb loads and prevent movement relative to the frame which could cause any fuel system component to be punctured separated or otherwise damaged when tested to the applicable procedures of FMVSS 301 2 No installed components or vehicle modifications by a subsequent manufac turer impinge on or cause distortion to the fuel system with sufficient energy to puncture separate or otherwise damage the fuel system when tested to the applicable procedures of FMVSS 301 Care should be taken that the structur al integrity of the vehicle is restored following any structural modifications NO BRACKETS See Note TYPICAL BOTH SIDES 5 5 3 0 max BETWEEN OF FRAME AND BOTTOM OF FLOOR NOTE NO BRACKETS ON OUTSIDE OF FRAME THAT PROJECTS MORE THAN 1 125
80. um per should be attached to the front crossmember directly opposite the side rails and to the front crossmember outboard of the side rails as required ABS module protector ex tension must be maintained or replaced by equivalent part The following statement applies to P 30042 model only If the standard front bumper is not used the Body Builder s bumper should be attached to the side rails and outboard of the side rails as required ABS module protector bar must be maintained or replaced by equivalent part If the body builder installs seating other than that supplied with vehicle it is the body builder s responsibility to ensure that the seating and restraint systems comply with FMVSS requirements The restraint systems supplied with the vehicle were designed to accommodate the seating reference points and seat travel of the original equipment seats only 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 components Do not interchange R 134A components refrigerant oil or service equipment with R 12 components refrigerant oil or service equipment P32 42 Rev 12 98 2 42 Chassis Holedrilling welding modifications oralterationstotheframeassemblyaretherespon sibility of persons performing these operations These same individuals assume com pleteresponsibilityforf
81. void stress risers that may adversely affect frame operating stresses When welding is performed anywhere on the vehicle precautionary measures should be taken to prevent damage to electrical system wiring front suspension air cylinders or components Priorto any welding parts or components which could be damaged by excessive temperatures must be removed or adequately shielded the battery cables should be disconnected at the battery Also prior to welding the area to be welded and surrounding area must be cleaned of all frame protective coating After welding when parts arecool carefully inspectwiring andelectricalcomponentsforshorts orotherdam age which could draw excessive currents and possibly cause an electrical system short when the battery is reconnected Apply protective coating to areas where coating was removed Alterations If the wheelbase is modified the alterer must take responsibility for compliance with af fected motorvehicle safety standards andforwarranty onitems such as driveshafts uni versal joints center bearings and rear transmission tailshaft transmission case frac tures output shaft bushings bearings brakes fuel systems and any other related component failures Wheel base modifications can affect the operation of the ABS sys temand may alter vehicle braking stability andorcompliance with FMVSS 105 Addition ally the customer must be alerted in the modifier s owners manual that parts for the re worked area ar

P32/42 CHASSIS

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