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1 C/K TRUCK (CURRENT)

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1. DUAL FUEL TANKS XE DBAS QUIPMENI TO DELE EAR TANK OPTION NQZ MUSI BE SPECIF IED 1575 0 1614 0 8g 0D 63 54 REAR TANK 20 GAL RAW CAPACITY I r J DRAW CAPACITY a s E P 224 Q EE a J HH gt j 390 0 15 35 e 1000 0 39 37 C314 1 1 1610 0 63 39 ul III 11 371 0 C K 310 536 2 14 61 21 11 BODY BUILDERS TO TRIM 508 0 C K 314 FILLER AND VE OS 20 00 318 O DESIRED LENGTH FRONT AXLE REAR AXLE INSTRUCTIONS FOR FUEL FILL MODIFICATIONS 83 2 CONNECTORS CLAMPS 3 28 ARE PROVIDED IN 22 4 0 88 C310 314 1 SEVERE 21 4 0 84 C318 Qu 2 e 6 lt i er fie r d w 1 M Wo J j ED 380
2. oni ZOF REAR AXLE Tu 5909 4 OVERALL 232 65 AA MUFFLER a 3430 3 1419 0 EE gt 135 05 gt T 55 87 7 30 161 8 112 0 NORMAL 6 3 _ 1864 899 4 REAR FACE 637 1754 4 41 5 37 gt 85 41 m OF ENGINE OF FRAME 5 E 6 91 sex 2 un 1348 5 347 7 13 69 if 4 Z NWN SP C7 Pu 6 Se OF ENGINE b is 383 0 no 2 T 7 p ES 2 916 0 13318 15 08 Z E 7 MUFFLER a Tt X 600 6243 a NER 98 7 1 MAN 17 E 92 8 8 21 T 15 ile 3 65 i 30 0 EMI HIE UN 1 i af SE 1 18 T HEN SAS M pex 7 mi Fit HE
3. ea 135 05 41 90 36 94 i AA pB e 10 C C a ZREAR WHEEL MUFFLER 99 64 lt DD 9 9 EE 175 4 383 0 1 a 352 2 3014 6 90 15 08 p i 13 87 11 86 8994 J 1298 8 35 41 d 51 13 NORMAL TOP TO CENTERLINE OF FRAME OF TAILPIPE ale Jn pote CRANK pud p k i 61 8 ENGINE 5 i 1 T 2 43 PM i _ lt m Vai p al lt zail I tate ce gt si TNI 221 8 2 1 347 7 821 7 1111 30 0 CSS FRONT WHEEL 13 69 32 35 1 18 OF FRAME 1 TO BOTTOM OF ia 1608 2 QVEHICLE 1 5 MUFFLER 63 31 e a 3595 0 570 0 141 50 22 44 282 3 2 2 12300 gt DI
4. 1298 8 3430 3 BBC o ae 51 13 AA gi MUFFLER 135 05 1883 0 ZCRANK 899 4 MUSS 74 1 gt 85241 226 REAR FACE L 55 87 NORMAL DD E 175 4 Z OF ENGINE 3098 0 m 301 4 161 8 6 91 916 0 pees 48 78 221 8 11 67 6 37 86 06 175 55 158 3 a 8 73 111 0 26 00 4 37 n 691 6 23 SS qm EE E rt pe i pat 7 ps Vw Ll am M 18 po P EP pA i Ferae SS d em I Os Zhan 5 50 Sep 1 m 13 69 8217 4 32 35 352 2 BOTTOMOF 1616 0 13 87 MUFFLER 63 62 i 3950 0 WHEELBASE M 50 ZENGINE j 155 50 CENTERLINE OF TAILPIPE v We 5909 4 OVERALL gy
5. 674 0 3340 0 WHEELBASE 1269 5 26 54 r 131 50 49 98 i t OZE PER A _ I 30 0 J amp 5 72 1 18 CENTERLINE 2 ENGINE 1 921 6 56 28 NTERLINE N NH t VEHICLE AN e SS _ 4 0 Ox n J lt 234 0 Em M30 9 25 990 2 38 98 Me m 969 0 38 15 1059 0 41 69 1660 0 lt A M S S 65 35 44 43 2945 0 855 0 115 94 33 66 775 5 3196 0 30 53 125 83 146 0 5 75 2790 8 764 5 INSIDE TO INSIDE 109 88 M T F END OF FRAME 556 0 INSIDE METAL OP OF FRAME T c 7 p jt u Papa JL 801 27 31 56 2721 5 858 2 INSIDE METAL 107 15 T 33 79 7 TO INSIDE OF FRAME 3285 9 1168 5 129 37 aud 46 00 NOTES 1000 4340 K10906 amp L31 SHOWN UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO INSIDE OF METAL CK Rev 12 98 Rev 11 99 C K Truck CURRENT 310 314 03 Chassis Cab 10 000 and
6. HB MINIMUM GROUND CLEARANCE TO BE CALCULATED BY USING GROSS AXLE I uw WEIGHT AND RECOMMENDED TIRE PRESSURE INCHE GROUND CLEARANCE EAR WH GROUND MAX TIRE MODE IRE GVW WHEE TRACK OFF SEI CLEARANCE WIDTH P245 75R16 6250 6450 SINGLE 628 0 50 0 44 0 252 1 9 93 256 0 10 08 10516 265 75R16 6250 6450 SINGLE 628 0 50 0 44 0 268 1 10 56 276 0 10 87 LT245 75R16 6250 6450 SINGLE 628 0 50 0 44 0 262 1 10 32 256 0 10 08 245 75R16 6600 8800 SINGLE 628 0 50 0 44 0 223 6 8 80 256 0 0 09 10053 P265 75R16 NEL SINGLE 628 0 50 0 44 0 237 6 9 35 276 0 10 87 T245 75R16 m Um SINGLE 628 0 50 0 44 0 223 6 8 80 256 0 10 08 10706 P245 75R16 6800 SINGLE 590 0 50 0 44 0 223 6 8 80 256 0 10 08 P245 75R16 7200 SINGLE 628 0 50 0 44 0 244 1 9 61 256 0 10 08 10906 T245 75R16 7200 SINGLE 628 0 50 0 44 0 253 1 9 96 256 0 10 08 T245 75R16 8050 SINGLE 628 0 50 0 44 0 230 6 9 08 256 0 10 08 t T245 75R16 7200 SINGLE 628 0 p 229 0 9 02 239 0 19 41 LT245 75R16 3500 SINGLE 742 0 60 6 6 32 256 0 10
7. H jag d 1521 0 60 C K31003 75 63 2131 0 84 C K31403 EA 2741 0 108 C31803 _ _ T P i i fate PX 3442 0 135 5 C K31003 4052 0 159 5 C K31403 4662 0 183 5 C31803 DIMENSIONS SHOWN ARE NOMINAL DIM A DIM B ESTIMATES BASED ON EVEN DISRIBUTION OF WEIGHT PRECENTAGES ALLOW FOR 3 CB CAB BODY CLEARANCE 4 10 12000 LB GW 35 41 111 03 CB 1 2 X BODY LENGHT PERCENT BODY AND 965 0 2886 0 WB PAYLOAD WEIGHT 19000 LB SAN 37 99 113 62 AT FRONT AXLE BODY PAYLOAD DISTRIBUTION REGULAR CAB FRONT REAR BODY LENGTHS FEET MODEL W B CA 8 9 10 11 12 15 14 15 16 C K31003 135 5 60 7 93 C K31403 159 5 84 13 87 9 91 6 94 C31803 183 5 108 18 82 15 85 11 89 8 92 5 95 WITH 24 INCH COMPARTMENT BEHIND CAB C K31403 159 5 84 6 94 C31803 183 5 108 11 89 8 92 5 95 CK Rev 12 98 Rev 11 99 32 Front Mounted Accessories Front Rear Weight Distribution for Equipment Mounted Ahead of Front Axle Overhang Center of Front Axle to the Equipment Center of Gravity 30 36 42 48 54 60 11
8. 38 481 7 18 96 421 7 16 00 SIDE VIEW REAR VIEW 1000 MW3 INSTALLATION NOTICE TRANSMISSION RATIOS GM NV4500 MANUAL 5 SPEED TRANSMISSIONS HAVE HEVES EE BEEN FACTORY FILLED WITH SYNTHETIC GEAR LUBE FIRST 5 61 WHEN THESE TRANSMISSIONS ARE DRAINED FOR PTO SECOND 5 04 INSTALLATION THEY MUST BE REFILLED WITH CASTROL THIRD 1 67 SYNTORQ LT SYNTHETIC GEAR LUBE GM PART NUMBER 12346190 QT 2 5 5 12346191 GAL LUBE CAPACITY 8 5 eee Cue TABLE OF POWER TAKE OFF DATA PTO DRIVE GEARS TRANSMISSION MODEL SAE NUMBER OF NORMAL PITCH ANGLE amp NORMAL REDUCT I ON PTO TEETH PITCH DIAMETER HAND OF PRESSURE AT PTO OPENING HELIX ANGLE DRIVE GEAR 6 BOLT ree 30 7 9366 4 3647 30 RH 22 4987 2579 GEAR PITCH LINE DISTANCE PTO DISTANCE DISTANCE DIRECTION 1000 VELOCITY OF GEAR MOUNTED FROM PAD FROM OUTSIDE OF 3 5 SPEED INPUT TO PTO e 1000 FACE FROM SHAF OENTERLINE Je O ROTATION TRANS RPM INPUT CENTERLINE OF GEAR FT MIN OF OPENING TO PITCH LINE DIM A OF GEAR ee 12 40 83 7184 OPPOSITE _ 579 675 0488 COUNTER i 1 344375 INCHES FORWARD 3 296
9. 4109 5 161 79 310 Z OF FRONT 4719 5 185 81 2314 WHEELS REAR 5329 5 209 82 C318 AXLE 2279 0 89 72 C310 me 9889 0 113 74 C314 2886 0 gt REFER TO FRAME 3499 0 137 76 C318 113 62 ARRANGEMENT 1521 0 60 00 C31003 1921 0 2131 0 84 00 C31403 4 1388 0 346 0 18 00 75 63 2741 0 108 00 C31803 64 65 eT 13 62 890 8 194 4 18 0 DIAHOLES 35 07 REAR FACE 7 65 BODY MOUNTING L 965 0 OF ENGINE REFER TO BODY _ eer 1 799 7 OUTLINE DRAWING EM 796 0 5 39 3830 788 0 A i E 31 34 _ u 15 08 31 02 2 0 ug MINIMUM CUT OFF LENGTH 1324 9 RELOCATE REAR I 52 16 CROSSMEMBER AS pw B E PROVIDED Ea T E 2p _ Ho A I 0 He T 1 sl ae 0 L Nm A Im lo 5 Deg 30 sec REFER TO FUEL ES _ E DRAWING Q 372 0 He 50 8 t 1 1 14 65 WHEELS 2 00 INSIDE TOP 353 4 13 91 OF FRAME TO CENTERLINE REFER TO INSIDE TOP OF FRAME es SUSPENSION TO BOTTOM OF MUFFLER OF TAIEPIP
10. 30 LH T Ecc M30 ONLY ond e 26 78 T 1035 1 7040 75 re 55 9 2224 E 49 98 FORWARD OF RH q Lel a A Leow l 1 at CENTERLINE jim og OF ENGINE I i 921 6 i T 36 28 CENTERLINE i OF VEHICLE N E a A _ LON ey m SZ Le 7 1 S 235 0 M ES 5 4 pue 1452 0 9 25 0 13 0 17 gt 57 17 969 0 2945 0 38 15 115 94 1128 5 7131 50 44 43 160 0 184 0 855 0 Tos WHEELBASE 33 66 25 83 775 5 146 0 5 75 INSIDE T INSIDE 2855 0 END OF FRAME 112 40 589 0 INSIDE METAL TOP OF FRAME DA A ax E c 3 5 7 E 801 8 A UST BI 2843 9 858 2 144 0 5 67 111 97 33 79 7 INSIDE METAL TO INSIDE TOP 3286 0 1168 5 129 37 7 47 46 00 INCHES 2 C10906 amp 131 SHOWN UNLESS OTHERWISE SPECIFIED CK Rev 12 98 Rev 11 99 ALL DIMENSIONS ARE TO OF METAL INSIDE 90 C K Truck CURRENT K 1 2 0906 Suburban Crossmember Arrangement
11. 650 0 id T gt 25 00 1331 0 52 40 1074 8 EE 687 9 42 31 7 27 10 576 1 22 68 m 239 95 9 45 N SN 9 7 916 0 q 36 06 HITS VEHICLE K d B MES MELLE 1775 132 8 MODEL 6 99 5 23 300 2 REAR AXLE 1690 4 11 82 66 55 FRONT WHEELS 76 5 3 01 C FRAME 4 9 0 19 C FRAME SUME 2300 4 INSIDE METAL TOP C K1 20753 37 9 1 49 OF MUFFLER 90 57 INSIDE METAL TO TOP OF CONVERTER C K1 20903 2045 4 80 53 N l S 1 LJ 2655 4 mE i C K10953 104 54 E INSIDE METAL 335 9 13 22 TO TOP OF INSIDE METAL 348 0 CONVERTER TO BOTTOM OF 13 70 MUFFLER 7 0 0 28 C FRAME 40 0 1 58 K FRAME INSIDE METAL TO TOP C10703 W L31 SHOWN OF FLANGE INCHES UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO INSIDE OF METAL CK Rev 12 98 Rev 11 99 C K Truck CURRENT C K 1 2 0906 Suburban 5 7L Gas Engine Option L31 and 7 4L Gas Engine Option L29 558 8 m Mis oe 22 00 87 03 MUFFLER 1074 8 42 31 CK10906 250 3 9 85 CK10906 1763 4 68 64 CK20906 joe 293 3 11 55 20903 577 3 02 73 10906 732 7 1020 2 40 16 20906 28 85
12. 4968 3 195 60 509 6 lt lt 3985 1 156 89 lt 24 00 346 0 MUFFLER LT TT 13 62 173 4 6 83 J 9 9 NA _______ 11 Eau E i VU P HE J 1 Y 1 7 4 MEE J J REFER TO FRANE DARANING REFER TO FUEL TANK DRAWING io 2860 0 1420 0 RN 112 60 55 91 REFER TO REAR FACE me DE ENGINE BODY DRAWING 35 88 PEE _ NOTES 383 0 4 INCHES 15 08 1313 0 i 340 0 13 39 C30943 amp L65 SHOWN lt 51 04 BOTTOM OF MUFFLER L TOP OF TO INSIDE TOP OF UNLESS OTHERWISE SPECIFIED TO INSIDE TOP FRAME ALL DIMENSIONS ARE TO Een C OF FRAME INSIDE OF METAL 764 5 x REAR AXLE T eed q Eu N Te 348 0 13 7 ET _ _ _ m PA INSIDE METAL TO CENTERLINE OF TAILPIPE CK Rev 12 98 Rev 11 99 C K
13. 41 0 EO 13 42 1276 0 50 24 341 0 15 42 An A A 22 56 FLOOR CONSOLE MOUNTING RPO D55 YF7 MID X 1 0 4 PLACES EACH SIDE m TILS MARKED 10 67 SEAT 649 0 Rev 12 98 Rev 11 99 C K Truck CURRENT C 30903 Regular Cab Pickup Crossmember Arrangement A 4383 0 172 56 FRONT WHEELS m A 3978 0 2680 0 REAR AXLE a 2507 0 _ 156 61 105 51 X Boss 98 70 136 2 2101 2 118 3 __ 600 0 5 36 175 5 4 66 79 80 2 158 3 160 0 5109 209 114 0 4 1983 0 23 62 23 7 6 30 WO C6P 6 90 4 49 FRONT 1150 0 5587 184 0 C209 WHEELS 45 28 d M no 7 24 C6P C309 e oR oL a REL zb ni m rx Let 11 0 625 0 43 68 0 NORMAL TOP 448 5 433 0 682 5 2143 4 4 OF FRAME i 24 60 17 66 17 05
14. 48 54 E PRONT WHEEL FRONT OF DASH 1063 3 41 86 8 533 0 __ uu i 20 98 ON 50 W S 868 7 4 34 20 1 380 5 14 98 20 SEAT WIDTH 13 71 19 ACCELERATOR er ree rive HEAD ROOM 925 0 36 42 I T Wm i 213 0 407 0 SHOULDER ROOM 145 4 NCHES 25 11 Nat 5 72 418 8 22559 8 59 16 02 C ds ta 14 37 E 1695 6 683 0 OF REAR 66 76 BODY MOUNT E 1676 0 SHOULDER ROOM H POINT 65 98 661 0 p 26 02 41 81 EFFECTIVE LEG ROOM 207 0 8 15 CLUTCH 203 7 8 02 BRAKE 285 8 31 48 X YE MEE YE TE NY l 1536 0 HIP ROOM 60 47 CK Rev 12 98 Rev 11 99 56 C K Truck CURRENT FRONT BODY MOUNTING HOLES
15. S 1002 0 5 39 45 7 764 5 e 4 REAR AXLE 354 5 13 96 INSIDE METAL TO H0 LOWEST POINT ON 5 14 HE LD 1000 2280 NOTES INCHES C30943 amp 105 SHOW UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO INSIDE OF METAL Rev 12 98 Rev 11 99 112 C K Truck CURRENT DU UEL TANKS ARE BAS QUIPMENT TO DELEI TANK OPTION NQZ MUST BE SFECIFIED REAR TANK 20 GAL MEN D RAW CAPACITY SS FUEL TANK 22 i DRAW CAPACITY 1 269 6 AE I N 7 I E i 235 0 Y J 9 25 5 d gt J per LJ JA SUED det HE H 7 Ur Et
16. 2064 4 _ 81 28 1415 8 55 78 5588 OXYGEN SENSOR 7 22 00 1076 3 42 37 E 631 5 577 6 24 86 e 22 74 250 3 9 85 250 3 0 85 a 1 916 0 E ane 36 06 LAL C2 300 2 177 5 102 6 4 04 11 82 99 2 2 0 9 C 0705 BELOW INSIDE METAL TO TOP OF MUFFLER 30 8 1 21 K10706 INSIDE METAL TO 9 0 0 20 C10706 TOP OF MUFFLER 38 0 1 50 K10706 INSIDE METAL TO TOP OF CONVERTER Va Se ONSE 0 5 0 02 10706 BELOW INSIDE METAL 316 5 TO TOP OF CONVERTER 12 46 32 5 1 30 10706 INSIDE METAL OF CONVERTER 10706 amp 131 SHOWN INCHES UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO INSIDE OF METAL CK Rev 12 98 Rev 11 99 Ordering Information Electrical diagrams are available from Chevrolet and GMC through service publica tions They have contracted the following companies to handle the ordering and ship ping of the manuals Helm Inc P O Box 07130 Detroit Michigan 48207 1 313 865 5000 for information and inquiries 1 800 782 4356 for credit card orders Routine orders will be shipped within 10 days of receipt Rush orders will be accom modated for an additional charge Order forms are available upon request and orders can be paid by chec
17. H POINT POINT 1595602 OREMOST H POINT SEAT IN 61 39K POSITION POSITION REARMOST POSITION 2398 0 308 6 299 94 41 INCHES CK Rev 12 98 Rev 11 99 C K Truck Current C K 109 209 06 Suburban Seating Intermediate Rear 20 381 0 00 15 00 VIEW IN DIRECTION OF ARROW REAR SEAT 55 13 J Arf D 1766 1768 VIEW IN DIRECTION OF ARROW INTERMEDIATE 40 60 SEAT RPO 5 000 0 ON TOP OF 649 0 INCHES Rev 12 98 Rev 11 99 69 1764 0 3528 0 69 45 138 89 A 4022 0 ZA 3214 4 158 55 i c gt 126 55 OP OF 36 7 ROOF 44 75 I J
18. K 10516 Utility 2 Door Crossmember Arrangement 674 0 2832 0 WHEELBASE CENTERLINE OF 26 54 111 50 AXLE lt f 23 M 460 8 18 1 CENTERLINE dr yl gt d OF ENGINE Hf L i I 4 4 990 2 223 0 E 38 99 8 78 1660 0 746 0 65 35 28 3759 7 2660 0 982 5 m 104 72 38 68 841 5 T 83459 2587 99 568 0 146 0 101 89 1 29 5 75 2140 99 84 29 I e lt s Ej EN _ E y B TA SU x oq Ma Jo 479 1 _ 7518 86 2058 0 569 0 6 57 81 02 1 OF FRAME TO INSIDE OF 2680 9 881 5 m 105 55 Tom 34 70 METAL NOTES 1000 3832 INCHES ALL DIMENSIONS ARE TO INSIDE OF METAL UNLESS OTHERWISE SPECIFIED CK Rev 12 98 Rev 11 99 99 2984 5 WHEELBASE 1
19. OPENING REAR BODY MTG HOLES 1523 6 FRONT OF DASH 2 PLACES 1403 3 59 98 eee 55125 655 761 8 3893 1323 0 29 99 15 33 52 09 1 OVERALL 1 M 1 1 4203 8 Lu 47 39 3842 0 A 1370 0 cri 151 26 ss 53 94 CB p t 1876 0 ht 77 7876 4 BREAK AWAY Y Y 76 43 OVERALL D48 Y TOP OF REAR lt 2852 0 BODY MOUNT 899 4 4 2482 112 28 T 85 41 4 7 6 77 1921 0 L104 75 63 2267 3 A 3650 1461 7 _ 37 99 89 26 gt 97 9 57 55 1920 0 2106 5 E 044 75 67 82 93 BELOW EYELINE E ET 5 2819 4 03 480 0 111 03 NORMAL TOP CANPER IFA 118 90 FRONT WHEEL INSIDE _ E OF FRAME sie 100 200 300 _ gt 1 22 CARGO LAMP 70 4 1 2 77 1 L A 136 0 1566 0 635 61 65 P 1305 5 Css SSS a r 4299 0 61 40 m L a gt f 161 14 60 42 0 1 1 65 035 1 24 174 0 SES MINE i 84 86 HT 6 85 583 gt REA i 865 0 105 6 gt 34 06 4 16 121 0 168 4 OW62 OW58 4 76 6 63 INCHES NORMAL TOP 27 0 TOP OF REAR INSIDE OF FRAME 1 06 BODY MOUNT 48500 HD 15 000 GVW ONLY K100 200 300 50 Rev 12 98 Rev 11 99 C K Truck CURRENT 57
20. Se i 390 0 15 35 C3lO _ wee 1000 0 39 37 C314 V4 224 a 1575 0 m 1614 0 371 0 C K 310 584 7 62 01 63 54 14 61 23 02 508 0 C K 314 20 00 316 K 2 REAR AXL R mU 2 lt RONT WHEE AQ 2 4 x UE lt O 120 LO Xm pu Bie U M U 20 OU Or mo gt z Z 0 m gt J j be ETUR T 7 7 2 W 4 p 1 1 E 2 gt my T Za n Pu ue E 354 8 13 971 EN INSIDE TOP OF DATA BASED ON C31403 amp L29 INSIDE TOP OF RAIL BOTTOM OF SHIELD E INCHES UNLESS O FIED DIMENSIONS HERWISE SPEC ARE TO OUTSIDE OF MET CK Rev 12 98 Rev 11 99 C K Truck CURRENT C K 310 314 318 03 Chassis Cab 15 000 15 GVWR
21. m 542 9 A 5 75R15 LT245 75 R16 CK Rev 12 98 Rev 11 99 C K Truck CURRENT 274 0 10 79 236 0 9 29 146 1 5 75 1 o O 45 4 LA OSS 9 500 1 Q 70 0 E 2 76 5 9 4700 2 9 5 27 2 13 00 52 22 HOLE 3 PLACES TRAILER HITCH CK Rev 12 98 Rev 11 99 103 1500 2500 3500 Front Axle Tire Data Chart 2 Wheel Drive E I ES GROSS AXLE WEIGHT RATE GROUND CLEARANCE WH GROUND MAX TIRE MODE LIRE GVW WHEE TRACK OFFSET CLEARANCE WIDTH C10053 P235 75R15 6200 SINGLE 175 1 6 89 252 0 8 92 C10706 P235 75R15 6300 IN E 616 0 0 13 Z2 0 TELS C10906 P235 75
22. 207 307 309 43 Crew Exterior NK Bi 2304 9 RPO 048 L L 94 29 2294 0 RPO 044 045 90 31 4022 0 138 92 1695 6 1764 59 66 76 69 47 1457 66 D L O u a T 57 39 7 2011 0 79 17 386 09 D L O 15 20 1 1320 8 D 5 480 0 2233 4 STRG WHL 51 96 18 90 87 93 394 0 744 0 EST in 15 51 29 30 I 5 533 0 Ws ae ri 1 __ 253 0 TOP OF REAR BODY MOUN 81 65 ex i 9 96 PICKUP BOX FLOOR v 530 0 di 20 87 Oy 1 583 0 J iiy 5 2860 0 BACK OF CAB OF REAR V 12 60 C i BODY MOUNT 4280 0 30943 3925 0 207 30743 La 144 3 168 50 154 50 5 68 1000 0 6511 0 30943 5880 9 207 30743 256 34
23. 58 38 57 09 _ m 739 8 29 14 1000 B 406 5 560 4 22 06 Eu 16 00 OUTSIDE METAL NORMAL IA 4 55 OUTSIDE OF OF FRAME FRAME TO BOTTOM 16 82 OUTSIDE T P OF FRAME TO BOTTOM OF SHIELD _ CD 500 29 5 GALLON 10 68 29 4 GALLON DRAW CAPACITY ee OP OF FRAME AT OF AXLE CK Rev 12 98 Rev 11 99 C K Truck C K 107 109 03 53 Pickup 4 3L Gas Engine Option L35 m _ 609 6 24 00 _ 924 5 687 9 86 42 27 10 604 5 23 82 0 4 36 09 WT x um 1 LL Ls VEHICLE 135 5 249 1 5 33 uq aa 9 81 1690 4 61 7 2 43 C FRAME 62 66 94 7 3 73 INSIDE TOP OF FRAME x 2300 4 TO TOP OF MUFFLER C K10753 90 64 6 7 0 26 C FRAME 2045 4 39 7 1 56 K FRAME ers C K10903 INSIDE TOP OF FRAME m 80 59 TO TOP OF CONVERTER ad LLLI 0 7 0 03 C FRAME 33 7 1 32 335 9 13 22 348 0 INSIDE TOP OF FRAME 2 13 71 TOP OF FLANGE MUFFLER 10903 W L35 SHOWN FRONT WHEELS INCHES UNLESS OTHERWISE S
24. re 5 30 GAL DRAW CAPACITY 41 18 23 348 9 13 74 OP OF FRAME O BOTTOM O SHIELD HEAT SHIELD 295 1 VN I u L Mur aa ee 319 9 NOTES 12 59 _ OF FRAME INCHES CENTERLINE _ _ OF TAILPIPE ALL DIMENSIONS ARE TO INSIDE OF METAL UNLESS OTHERWISE SPECIFIE CK Rev 12 98 Rev 11 99 1000 5852 28 C K Truck CURRENT 3427 0 134 92 1831 5 _ 609 6 72 11 TL 24 00 947 0 _ 846 0 37 28 13 62 141 0 5 55 185 4 7 30 ch ih _ Jl NS 600 1 fi _ NL 34 4 1 35 345 5 13 60 INSIDE METAL 463 0 INSIDE OF METAL EUR 18 23 TO BOTTOM OF CONVERTER 2343 ER M
25. AT SILL 618 0 RUNNING STEP IN DIMENSIONS 24 33 BOARD HEIGHT Z W lt 250 53 2 1416 05 MIDPOINT BETWEEN 4 92 2 09 99 79 1000 CENTERLINE OF FRONT 3832 1 AND REAR AXLES RAMP OVER ANGLE POINT CK Rev 12 98 Rev 11 99 C K Truck CURRENT C K 10706 Utility Exterior 4026 5 131 9 m 158 52 5 19 1 1 1 lt 2 V E e 4158 4 rg 63 09 2011 2 99272 79 18 1009 1757 9 69 21 514 9 4256 41 20 27 167 57 42 0 g 1 o 01 02 i O v s O N N NUI STEP HEIGHT AT SILL 618 0 5005 A 500 24 33 500 1200 0 369 7 47 24 14 55 2100 0 l9 82 68 479 5 505 5 lt 18 88 19 90 930 9 5861 56 65 2984 5 SEE FRONT END CI m SHEET METAL og FOR OPTIONS 4465 8 INCHES 175 82 CK Rev 12 98 Rev 11 99
26. REFERTO DRAWING FUELDRAWING DATA BASED ON C31803 amp L65 amp C5B INCHES CK Rev 12 98 Rev 11 99 C K Truck CURRENT C 109 209 06 Suburban 2 Wheel Drive w 6 5T Diesel Engine 4072 8 P 160 35 2269 8 609 6 89 36 24 00 1781 7 346 0 ue 70 15 13 62 23 80 J SO l gt 916 0 a z 36 06 s 1 254 p 184 0 ee 5 42 GAL DRAW 7 24 4 85 CAPACITY cM _ i a d IN 4 E 12 610 0 24 02 882 0 34 72 CENTERLINE OF FRONT WHEELS 7645 ZREAR AXLE INSIDE 229 0 9 02 METAL 2 FROM INSIDE ee PEEL OF FRAME TO BOTTOM Bree tee TO CENTERLINE 5 OF TAILPIPE A 17330 1 M INSIDE ad ut m METAL B Hep 327 2 12 88 194 0 7 64 HEAT SHIELD INSIDE METAL INSIDE M TAL TO BOTTOM TO BOTTOM OF OF PLASTIC SHIELD CONVERTER gt INCHES 25 10906 165 UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO INSIDE OF METAL CK Rev 12 98 Re
27. 2948 0 116 06 DIESEL EXHAUST ONLY NOTES 2185 0 wie 1565 0 DIM C20953 amp L65 ONLY ZFRONT WHEEL E 86 02 61 61 4322 a 2656 3 1243 7 INCHES 17 02 AA 404 58 00 4896 4573 0 TIRE CARRIER CROSSMEMBER apa UNLESS OTHERWISE SPECIFIED ALL 180 04 EE DIMENSIONS ARE TO OUTSIDE OF METAL 24 00 13 62 Sada 4638 3 13 40 CC 182 60 13 40 CK Rev 12 98 Rev 11 99 C K Truck CURRENT K 109 209 53 Extended Cab 4 Wheel Drive w 6 5T Diesel Engine BB MUFFLER 112 0 136 4 175 4 4 41 y i OF ENGIN EH f 1 m J 916 0 1 ZS 1 36 06 US F tj t Y 30 0 f 1 18 11 N Y 1 H ECCLE Y 132 0 2 UT
28. m N 7 44 638 0 25 12 898 0 35 35 VIEW IN DIRECTION OF ARROW A FRONT FULL BENCH SEAT RPO 52 FRONT SEAT MOUNTING 189 0 2237 0 7 44 638 0 25 12 35 35 VIEW IN DIRECTION OF ARROW A FRONT SPLIT BENCH SEAT RPO AE7 653 0 25 70 1 934 0 36 69 925 0 RPO A52 amp AM7 36 42 RPO AQ5 amp AE7 41 5 gt 649 0 H POINT SEAT IN REARMOST POSITION H POINT H POINT H POINT H POINT FOREMOST REARMOST FOREMOST REARMOST POSITION POSITION POSITION POSITION x 308 6 299 0 301 0 12 14 11 77 12 24 11 85 ES 294 0 w 1121 0 1219 0 4 69 11 57 44 13 48 00 CK Rev 12 98 Rev 11 99 gt sl 189 0 7 44 638 0 598 0 eoo Tg 35 35 FRONT HI BACK BUCK IN DIRECTION OF ARROW A ET SEATS RPO 95 S 898 0 449 0 17 68 35 35 VIEW REAR IN DIRECTION OF FULL BENCH SEAT ARROW B AM 60
29. or must be maintained at a temperature below 1859 at all times This is most essential if the vehicle is put through a paint baking process The or will become inoperative if its temperature exceeds 185 F Therefore it is recommended that temporary insulation be placed around the ECM PCM TOM or VOM during the time the vehicle is in a paint oven or undergoing another high temperature process Section 7 Transmission Light duty models equipped with manual transmission have a clutch operated start safety switch Starter should operate whenever the ignition is turned to start and the clutch is fully depressed Readjust if necessary as outlined in the Truck Service Manu al Models equipped with automatic transmissions have a steering column mounted neu tral park start safety mechanical lockout feature which interfaces with the steering column ignition switch Starter should operate only when gear shift lever is in neutral or park position Readjust the shift linkage if necessary as outlined in the Truck Ser vice Manual Power Take Off PTO systems refer to General Section 0 e The NV4500 manual 5 speed heavy duty overdrive transmission RPO MW3 requires the use of special synthetic lubricant to reduce transmission internal operating temperatures The lubricantis installed in all NV4500 transmissions at the factory CK Rev 12 98 Rev 11 99 5 instances where it is neces
30. S 18 36 ts 3205 0 Eit Eo 126 18 S M H 4 878 29068702 975 0 205 0 EEES M30 RH 22 64 4 19 88 1035 17 40 75 215250 4550 0 1084 2622 70 ee MT 1883 0 FRAME OUTLINE DIMENSIONS ARE PICKUP BOX MOUNTING HOLE LOCATIONS MARKED 1175 17 46 26 74 13 7 SYMMETRICALLY OPPOSITE ABOUT THUS A 8 PLACES DIMENSIONS OF MOUNTING 2420 0 CENTERLINE OF VEHICLE HOLES ARE SYMMETRICALLY OPPOSITE ABOUT s 95 27 CENTERLINE OF VEHICLE INCHES M30 ONLY La 2950 0 LH CENTERLINE 116 14 IS 56 9 2 24 3170 0 FORWARD OF RH 124 80 7 CENTERLINE 3543 5 139 50 gt 4449 0 175 15 E CK Rev 12 98 Rev 11 99 C K Truck CURRENT K 1 2 0753 Extended Cab Pickup Crossmember Arrangement CN 2637 0 103 82 1150 0 28 VEHIC IAS mA Ema le le FRONT WHEEL amp 22 64 M30 M50 MG5 990 2 38 98 MT 1059 0 41 69 r 74 2420 0 95 27 4 2950 0 48 _ _ 116 14 9170 0 _ 124 80 55435504 139 50 4449 0 175 15 L FRONT WHEEL t OF REAR WHEEL 2935 0 115 51 2247 4 1150 26 5 88 48 4 98 190 0 I 7 48 C Le Zt i 686 5 44 0 2
31. WHEEL OFFSETS WHEEL OFFSETS dA t rem Ta TER di Sy In Ae A ee rt INSIDE FRAME C7 GE 850 00 i t 33 47 TRACK m TRACK B 0 _____ SECTION A A ROTATED 90 G WHEEL INCHES MAX GROWN TIRE RADIUS ON MAX GROWN TIRE WIDTH WITH OPT GTY WIDE TRACK SPECIAL EQUIP TRACK NARROWEST RIM WIDEST RIM OPT 859 B TRACK G SERIES TIRES GVW RANGEREAR WHEEL TRACK DIM DIM DIM D DIM E DIM Fa DIM G DIM H DIM J C3500 LT245 75R16 20 00 SINGLE 705 36 17 0 1981 38 1449 36 277 0 74 0 400 0 256 0 6 6 26 3 K3500 LT245 75R16 99 200 SINGLE 705 36 17 0 1961 36 1449 36 277 0 74 0 400 0 258 0 6 6 28 3 LT225 75R16 DUAL 649 52 27 0 2139 52 59 52 133 7 04 5 384 0 236 0 490 0 6 6 26 3 C3500 W O GTY 7 50 X 16LT DUAL 649 52 27 0 2139 52 59 52 133 7 921 430 0 236 0 490 0 6 6 26 3 vane LT225 75R16 21 DUAL 649 52 27 0 2139 52 59
32. r Pt S 30 0 VEHICLE a 19 CS Aor E 7 oy 1 18 T s 21 1 HI F i xd EL t LL AGH XY w 175 5 347 7 M L 5 4 E a 6 91 13 69 823 0 1 i OF FRAME 17 8241 354 2 T FRONT WHEEL TO BOTTOM OF 1616 0 13 94 Lac SON 17 0 MUFFLER 6360 I 63 62 tes I TRE 1320 f 3950 0 WHEELBASE TO CENTERLINE le See T 155 50 OF TAILPIPE AB 5 20 5909 4 i l 222 jag 5 232 65 WHEEL A 2593 0 pee 102 09 7 i d NOTES 2185 0 1565 0 280 3 e et SS 11 04 86 02 61 61 432 2 __ noe INCHES 2 2 CARRIER CROSSMEMBER 165 DIESEL ONLY 3383 UNLESS OTHERWISE SPECIFIED 13 32 ALL DIMENSIONS ARE TO OUTSIDE OF METAL VIEW IN DIRECTION OF ARROW Z CK Rev 12 98 Rev 11 99 C K Truck CURRENT K 20953 amp C6P 8600 GVWR K 30953 9200 GVWR Extended Cab 4 Wheel Drive w 6 5T Diesel Engine
33. 1957 2 gt 77 06 3041 28 1695 56 AT STRG WHL 79 18 T 66 75 s WX 1560 0 D L O 73 J 61 42 1304 3 000 9 51 35 1254 IT 3032 9 AT STRG WHL 49 18 90 391 69 1463 0 57 60 Y _ 480 0 1500 59 CJ 1232 63 W TR PNL o 48 53 1262 0 WHL HOUSE 7 46 69 T 649 2 1875 0 73 74 NORMAL TOP L3 M FRAME MAX HEIGHT ROOF CARRIER a5 g6 1 80 ce ARES e MAX CARGO HEIGHT 4787 9 OVERALL 188 50 CK Rev 12 98 Rev 11 99 C K Truck CURRENT C K 10516 Utility Side Step Running Boards Option BVE 1200 0 i i RAMP OVER ANGLE 47 24 STEP IN HEIGHT
34. 60 2 2 37 OUTER REINFORCEMENT 47 6 1 87 36 0 1 42 190 0 7 48 INNER REINFORCEMENT 6 6 0 26 pu 41 OUTER REINFORCEMENT 7 1 64 Rev 12 98 Rev 11 99 C K Truck CURRENT C 310 314 318 03 Chassis Cab 15 000 Ib GVWR Crossmember Arrangement 5442 0 135 51 C310 4052 0 159 53 C314 1296 0 4662 0 183 54 C318 51 02 WHEELBASE 61 02 525 0 20 67 425 0 16 73 E 1 H q Y 1050 0 41 34 33 46 i uM 1 850 0 32 68 1 INSIDE OF Lon METAL 1983 0 1123 5 2695 0 852 49 106 10 44 23 7 6 0 50 33 56 4 550500 130 12 INSIDE OF 7 C 314 318 ONLY s ias TT METAL 3915 0 154 13 C318 ONLY G OF FRONT AXLE BACK OF CAB 190 0 10 0 R 7 48 0 39 OF REAR
35. L 10 8 ST 10 4 8 HOLES 146 0 E js 2 25 0 2 94 24 55 0 36 0 98 VN 4 1 81 46 0 PAB MM S 1 81 2 94 VIEW IN THE DIRECTION Pos e OF ARROW C CK Rev 12 98 Rev 11 99 C K Truck CURRENT C K 1500 Series Rear Axle Tire Data Chart TU INSIDE FRAME 45 1005 64 23 71 39 59 TRACK Gd so 425 0 LLP deo TIRE CHAINS NOT SINGLE WHEELS 34 74 GROWN TIRE RADIUS ON NARROWEST RI USED WITH K1500 AND A TRACK F N MAX GROWN TIRE WIDTH ON WIDEST RIM LT265 75R16 TIRES TRACK SERIES TIRES GVW RANGE REAR WHEEL TRACK DIM DIM DIM D DIM E x DIM FA C1500 P225 70R15 5600 SINGLE 642 0 0 0 886 0 398 0 69 5 225 0 358 5 244 0 P225 75R15 5600 SINGLE 642 0 0 0 886 0 398 0 69 5 236 0 369 5 244 0 P235 75R15 5600 SINGLE 642 0 0 0 894 0 390 0 60 5 244 0 374 5 252 0 P235 75R15 5600 6800 SINGLE 616 0 13 0 868 0 364 0 48 0 243 0 374 5 252 0 P275 60R15 5600 6200 SINGLE 642 0 0 0 925 0 359 0 45 5 235 0 355 5 283 0 K1500 P245 75R16 6100 6450 SINGLE 614 0 44 0 870 0 358 0 42 5 232 0 400 0 256 0 P245 75R16 6200 6800 SINGLE 602 0 44 0 858 0 346 0 36 5 232 0 400 0 256 0 P245 75R16 6800 SINGLE 616 0 44 0 872 0 360 0 42 5 232 0 40
36. REAR AXLE 899 4 1921 0 1516 5 59 70 K31003 1300 5 854 9 4 75 63 7 2126 6 83 72 1403 51 20 gt REFER TO BODY DRAWING OF ENGINE E 398 4 A LR C 15 68 Lt 861 5 2830 18 0 DIA SHEAR PLATE 33 92 15 08 1330 4 HOLES LH AND RH 52 38 REAR shee 1 768 STABILIZER sb T 1 97 y Hn 3 68 79 _ 22 4 t4 E A 1 5 30 153 2 46 4 1 83 130 0 6 03 TOP OF FRAME 5 12 TO TOP OF FRONT 374 1 14 73 MUFFLER 378 6 14 91 TOP OF FRAME i TO CENTERLINE OF MUFFLER LL LLL DATA BASED ON K31403 amp L65 INCHES UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE TO OUTSIDE OF METAL 3437 5 135 33 K31003 4047 5 159 35 K31403 WHEELBASE MINIMUM CUT OFF LENGTH RELOCATE REAR CROSSMEMBER AS PROVIDED C K Truck CURRENT 310 314 318 03 Chassis Cab Regular Cab 2 Wheel Drive 15 000 GVWR w 6 5T Diesel Engine
37. C K 107 207 53 Extended Cab Interior BATTERY n ZFRONT WHEELS MODELS WITHOUT 7 REAR SEAT HAVE 1147 3 L 40 5 CU FT OF STORAGE 1718 0 SHOULDER ROOM 67 64 OR CARGO REAR SEAT 16955 AT STRG WHL OR CARGO 66 65 1631 0 HIP ROOM 64 21 OR CARGO L _ 1933 0 STRG WHL A I 75 85 2234 0 90 31 1 _ B 1531 0 671 0 60 28 26 42 384 6 h 15 12 elon REAR SEAT WIDTH E 425 0 16 73 NOTE 9520 EFFECTIVE 37 48 HEAD ROOM FOR ADDITIONAL INFORMATION 4 SEE CONVENTIONAL 03 MODEL SEE _ DIMENSIONS MARKED THUS ARE ME FOR 53 MODEL WITH 7 CE I EN 7 INCHES 1020 1445 4200 OF REAR 365 0 4 02 5 69 16 54 B 434 OF FLOOR 34 8 EFFECTIVE LEG ROOM 1 71 H POINT SEAT IN REARMOST POSITION CK Rev 12 98 Rev 11 99 58 C K Truck REAR BODY MOUNTING HOLES
38. I 250 3 9 85 10906 293 3 11 78 CK20906 BL ur EET r aa M m G 301 2 11 86 CK10906 132 3 181 4 7 14 CK20906 5 21 177 7 7 00 CK10906 260 4 10 25 CK20906 CIO 2 3 0 09 C1 20906 BELOW INSIDE METAL BELOW INSIDE METAL ie TO TOP OF MUFFLER ABOVE INSIDE METAL 30 7 1 21 K1 20906 15 3 0 60 20906 ABOVE INSIDE METAL 48 3 1 90 K20906 TO TOP OF MUFFLER INSIDE METAL TO TOP OF CONVERTER E ___ PACK 0 5 0 02 C10906 BELOW INISDE METAL 317 5 32 5 1 28 K10906 u 12 50 ABOVE INSIDE METAL 41 7 1 64 C20906 8 7 0 34 K20906 INSIDE METAL TO TOP C20906 amp L31 L29 SHOWN OF CONVERTER INCHES UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO INSIDE OF METAL CK Rev 12 98 Rev 11 99 C K Truck CuRRENT C K 200 amp 6 309 03 53 Pickup 5 7L Gas Engine Option 131 and 7 4L Gas Engine Option 129 558 8 5 22 00 87 03 MUFFLER 1074 8 42 31 CK10906 250
39. s MU 2 OFVEHICLE X Gace 5 E 5 20 1 N a Li mu SP T 5 30 189 1 _ 4322 9 T 252 8 7 45 sae gt cU 17 02 ZOF FRONT 9 95 8230 13 94 WHEELS dd 82 40 TOP OF FRAME ZOF FRONT TRANSFER OF CONVERTER 1616 0 O CENTERLINE OF WHEELS REAR AXLE TO TOP OF FRAME 63 62 TAILPIPE 2012 5 3950 0 WHEELBASE we 79 23 155 50 2948 0 12 33 L65 DIESEL EXHAUST NOTE 116 06 8 69 SYSTEM DIMENSIONS 2185 0 1565 0 26568 9450 INCHES 86 02 75 61 61 104 58 37 20 0 UNLESS OTHERWISE 4573 0 TIRE CARRIER CROSSMEMBER BB 0400 EE 13 62 SPECIFIED 180 04 mas 338 3 46385 ALL DIMENSIONS 13 32 cc ARE TO OUTSIDE 13 32 182 61 OF METAL VIEW IN DIRECTION OF ARROW Y CK Rev 12 98 Rev 11 99 C K Truck 207 307 43 Crew Cab 2 Wheel Drive DRAWING NOT AVAILABLE AT TIME OF PUBLICATION CK Rev 12 98 Rev 11 99 C K Truck CURRENT K 207 307 43 Crew Cab 4 Wheel Drive DRAWING NOT AVAILABLE AT TIME OF PUBLICATION CK Rev 12 98 Rev 11 99 20 C K Truck CURRENT C 30943 Crew Cab 2 Wheel Drive
40. 1256 0 1000 A B Oo 49 45 1317 65 a DIMENSIONS OF 51 88 D METAL FORM ARE uS LESS INTERIOR TRIM SECTION D D 60 20 DIMENSIONS OF FORM FEATURES ARE 5 0 MM 2366 0 93 15 Rev 12 98 Rev 11 99 C K Truck CuRRENT C K 109 209 06 Suburban Interior Trim SECTION B B PANEL ASM SECTION TRI PO C69 SECT HON Geo SECTION D D INCHES Rev 12 98 Rev 11 99 C K Truck CURRENT C K 109 209 06 Suburban Seating Front AU __ 638 0 25 12 89 0 7 44 898 B898 0 898 0 35 35 35 35 35 35 VIEW IN DIRECTION OF ARROW VIEW IN DIRECTION OF ARROW VIEW IN DIRECTION OF ARROW A FRONT FULL BENCH SEAT RPO 52 FRONT SPLIT BENCH SEAT RPO AE7 FRONT HI BACK BUCKET SEATS RPO A95 2237 0 1000 0 q 25 20 Q FRONT WHEEL es h 1 Oe 932 0 52 POINT 36 69 I 855 0 925 0 RPO A95 AE7 33 66 36 42 OF FLOOR X M CD 1
41. 448 5 c 1059 0 41 69 17 66 101 1 118 3 27 03 1968 0 3 38 4 66 8708 0 7 77 48 433 0 27 87 17 05 103 18 amp VEHICLE K100 K200 K200 C6P 7920 0 300 116 14 E 3340 0 5 ra 131 50 T sc a 466 0 4400 0 gt FRONT WH 05 0 18 35 0 EEL 1662 6 19 88 173 23 us 78 07 NOTES 2165 0 85 24 FRAME OUTLINE DIMENSIONS ARE SYMETRICALLY OPPOSITE ABOUT CENTERLINE OF VEHICLE iein PICKUP BOX MOUNTING HOLES ARE MARKED THUS 8 PLACES 2915 0 114 76 INCHES 3288 5 129 47 4194 0 165 12 CK Rev 12 98 Rev 11 99 C K Truck CURRENT 1 2 0753 Extended Cab Pickup Crossmember Arrangement cc FRONT WHEELS REAR AXLE 177 68 2935 0 A 4108 0 115255 116 0 3061 0 MEA T 2356 2 175 5 11 0 68 0 4 57 2 68 120 51 6 90 43 A 2637 0 6 30 103 82 30 35 Eri H T pon nol EE 1400001 ff s Se FF T 55 11 ao 1 FRONT WHEELS T 6 NORMAL 5 si Li ic OF FRAME 1 680 2 2 448 5 433 0 24 60 17 66 17 05 7 t a d 5 VEHICLE Nm
42. 690 161 8 6 37 Hon 1575 0 1565 0 62 01 gt T 61 61 3963 0 TIRE CARRIER 281 0 11 06 156 02 CROSSMEMBER 339 0 5299 4 13 35 208 63 2820 3 1419 0 gt 111 03 880 55 87 1616 0 1299 7 d 51 17 63 62 13 83 12307 OUTSIDE OF METAL 383 0 TIC F q amp 8 TO CENTERLINE OF B TAILPIPE 15 08 ty 899 4 2 iem 1 823 0 85 41 od oe J 82 40 VOF CRANK 175 5 s 6 91 25 98 RO 2 39 BEC J y ie i 9 Sie 14 29 0 57 345 4 TOP OF CONVERTER 13 60 TO TOP OF FRAME OUTSIDE METAL BOTTOM OF INCHES NOTES 3340 0 WHEELBASE 131 50 UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO OUTSIDE OF METAL MUFFLER _ 165 EXHAUST DIMENSIONS
43. C K Truck CURRENT CARGO DOOR D48 ELECTRIC BELOW EYELINE MIRROR C K 10706 Utility Exterior OPTION 55 CC 2392 2 94 18 Rev 12 98 Rev 11 99 INCHES 78 C K Truck CuRRENT C K 10706 Utility Seating Arrangement 00 2400 0 94 49 1724 6 bet 944 1 67 90 80 48 L 1993 6 1531 0 60 28 23 4 564 8 Jy 54 05 889 6 35 02 4 981 4 38 63 AN FN Ny 500 576 5 lt 22 78 ACCELERATOR 653 9 25 74 BRAKE 1158 5 45 61 SEATS POINTS 1651 7 65 03 SHOULDER 1642 8 642 8 BE Xl Pubs nay PREULDER Ne 1509 4 iip aig 5 2 ti TER 7 59 43 59 65 59 65 DO NTS H POINTS 49 2 449 0 m 58 898 0 17955 8980 17 68 898 0 35 35 35 38 35 35 5 HIGH BACK AE7 BASE FRT SPLIT BENCH AM SPLIT FOLDING REAR SEAT BUCKET SEATS REAR VIEW CK Rev
44. NGIN CK Rev 12 98 Rev 11 99 36 C K Truck CURRENT SNOWPLOW INSTALLATION Model Availability Recommended Procedures and Guidelines The chart on the following page shows GMTG approved models available with snow plow prep package option VYU The following models produced by General Motors Truck Group are not recom mended for snowplow application K Series 4x4 2 door and 4 door utilities Tahoe Yukon K Series 4x4 Suburbans and Crew Cab Pickups General Motors recommends that when a snowplow is mounted on a vehicle only one passenger should accompany the driver More than one passenger may exceed Front Gross Axle Weight Ratings Prior to installing a front mounted snowplow the following process should be followed and necessary information obtained e Establish vehicle curb weight e Establish chassis manufacturers front and rear axle weight ratings Chevrolet and GMC truck dealers can provide availability specifications weights Gross Vehicle Weight Ratings GVWR and Front and Rear Gross Axle Ratings GAWRF GAWRR For vehicles already built this information can be found on the certification label installed on drivers door door frame or provided on cover of incomplete vehicle document The following information should be obtained and provided by the manufacturers of snowplows and salt spreaders Specifications weights and center of gravity data e Vehicle instal
45. Or 17 1 I air AMPS 43 98 gt 88 8 SN CARRER 5580 YA 4 79 17 N 1 480 0 744 0 1301 2 18 89 29 30 T 51 23 7 559 6 507 7 22 00 19 99 RPO D44 D48 3 h 1038 00 ry 40 86 MIN 764 5 L 1 i 764 5 649 73 3 E 115 5 Pi 4 59 911 0 3340 0 WHEELBASE INSIDE METAL E 2 131 49 OF FRAME AT RR AXLE 49 BT 5587 68 OVERALL WHEEL HOUSE 219 97 N I MUM CK Rev 12 98 Rev 11 99 C K Truck CuRRENT C K 109 209 06 Suburban Exterior End Gate ENS F SHEE E ARE ESS R TRI IMENS R FOR EATURE E 5 0MM IH Ji L Z METAL FORM L 2594 94 N 20229 7 27 M A VE ic SRI O O M 2 Re
46. 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 TBI and CPI systems Coupled hose or nylon quick connects must be used Clamped hose is not acceptable for TBI and 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 All gasoline engine vehicles are equipped with fuel evaporative emission control equipment which is certified to be in compliance with the Federal or applicable Califor nia vehicle emission standards Alterations to fuel tank and metering unit lines can ister or canisters canister filters canister purge control valves relay switches tank auxiliary vent valve engine speed controller or other devices systems are therefore not allowable since vehicle adherence to C A R B and Federal regulations may be affected Diesel powered vehicles incorporate water drain provisions in the fuel system These valves are only to be opened when siphoning water and contaminants from the fuel system Body attachment brackets and u bolts must be located suc
47. including but not limited to Automatic transmission assembly A T A T control from steering column to transmission linkage A T control from floor shift mechanism to transmission linkage A T steering column assembly A T floor shift mechanism A T neutral safety back up switch assembly and wire Chassis wiring harness position indicator dial A T position indicator pointer A T position indicator actuating linkage Transmission shift position pattern knob plate or label FMVSS 103 Windshield Defrosting and Defogging Systems This vehicle when altered will conform to FMVSS 103 providing no alterations are made which affect the function physical or mechanical properties environment loca tion or vital spatial clearances of the components assemblies or systems identified below Windshield defrosting and defogging systems including but limited to Heater and defroster control Vacuum control hoses Windshield assembly Heater and defroster assembly electrical mechanical vacuum including motor and blower Heater and water hoses hose assemblies Heater blower motor resistor assembly Defroster air duct assembly it affects high blower speed Engine water outlet thermostat assembly Heater and air conditioning wiring harness Engine wiring harness CK Rev 12 98 Rev 11 99 Defroster air distributor assembly manifold Defroster air to windshield outlet assembly nozzle Defroster air hoses distributo
48. 0 TOP OF REAR 2478 0 L505 BODY MOUNT reali 808 64 41 W203 3950 0 104 j 11815 TAIL GATE 155 51 46 52 OPENING 6030 9 _ BOTTOM 237 40 1103 Rev 12 98 Rev 11 99 C K Truck CURRENT C K Truck Pickup Box Fleetside Wideside and Heavy Hauler Big Dooley G OVERALL LENGTH L507 76 7 3 02 1656 0 FLANGE WIDTH 65 20 TOP 15720 INSIDE WIDTH 61 89 REAR FLANGE 19494 MAXOVERALL i dd 4 76 75 WIDTH INSIDE 16200 WIDTH 63 78 1679 0 I I Na 1644 0 INSIDE WIDTH 66 10 id i 64 72 INNER PANEL A 2394 2 gt 9426 49 0
49. 08 20806 T245 75R16 8600 SINGLE 742 0 To 93 4 7 61 256 0 10 08 T245 75R16 9200 SINGLE 742 0 7 0 60 6 6 32 256 0 10 08 30900 gt 25 75 16 10000 757 0 50 5 5 93 239 0 9 4 7 50 16LT 10000 DUA 757 0 27 0 34 8 28 244 0 9 6 T245 75R16 9000 SINGLE 742 0 Z5 86 1 7 33 256 0 10 08 K30943 T225 75R16 1 0000 DUA 757 0 27 0 76 2 6 94 234 0 9 2 7 50 16LT 10000 DUA 757 0 Zur m 209 5 8 25 244 0 9 6 met LT225 75R16 100007 12000 DUA 757 0 48 0 5 83 234 0 9 2 7 50 166 10000 12000 UA 757 0 zu 79 0 7 05 244 0 9 6 LT225 75R16 10000 12000 757 0 210 48 0 5 83 234 0 9 2 7 50 16L 10000 12000 757 0 27 0 79 0 7 05 244 0 9 6 CK Rev 12 98 Rev 11 99 105 3500HD Front Axle Tire Data Chart Chassis Cab 15 000 GVWR SLR GROUND CLEARANCE TRACK MAX TIRE WIDTH MAX I _ WHE GROUND T MODEL TIR GVW WHEE TRACK 1 CLEARANCE TIRE WIDTH C31003 LT225 70R19 5 15000 DUAL 1771 0 127 0 274 4 10 80 228 0 8 98 C31403 LT225 70R19 5 15000 DUA
50. 11 000 Ib GVWR Crossmember Arrangement 1150 0 575 0 22800 ____ _ OF REAR WHEEL OF FRONT WHEEL 45 28 2264 REAR WHEEL me 87 70 16 73 NORMAL OF FRAME 4 A 850 0 355 VEHICLE 33 46 1 40 lt refy eu _ 330 5 1 wo eii 98 13 01 153 2 MW3 14000 6 03 1110 87 43 73 55 11 7807 1798 0 30 73 7 70 78 A 80 10 1159 6 45 65 lt 22635 2695 0 89 11 106 10 3305 0 C31403 ONLY 1296 0 3070 0 120 87 31003 130 12 51 02 3680 0 144 88 3242 5 127 66 C31003 B 3852 5 151 67 3442 0 135 50 C31003 2 4052 0 159 50 C31403 58 0 140 0 2 28 5 51 6 6 0 25 190 0 SECTION 7 48 10 0 R 0 39 SECTION CK Rev 12 98 Rev 11 99 C K Truck 310 314 03 Chassis Cab 10 000 and 11 000 15 GVWR Frame Reinforcement 2616 0 102 99 31003 3226 0 127 00 31403 2711 0 106 73 C21409 ONLY 2410 0 94 88 a 31003 ONLY 2386 8 93 96 1149 0 45 24 TUI
51. 12 98 Rev 11 99 C K Truck CURRENT C K 1 2 3 0000 Mirror Options General Arrangement 2092 0 82 36 1 065 AVAILABLE 20903 DF2 AVAILABLE 30903 31003 31403 31803 ONLY NOTE MIRRORS SHIPPED LOOSE OPTION FOR 10703 ONLY NOTE MIRRORS SHIPPED LOOSE 2267 3 89 26 PEN 2394 8 94 28 1861 8 73 30 OPEN FOLDED 2069 5 81 48 FOLDED fa 048 10706 OPTION 044 BASE FOR MODEL 31803 ONLY D48 ELECTRIC amp DE2 MANUAL OPTION D44 PAINTED OPTION D45 STAINLESS CHECK WITH DEALERS FOR OPTION AVAILABILITY INCHES CK Rev 12 98 Rev 11 99 80 C K Truck Front Floor Seat Mounting du O FRONT BUCKET SEAT MOUNTING 1 30 RPO A95 A50 10 X 1 5 4 PLACES EACH SIDE ARKED A
52. 1370 109 202 28 14 SAME AS AVAILABLE WITH 4401 7941 INPUT 4 2993 1 108 ENGINE RPO ROS ONLY 109 202 28 14 SAME AS BORG WARNER 4470 1000 1671 NPUT 4 2993 1 108 4 Rev 12 98 Rev 11 99 C K Truck CURRENT C K 309 03 53 310 314 03 Power Take PTO Transmission POWER TAKE OFF OPENING LOCATION TRANSMISSION MWS 4 OF TRANSMISSION amp OF FRONT WHEELS t OF VEHICLE ge A NORMAL TOP OF FRAME 30 0 1 18 5 30 3 ae j 1 665 8 520 7 20 50 630952 oo 460 7 18 14 C K30953 y T 519 9 20 47 30903 459 9 18 11 C K30903 i 530 7 20 89 C K310 31403 470 7 18 53 C K310 31403 1000 SIDE VIEW REAR VIEW PTO INSTALLATION NOTICE MW3 TRANSMISSION RATIOS GM NV4500 MANUAL 5 SPEED TRANSMISSIONS HAVE BEEN FACTORY FILLED WITH SYNTHETIC GEAR LUBE REVERSE 5 6 _ FIRST 5 61 WHEN THESE TRANSMISSIONS ARE DRAINED FOR PTO BE INSTALLATION THEY MUST REFILLED WITH CASTROL ae SYNTORQ LT SYNTHETIC GEAR LU
53. 185 5 19 29 4133 _ 145 0 5 94 OW95 7 30 41 44 H503 16 27 5 71 676 0 a SS OW78 DE T 68 2 TOP OF OF FLOOR 71 865 4h 2 68 1354 0 53 31 1 TAIL i i OPENING BOTTOM pat 6 TE mcer r E J ic GAS FILLER Rer 145 0 GROUND LINE ern OF FOR ADDITIONAL INFORMATION REAR a 1065 0 SEE CAB CHASSIS DATA BODY MOUNT 41 93 AND CHASSIS 03 MODEL 899 4 2985 0 WHEELBASE 1055 2 35 41 1104 117 52 L101 41 54 INCHES C K Truck CURRENT C K Truck Pickup Box Fleetside Wideside 8 ft 2575 0 L507 NOTE 101 38 SEE FLEETSIDE BODY OVERALL LENGTH E63 WITH CONVENTIONAL MU ce AU CAB 03 FOR OPTI
54. 2 1 93 16325 BETWEEN 53 0 _ g 64 27 STAKE ENLARGED TYPICAL 2 09 POCKETS SECTION U U 134 5 _ ALL STAKE POCKETS ARE 5 30 APPROXIMATELY 37 7 X 53 7 1 48 2 11 AUXILIARY FENDER FOR CAMPER PACKAGE 281 WITH DUAL REAR WHEELS Z RPO 805 AND FLEETSIDE BODY E63 D L505 H B L506 21 65 N L504 K 85 5 LOCATION pe 1574 4 TAIL GATE OPTIONAL SPARE TIRE LONG BOX 898 0 e 61 98 w204 OPENING LOCATION SHORT BOX 35 22 490 0 3 154 5 154 5 151 7 e ANNE 2650 H504 E 19 29 6 08 amp 6 08 5 97 T 49 06 1 4o04 5 97 W201 10 43 on 41 44 c p NY 6024 T I 253 0 7 0 Eee H 3 9 9 4 AT _ A D N pr NE Zi GAS FILLER DOOR 144 3 GROUND LINE 5 68 8190 H 32 24 394 77 OF REAR J L404 378 1 1636 0 55 I 1 55 OW95 BODY MOUNT 1488 7 64 41 W103 553 85 41 H WHEELBASE L101 M 1105 iaa L104 BOTTOM L L103 Rev 12 98 Rev 11 99 C K Truck CURRENT C K Truck Pickup Box Fleetside Wideside and Heavy Hauler Big Dooley Series 107 207 53 C K 30903 C K 30953 207 307 43 2540 0 3020 0 3020 0 2540 0 100 00 118 90 118 90 100 00 1961 0 2
55. 2 PLACES CENTER BODY MOUNTING HOLES 2 PLACES H 1 FRONT WHEELS 1 _ m 1561 2 61 46 d Uuy 1407 2 i CD 55 40 681 2 M 1323 0 26 82 a 52 09 i Cr 1 x 583 M 7j p 4 BODY MOUNT 2 GN _ Nd 2 1810 0 8994 gt E 35 41 126 2420 0 _ 95 28 3430 4 135 05 L403 T 2530 0 99 61 480 0 440 18 90 1 73 CHMSL CARGO LAMP 1 1318 6 589 gt NORMAL TOP INSIDE FRAME 1566 0 51 91 C 100 200 300 a NORMAL TOP 586 INSIDE OF 51 13 K FRAME NOTE 1 2 300 6 0 FOR ADDITIONAL INFORMATION 0 24 SEE CONVENTIONAL CAB 03 1 MODEL 583 _ _ DIMENSIONS MARKED THUS FRTSIL lamen 583 53 MODEL WITH 220 a gt FRT 618 0 1 65 RR 663 0 L 70 REAR 2895 0 113 98 MOUNT CK Rev 12 98 Rev 11 99 C K Truck CURRENT C K 207 307 309 43 Crew Cab Interior
56. 21 oe EE Vi 1691 0 18 5 6657 0 52 2263 5 89 11 3680 0 144 88 1403 3070 0 120 86 1003 3852 5 151 67 1403 3242 5 127 65 1003 3442 0 135 50 1003 4052 0 159 50 1403 ZFRONT WHEELS 6 6 0 26 190 0 7 48 0 39 SECTION B 68 5 2 70 NORMAL TOP OF FRAME AXLE Od 140 5 5 51 E INCHES SECTION C K Truck CURRENT 310 314 03 Chassis Cab 12 000 Ib GVWR Frame Reinforcement 2616 0 102 99 K31003 3226 0 127 00 31403 2711 0 106 73 K31403 ONLY 2410 0 94 88 K31003 ONLY 2368 8 93 25 pess 1149 0 45 23 0 nm 712 Vg BRYA s 11 8 0 46 INNER REINFORCEMENT A SS BS 1000 sin e 18 2 2 28 i lt 0 88 190 0 5 0 7 48 0 20 196 0 196 0 7 72 7 72 73 4 2 98 51 3 2 02 SECTION 41 7 1 64 i SS 658 SECTION
57. 231 53 Rev 12 98 Rev 11 99 C K Truck CURRENT C K Truck Pickup Box Sportside 6 5 ft 583 CK Rev 12 98 Rev 11 99 1958 8 OVERALL 77 12 WIDTH 3 fF BETWEEN STAKE 1315 0 1434 5 49 0 POCKETS 51 77 56 47 1 93 TYPICAL SECTION D _ J al 55 y FROM INSIDE 59 0 1804 8 1293 5 OF FRONT 2 32 71 06 ALL STAKE POCKET o ga W204 END PANEL OPENINGS ARE APPROX RTE a 2 2 OPENING TOP 4939 6 194 47 103 m 2 30 0 CLEARANCE TO BACK eue 1 18 OF VEHICLE 12480 W605 2556 5 49 13 100 65 INSIDE WIDTH 1999 0 L505 IAM 78 70 1962 0 1506 _ E 77 25 m 182 5 7 19 9 0 sud 035 151 0 OW77
58. 35 135 39 139 159 5 19 119 23 123 26 126 30 130 34 134 38 138 183 5 16 116 20 120 23 123 26 126 29 129 CURRENT Example When mounting an item of equipment with the center of gravity 48 inches behind the center of rear axle on a truck with a wheelbase of 159 5 inches the chart shows the front rear percentage to be 30 130 If the tailgate weighs 600 Ibs 3 32 30 times 600 165 equals minus 180 lbs Mounting the liftgate makes the front axle 180 105 lighter The rear axle weight is increased by 1 30 130 times 600 lbs equals 780 lbs In effect 180 165 are transferred from the front to the rear axle and the weight is increased by the transferred weight plus the weight of the tailgate or 780 105 Chassis Cab Payload Weight Distribution C K Crew Cab Chassis Cab Front Rear Dimensions IN Body Lengths FT 30943 05 168 5 55 9 97 0 249 6 14 86 10 90 6 94 3 97 30943 168 5 55 9 97 0 249 6 14 86 10 90 6 94 3 97 K 30943 W R05 168 5 55 9 97 0 249 6 14 86 10 90 6 94 C K Chassis Cab Front Rear Dimensions IN Body Lengths FT C 30903 131 5 55 9 97 6 208 2 13 87 4 96 31003 1355 60 0 110 9 221 5 15 85 7 93 C31403 _ 159 5 84 0 135 0 245 5 28 72 21 79 13 87 6 94 K 20903 __ 131 5 55 9 97 6 208 2 13 87 4 96 30903 __ 131 5 55 9
59. 52 133 7 64 85 384 0 236 0 490 0 6 6 26 3 W O 7 50 x 1617 S OB DUAL 649 52 27 0 2139 52 59 52 133 7 951 430 0 236 0 490 0 6 6 26 3 7225 75816 DUAL 852 92 27 0 2342 92 1362 92 235 0 093 384 0 236 0 490 0 6 6 26 3 W 7 50 X 16LT 2 DUAL 852 92 27 0 2342 92 1362 92 235 0 son a 2560 480 0 26 3 LT225 75R16 5 DUAL 852 92 27 0 2342 92 1362 92 235 0 09 4 384 0 236 0 490 0 6 6 26 3 W GTY 7 50 X 16LT 281 DUAL 852 92 27 0 2342 92 1362 92 235 0 430 0 236 0 490 0 6 6 26 3 C3500 225 70R19 5 15 000 DUAL 696 20 27 0 2178 20 1214 20 157 2 95 0 408 1 228 0 482 0 S5 BASE 140 3 CK Rev 12 98 Rev 11 99 C K Truck CuRRENT C K Truck Engine General Arrangement OF ENGINE A C COMPRESSOR t OF FRONT WHEELS ALTERNATOR 4 OF CRANKSHAFT ER STEERING PUMP L AIR INJECTION PUMP uu amp OF SERPENTIN 30 0 1 18 A ENGINE 711 6 28 02 L56 L65 747 2 29 42 683 2 26 96 L30 L31 22 50 1 55 OF ENGINE CK Rev 12 98 Rev 11 99 C K Truck CURRENT C K 30943 Pickup Crew Cab 2919 0 1565 0 x am 99 02 61 61 95 6 3 76 E me The P 10 39 i Ya
60. 97 6 208 2 13 87 4 96 31003 135 5 60 0 110 9 221 5 15 85 7 93 31403 159 5 840 135 0 245 5 28 72 21 79 13 87 C K 3500 HD Chassis Cab Front Rear Dimensions IN Body Lengths FT No we ca ce o l a 9 10 12 14 15 16 31008 1355 60 11 2241 708 897 31403 1595 135 281 7831367 694 31803 183 5 108 159 2721 82 11 89 8 92 5 95 Model Rev 12 98 Rev 11 99 C K Truck CURRENT NORMAL TOP OF FRAME amp OF VEHICLE FRONT WHEEL 3 lae 4 OF TRANSFER CASE gt 4 45 1133 0 44 61 E 17 44 7 SIDE VIEW REAR VIEW TABLE OF TRANSFER CASE POWER TAKE OFF DATA PTO DRIVE GEAR 1000 TRANSFER CASE SAE NUMBER OF NORMAL PITCH ANGLE amp NORMAL REDUCTION PTO TEETH PITCH DIAMETER HAND OF PRESSURE AT PTO OPENING HELIX ANGLE DRIVE GEAR BORG WARNER 1370 6 BOLT 243 9578 162 1246 4401 RH at 9 6046 6 3829 aD ket 6 BOLT 243 9578 162 1246 BORG WARNER 4470 at 57 9 6046 6 3829 21 6 LH 20 1 0 PTO GEAR PITCH LINE PTO DISTANCE DISTANCE DIRECTION 1000 RPM VELOCITY OF MOUNTED ON FROM PAD TO FROM PAD TO OF INPUT TO PTO e 1000 SHAFT CENTERLINE PITCH LINE ROTATION TRANSFER CASE TRANS RPM INPUT OF GEAR OF GEAR FT MIN TRANSFER CASE PTO BORG WARNER
61. A VI aT V d V X 7 n _ A s lt 93 2 48 6 3 67 80 6 T 1 03 3 17 58 0 2 28 118 Tm 0 46 0 46 2 72 22 7 0 89 H E 1 39 81 57 190 0 7 48 1 184 0 190 0 184 0 7 24 7 48 7 24 BEINFORGEMENT INNER REINFORCEMENT OUTER OUTER REINFORCEMENT REINFORCEMENT SECTION A A O28 SECTION C C SECTION B B CK Rev 12 98 Rev 11 99 C K Truck CURRENT K 310 314 03 Chassis Cab 12 000 Ib GVWR Crossmember Arrangement N 1150 0 45 28 575 0 22 64 mro e Em 425 0 16 73 U 1 30 1059 0 41 69 Li 1460 0 57 48 2034 5 80 10 2695 0 106 10 3305 0 K31403 ONLY 130 12 FRONT WHEELS U CK Rev 12 98 Rev 11 99 850 0 33 46 330 5 13 01 780 7 30 73 1159 6 45 65 1296 0 51 02 REAR AXLE 708 0 27 87 58 0 2 28 2230 0 87 80 1657 0 5 65 23 208 5 an 8
62. ARROW A FRONT BUCKET SEATS 50 FRONT HI BACK BUCKET SEATS A95 1000 2237 AUT q FRONT E N 910 0 35 82 TOP OF FLOOR Ly REARMOST POS I TION W 1 400 0 400 0 0 932 0 RPO A50 15 75 15 75 60 59 36 69 H POINT H POINT H POINT H POINT a n FOREMOST REARMOST FOREMOST REARMOST 36 42 REAR SEAT RPO POSITION POSITION POSITION POSITION 308 6 299 0 353 0 392 0 12 14 11 77 13 90 15 43 119 2 294 0 1146 0 1161 5 _ Y 4 69 11 57 45 12 45 73 INCHES CK Rev 12 98 Rev 11 99 C K Truck CURRENT 2294 0 90 31 l a DA4 D45 IL 3214 4 126 55 1038 00 Ll S4 40 86 MIN 1 T 1264 0 49 76 WHEEL HOUSE MINIMUM CK Rev 12 98 Rev 11 99 C K Truck CURRENT C K 10516 Utility Exterior End Gate UNLESS OTHERWISE SPECIFIED DIMENSIONS OF SHEET METAL FORM ARE LESS INTERIOR TRIM DIMENSIONS OF FORM FRATURES ARE 5 0MM za 7 2 94 29 2294 0 RPO 044 045 90 31 4022 49 58 32 gt
63. CuRRENT 86 129 80 associated with the test weight listed in the application for the ve hicle in question and B Adding the weight of all options that are offered by the original manufacturer for the applicable truck line that were not included in the curb weight reported in the application In the case of mutually exclusive options only the weight of the heavier option is to be used when computing the maximum vehicle weight Some original manufacturers provide their sales organizations with a Data Book that lists the curb weights of complete Light Duty Trucks equipped with standard equip ment not including the weight of any optional equipment The Data Book also de scribes the options including their weight the original manufacturer offers A sec ondary manufacturer may use the Data Book curb weight and option weights to determine the maximum vehicle weight for a given vehicle by adding the weight of ev ery option offered by the original manufacturer for the vehicle to the curb weight in the Data Book In the case of mutually exclusive options only the weight of the heavier option is to be added to the Data Book curb weight The weight of optional engines transmission and emission control systems is added to the Data Book weight only when the vehicle in question actually contains these options Those who wish to remove the Pickup box from a Pickup Truck for the purpose of installing special equipment or another t
64. Environmental Protection Agency EPA National Highway Traffic Safety Administration NHTSA and Califor nia Emission Certification and or Fuel Economy regulations are met this vehicle must be completed in strict accordance with all instructions contained in this manual espe cially the following instructions which relate to A Emission Related Components Further compliance of this vehicle with EPA and or California Emission Certification requirements will be maintained providing no alterations except where noted are made to the components identified below EGR system Ignition system Exhaust emission control system Crankcase emission control system Evaporative emission control system Air inlet system Exhaust system Catalytic converter TBI unit Electronic closed loop TBI system Engine assembly Fuel system Transmission assembly Axle ratio Tires Diesel fuel injection controls Turbocharger and associated controls Electronic closed loop carburetor Engine electronics Exhaust oxygen sensor Applicable only to Light Duty Trucks All Federal California gasoline powered Heavy Duty vehicles will have an evaporative emission control system that is certified for a fuel tank capacity not to exceed the amount shown on the Vehicle Evapora tive Emission Control Information Label located on the air cleaner Persons wishing to add fuel tank capacity above the amount shown must contact California Air Resources Board a
65. GVWR of 10 000 Pounds or Less This vehicle when altered will conform to FMVSS 114 providing no alterations are made which affect the function physical or mechanical properties environment loca tion or vital spatial clearances of the components assemblies or systems identified below Steering column lock assembly CK Rev 12 98 Rev 11 99 C K Truck CURRENT U S CFR 49 PART 567 CMVSS 115 Vehicle Identification Number This vehicle when completed will conform to CMVSS 115 and U S CFR 49 part 567 providing no alterations are made to the Vehicle Identification Number or to the envi ronment location vital spatial clearances or visibility of the VIN Plate FMVSS 116 Motor Vehicle Brake Fluids This vehicle when equipped with approved hydraulic brake fluid will conform to FMVSS 116 providing no alterations are made which affect the physical or chemical properties of the brake fluid FMVSS 120 Tire Selection and Rims for Vehicles Other than Passenger Cars This vehicle when completed will conform to FMVSS 120 providing no alterations are made which affect the function physical or mechanical properties or the attach ment of the wheels and tires The tire and wheel information shown on the Incomplete Vehicle Document Label must be transferred to the final stage manufacturer s Certification label or Tire formation Label providing no equipment changes are made FMVSS 124 Accelerator Control Systems T
66. Regular Extended Regular Regular Regular Regular Wheelbase 141 5 131 5 155 5 131 5 155 5 131 5 131 5 135 5 159 5 Pickup Box Length 6 5 8 8 8 8 GVWR 8600 8600 8600 9200 9200 8600 9200 12000 12000 GAWR Frt 4500 4500 4500 4500 4500 4500 4500 4500 4500 Opt Code Base B Equipment Includes Tow Hooks B B B B B Dual Cranking Batteries 600 CCA L65 B B B B B Alternator 105 AMP L65 B B B B B Engine Oil Cooler Air to Oil L65 Only B B B B B Battery 600 CCA B B B B B B B B B Aux HD Trans Cooler Auto Only B B B B B B B B B Engine Oil Cooler Water to Oil Gas Only B B B B B B B B B Alternator 105 Amps B B B B B B B B B B B B B B B B B B HD Heater Blower Snowplow Prep Package Includes HD Een Springs E 5 Adj F60 X X X X X X X X X HD Power Steering Cooler 5 5 5 5 5 Suggested Optional Equipment 40 E Locking Differential 770 CCA Not Available us L65 Heater Dual Alternators 100 Amps L65 Only Rear Window Defogger 558 Skid Plates A A A A A A A A Sliding Rear Window Not Available with C49 A A A Cabs Marker Lamps U01 A A A S T 1 5 HD Rubber Mats BG9 A A A A A power steering cooler is standard on K2500 series with option code 129 7 4L gas or option code L65 6 5T Diesel engines A Available B Base S Standard X Included 1 Included with R05 Dual rear wheels K2500 and K3500 series vehicles with GVWR s of 8600 Ibs or above
67. TOP OF FRAME Jf ap gt OF ENGINE NORMAL TOP zr P TO BOTTOM OF OE ERAME ENGNE 009000 1331 8 ea MUFFLER X 52 43 254 8 lt eCRANK ERR m a T nes 36 94 vi ES iY eae au St ERE 1 gt p xc Dg p EN Hum c FREE St pa LIF gt 300 1 18 U i ib 5 50 8217 LJ UJ 30 1 32 35 1 19 1608 0 TEN mu EM TOP OF CONVERTER 633 8388 OF FRAME 13 87 185 4 TRANSFER 570 0 909 4 TO CENTERLINE 7 30 CASE 22 44 12418 22 OF TAILPIPE 189 8 2175 0 1230 0 7 47 n 85 63 48 43 315 3 4 12 41 DIESEL EXHAUST DIMENSIONS J BM K10753 amp L56 NOTES K20753 amp L65 340 3 AA 28010 pp 945 0 INCHES 13 4 i 3 40 80 59 er 20 UNLESS OTHERWISE BB 4362 SPECIFIED ALL VIEW IN DIRECTION OF ARROW 7 24 00 13 62 DIMENSIONS ARE cc OUTSIDE METAL Rev 12 98 Rev 11 99 C K Truck CURRENT 109 209 53 Extended Cab 2 Wheel Drive w 6 5T Diesel Engine
68. are also available through Pioneer Standard Company 1 800 PACKARD Pioneer may also be able to assist in making necessary wiring additions by providing custom wiring stubs or jumpers to your specifications Fusible Link Repair Procedure 1 Cut damaged fusible link from wiring harness assembly splice 2 Strip insulation from harness wire as required to splice on new fusible link 3 Fabricate a new fusible link wire approximately 6 to 8 in long from the same wire size as the original link Acceptable fusible link material will be imprinted with the wire size and the wording to identify it as fusible link Fusible link cable is not the same as normal vehicle wiring 4 Terminate fusible link harness wire with a suitable compression splice clip and sol der with an electrical grade rosin core solder Splice area with heat shrink tubing to provide electrical insulation as well as mechanical strain relief at the splice 5 Strip terminate solder and insulate remaining end of fusible link with appropriate termination to be compatible with the rest of the electrical system 6 For further information refer to the instruction manual in the wiring repair kit ref erenced elsewhere in this section Accessory Power Supply Feed For power requirements to service additional devices to be added by Builders Upfitter the power supply source may be at either of the two fuse center output studs at the underhood fuse center Each stud
69. electrical system such that the operation of the completed vehicle is not com promised If there are questions regarding these or other vehicle interface recom mendations please contact General Motors High Idle Control Diesel Vehicles Only When it is desirable to increase the engine idle RPM when the vehicle is in Park or Neutral to facilitate the operation of a PTO or other electrical accessories there are pins on the diesel powertrain control module PCM which can be accessed to do so Connecting to and subsequently grounding either or both of the pins at the PCM de scribed in the following connecting guidelines and shown in the following illustration will cause the engine idle RPM to be raised to the values indicated below whenever the shift selector is placed in Park or Neutral Wire s from the PCM must be con nected to ground through a driver controlled switch s to be able to enable or dis able this high idle feature Note These are extremely low current circuits It is there fore very important that low energy switches be utilized for grounding these circuits The use of low energy switches will help to prevent future system failures that are caused by a film build up on the switch contacts e Plugging a terminated wire into cavity B 7 of the 24 pin brown Micro Pack connector at the PCM and grounding the other end of this wire lead through a Body Builder installed control switch will enable a high idle m
70. fuel vent hose should be shortened by an amount equal to that removed from the fuel fill hose that length should be taken from the fuel tank end only Aminimum of 8 0 inches of fill hose must be maintained between the filler neck and the fuel tank as measured in an outboard direction from the tank surface at the fill hose nipple to the outlet end of the filler neck 43 Both the fill and vent hoses must be routed and supported if needed such that there are no sags or kinks As viewed from the filler neck both hoses must be level or sloping downward toward the tank 6 Fuel fill hose clamps are to be driven to 19 25 Ibs in torque 7 Fuel fill vent hose clamps are to be driven to 13 18 Ibs in torque 8 If the application requires removal of the factory installed Diesel Fuel Only label the label must be replaced Figure 2 Pickup Box Removal Fuel Fill System Modifications Gasoline Parts are provided through your Chevrolet GMC Dealer to convert the fuel fill and vent system to meet the packaging requirements of the particular bodies that are installed on the chassis See page 39 for part numbers and diagrams Certain guidelines must be adhered to in modifying the fuel fill and vent system to en sure that the completed product meets the manufacturers requirements 1 The fuel fill and vent system must be installed such that there is adequate clear ance between the fuel fill and vent system and the tires unde
71. internal flow restrictors e Heater hose 3 way or 4 way valves must be used to provide constant water flow through the intake manifold pad area used to mount the TBI unit FORWARD LAMP HARNESS NOTE TBI unit does not have internal coolant passages e lfin line shut off valve is used in combination with way valves shut off valve must not be closed until 3 way valve at engine is in the proper position Section 13 Cooling Tae Soares W Red White Valve Corp Carson CA 213 549 1010 To provide satisfactory engine cooling the following conditions must be met 5 ay Ranco Controls Div Delaware OH 614 876 8022 1 Do not locate any large objects in front of the radiator core or grille such as batteries away Ranco Controls Div Delaware OH 614 876 8022 spare tires lights sirens etc They restrict air flow into the radiator core and influ ence fan blade stress Be sure to add coolant to system after adding capacity to system heaters 2 Grille opening size configuration and the external baffles provided should not be al tered in any manner Any reduction in cooling ability may adversely affect engine transmission performance CK Rev 12 98 Rev 11 99 C K Truck CURRENT C 30903 9000 GVWR Regular Cab 2 Wheel Drive w 6 5T Diesel Engine 4028 3 158 59 2130 1 609 6 83 86 24 00 MUFFLER 175 4 346 0 112 0 dr 13 62 441
72. operation when PTO is active 5 Remove Terminal Position Assurance TPA clip from front of connector CK Rev 12 98 Rev 11 99 130 Separated Function Stop Turn Lamps C K cab chassis vehicles are shipped from the factory with combined function stop turn lamps If separated function lamps are desired the brake lamp circuit must be deactivated and the stop lamps which are added at the rear of the vehicle by the Body Builder connected to the center high mounted stop lamp CHMSL wire as described below Note If this procedure is implemented there will be no capability to directly connect to a trailer with combined function stop turn lamps Procedure 1 the rear of the chassis there is a white wire taped back to the chassis harness just forward of the tail and stop lamp harness connector that is located near the intersection of the left hand frame rail and rear cross member This wire is pro vided to allow for the addition of a CHMSL center high mounted stop lamp with combined function lamps This wire can also be used as a feed for dedicated stop lamps if they are added to the vehicle This circuit can still be used to feed a CHMSL if so desired REAR LAMP WRG HARNESS EXTN REAR C MBR AUX CHMSL WIRE FRAME ASM HARNESS ASM TAIL amp STOP LP M Wl FRAME C K Truck CURRENT 2 In the underhood electrical center remove the Brake Lamp Relay from its sock et and remove the 30
73. shaft or its mounting the knee bolster or its mounting the steering wheel horn pad driver air bag mod ule or its mounting and covering passenger air bag module or its mounting or cov CK Rev 12 98 Rev 11 99 C K Truck CURRENT FMVSS 209 Seat Belt Assemblies The seat belt assembly provided by General Motors at any designated seating posi tion will conform to the standard providing no alterations or substitutions are made to the seat belt assembly attachment hardware Owner s Manual Instructions or seats provided For vehicles having GVWR of 8500 pounds or less the vehicle model number as shown on the label on the cover of this document must be included on the final stage manufacturer s certification label FMVSS 210 Seat Belt Assembly Anchorages This vehicle when altered will conform to FMVSS 210 providing no additional occu pant seats or seat belt assembly anchorages are added and no alterations are made which affect the function physical or mechanical properties environment location or vital spatial clearances of the components assemblies or systems identified below Seat belt systems including but not limited to Seat belt assemblies Seat position adjustment capability Seat belt anchorage brackets reinforcements Seat assemblies Floor pan assembly Seat belt routing FMVSS 212 Windshield Mounting GVWR of 10 000 Pounds or Less This Incomplete Vehicle when completed will conform to FMVSS 212
74. those compo nents 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 occupants in units completed by body builders Holes and openings through the floor and all other parts of the body must be permanently and adequately sealed by the body builder to avoid exhaust intrusion into any occu pant area If it is necessary to change the exhaust outlet location the exhaust dis charge must be unobstructed and directed away from occupant areas Alteration of the exhaust outlet or its position may increase exhaust noise and render the vehicle illegal in those areas with pass by noise regulations All vehicles 210 000 Ibs GVWR come under Federal noise regulations vehicles 10 000 105 GVWR are regulated by various state and local regulations of the Environmental Protection Agency see those regulations for rules test procedure and noise levels permitted Tail pipe outlet location must be tested statically and with the vehicle in motion to en sure that exhaust gases do not penetrate side or rear windows or under body seams and holes Auxiliary power plants should also be tested under the same conditions Tail pipe exit ahead of rear wheels is not recommended Check for leaks in exhaust systems and repair as required Exhaust temperatures can exceed 1600 F under extreme operating conditio
75. without EN 7 3 Band 790992 2 4 Hose Fuel Tank Filler 15640379 1 5 Hose Fuel Tank Vent 15640380 1 6 Clamp 3817244 2 7 Strap 15560979 6 8 Clamp 2464901 4 9 Bolt Screw 11514546 3 10 Asm 15671703 Rev 12 98 Rev 11 99 C K Truck CURRENT The following dimensions and diagrams should be followed when using the original Recommended Fuel Fill Access Zone fuel fill and vent system that was installed on the vehicle If the replacement fuel fill and vent system which is available from your Chevrolet GMC Dealer is used see the fuel fill system modifications on pages 39 40 10 50 C 100 200 300 11 50 12 00 K 100 200 300 13 00 NOTE Body Builder to trim fuel filler and vent hose to desired length Fuel and vent line must maintain a downward flow to fuel tank Hose must be installed so that no fuel may be trapped 15 0 TO REAR OF 18 0 NORMAL TOP OF FRAME CK Rev 12 98 Rev 11 99 C K Truck CURRENT Fuel Fill System Modifications Connector amp Label Diesel Vehicles Only Description Pipe Fuel Tank Fill 15958425 Instruction Fuel 15001539 Tank Fill Pipe Clamp Assemb 2 ly Fuel Tank Fill 3817244 Pipe 2 Fuel 14039900 1 Only 3 HOSE FUEL Label Diesel Fuel 52350605 1 Onl Only Canadian HOSE FUEL RETAINING BEAD HH FIGURE 1 TYPICAL INSTALLATIO
76. 0 0 256 0 P245 75R16 7200 SINGLE 622 0 50 0 870 0 364 0 42 5 232 0 400 0 256 0 P265 75R16 6100 6450 SINGLE 614 0 50 0 890 0 338 0 31 5 241 0 413 5 276 0 P265 75R16 6200 6800 SINGLE 602 0 50 0 878 0 326 0 25 5 249 0 413 5 276 0 LT245 75R16 6100 6450 SINGLE 614 0 50 0 870 0 358 0 42 5 232 0 400 0 256 0 LT245 75R16 6200 6800 SINGLE 602 0 50 0 858 0 346 0 36 5 232 0 400 0 256 0 LT245 75R16 7200 8050 SINGLE 622 0 50 0 878 0 366 0 42 5 232 0 400 0 256 0 CK Rev 12 98 Rev 11 99 C K Truck CURRENT C K 200 300 Rear Axle Tire Data Chart Pickup r H A fe m L ote Sle INSIDE FRAME 1005 64 59 59 WHEEL OFFSETS TRACK 9 RACK m F hat B C L SECTION 32 36 ROTATED 90 oS FOR DUAL WHEELS G DM 2 WHEEL OFFSETS F Es 34 74 SINGLE WHEELS TRACK INCHES TIRE CHAINS NOT TO USED DUAL WHEELS RR AXLE 9 5 RING GEAR MAX GROWN TIRE RADIUS ON NARROWEST RIM WITH K1500 AND LT265 75R16 TIRES OR A TRACK e RR AXLE 10 5 RING GEA
77. 08 5 27 03 7 1 73 8 21 a 87 51 2875 0 113 18 Ls 3205 0 126 18 FEX B 141 53 XE x 178 34 NOTES FRAME OUTLINE DIMENSIONS ARE SYMETRICALLY OPPOSITE ABOUT CENTERLINE OF VEHICLE PICKUP BOX MOUNTING HOLES ARE MARKED THUS N 8 PLACES INCHES CK Rev 12 98 Rev 11 99 C K Truck CURRENT 1 2 3 0953 Extended Cab Pickup Crossmember Arrangement FRONT WHEELS A 4993 0 77 196 57 A 4588 0 IN Oi 46 26 MG5 M50 084 5 42 70 MT 1 42 64 44 98 10 87 43 73 M30 ONLY LH CENTERLINE IS 56 9 2 24 FORWARD OF RH CENTERLINE CK Rev 12 98 1883 0 1983 0 Rev 11 99 3290 0 129 53 2711 2 106 74 175 5 116 0 1237 160 0 4 6 91 jS 4 57 FRONT WHEELS 6 50 2 68 119 9 5 36 7 24 l a Dahi F3 L p 1 18 NORMAL ds OF FRAME 680 2 2753 4 26 87 108 40 BE 6 REAR AXLE 105 77 3230 0 127 17 3560 0 m 140 16 3950 0 155 50 5010 0 197 24 C109 209 FRAME OUTLINE SYMMETRICALLY CENT
78. 17 50 CENT 50 0 0 OF 1 18 930 4 36 63 CENTE OF VE Z o 990 2 38 99 1465 0 57 68 lt 1969 0 77 52 3984 560 4 22 06 OUTSIDE 2589 5 NORMAL TOP OF FRAME 101 95 1000 1109 6 43 56 210 0 8 27 500 49 500 4 237 4 238 9 35 198 8 7 85 FRAME RAIL METAL THICKNESS 4 4 mm CK Rev 12 98 Rev 11 99 100 C K Truck CURRENT 2984 5 WHEELBASE 117 90 686 4 27 02 CENTERLI OF ENGIN 930 4 55 535 CENTERL INE OF VEHICLE 7 990 2 319 3 38 99 12 57 1465 0 57 68 1969 0 77 52 2589 5 593 4 23 36 101 95 OUTSIDE MET NORMAL TOP FRAME RAIL METAL THICKNESS 4 mm CK Rev 12 98 Rev 11 99 C K Truck CURRENT
79. 26 87 84 59 5 29 1 680 2 4 2076 6 2 jc 26 78 81 76 575 0 542 0 2620 0 22 64 103 15 e ct 4 2950 0 bun o 2 as 116 14 a n M30 LH 55525 466 0 3340 0 19 88 18 35 131 50 1400 0 4400 0 55 11 173 23 1175 17 46 26 IM 21 09 0 2 85 0 30 ONLY CENTERLINE IS 56 9 2 24 1084 50 42 70 a C209 W C6P 309 FORWARD OF RH CENTERLINE 1 106 10 1142 64 44 98 22 2915 0 109 209 WO C6P SAI PICKUP BOX MOUNTING HOLE LOCATIONS MARKED 1110 87 43 73 3288 5 FRAME OUTLINE DIMENSIONS ARE THUS A 8 PLACES DIMENSIONS OF MOUNTING 189 423 SYMMETRICALLY OPPOSITE ABOUT HOLES ARE SYMMETRICALLY OPPOSITE ABOUT 4194 0 CENTERLINE OF VEHICLE CENTERLINE OF VEHICLE INCHES m 165 12 CK Rev 12 98 Rev 11 99 82 C K Truck CN 4383 30 2680 0 172 56 105 51 amp REAR WHEEL 3978 0 1992 4 NORMAL 156 61 78 44 208 5 OF FRAME 125 0 8 21 a 0 4 84 190 0 98 70 7 48 CN 2027 0 FRONT WHEEL 2 1 79 8 Fy L L 15 M30 MG5 M50 EY uL Do 990 2 38 98 or MT1 MW3
80. 3 9 85 CK10906 1763 4 68 64 20906 293 3 11 55 CK20903 577 3 22 73 CK10906 7327 1020 2 40 16 CK20906 28 85 250 3 9 85 10906 293 3 11 78 CK20906 916 0 B 36 06 A 460 ES 1 7 301 2 11 86 CK10906 132 3 181 4 7 14 20906 5 21 177 7 7 00 10906 260 4 10 25 20906 2 7 0 12 10906 2 3 0 09 C1 20906 BELOW INSIDE METAL BELOW INSIDE METAL 30 3 1 19 K10906 TO TOP OF MUFFLER ABOVE INSIDE METAL 30 7 1 21 K1 20906 15 3 0 60 C20906 ABOVE INSIDE METAL 48 3 1 90 K20906 TO TOP OF MUFFLER INSIDE METAL TO TOP OF CONVERTER 4 L RA ja ______ 2 10 0 5 0 02 10906 BELOW INISDE METAL 317 5 32 5 1 28 K10906 12 50 ABOVE INSIDE METAL 41 7 1 64 C20906 8 7 0 34 K20906 INSIDE METAL TO TOP C20906 amp L31 L29 SHOWN OF CONVERTER INCHES UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO INSIDE OF METAL CK Rev 12 98 Rev 11 99 C K Truck CURRENT C K 30943 Crew Cab 5 7L Gas Engine Option L31 and 7 4L Gas Engine Option L29 635 0 3071 1 m Vene MUFFLER 1709 2 293 3 m 688 3 67 29 11 55 27 10 1020 2 40 16 293 3 11
81. 346 0 1516 5 1008 DRAWING 7 6203 1714 362 ee ar 0910 6 75 REFER TO FUEL 35 41 75 63 21265 C31403 1300 5 ee 796 0 e TANK DRAWING 51 20 ner 31 34 REFER TO BODY DRAWING ENGIN Do 890 6 OE ENGINE 374 1 14 73 u 0 i 1 18 Z p See 35 06 383 0 OF FRAME 3392 M m Bos SE 2 i 15 08 n NORMAL MUFFLER E rH 1297 2 OF FRAME 1 yr sale 51 07 20 0 50 0 1 ec PH 79 1 97 Sern Er m 2 gt VEHICLE i 1 QRE ECL e L 7 ED Rey um 15 unm AY 1 4 50 8 UE 1 153 2 9 75 2 00 5 30 13 4 0 53 6 03 T 956 0 OF REAR AXLE TOP OF CONVERTER C OF FRONT His Ll 87 64 77 L 378 6 14 91 WHEELS WHEELS REAR STABILIZER TOP OF FRAME TO 18 0 DIA BODY BILIZER 61 CENTERLINE MOUNTING HOLES TAILPIPE 1581 8 2 2 3437 5 135 33 C31003 ra 62 25 4047 5 159 35 C31403 WHEELBASE DATA BASED ON C31403 8 165 INCHES UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE TO OUTSIDE OF METAL MINIMUM CUT OFF LENGTH RELOCATE REAR CROSSMEMBER AS PROVIDED CK Rev 12 98 Rev 11 99 C K Truck CURRENT K 310 314 03 Chassis Cab Regular Cab 4 Wheel Drive 12 000 GVWR w 6 5T Diesel Engine 4109 5 161 7
82. 35 0 a 1063 4 n 143 11 41 87 D 113 78 1043 0 2218 4 1400 0 87 94 55 11 638 0 1185 8 46 69 25 42 MT1 BOX MTG 1217 6 47 93 SLOT as amp OF ENGINE Dx LO 1 175 5 682 3 4280 0 550 8 6 91 7 26 86 168 50 21 69 I M TO I M 3041 2 833 0 32 80 119 733 BOX MTG BRKT 2967 0 107 5 116 81 764 5 4 23 589 0 r M TO INSTDE MN OF FRAME I 2c i m A ae 783 8 L 30 86 3 5 162 5 0 14 6 40 TOP OF BOX MOUNTING NOTES BRACKET TO INSIDE OF FRAME INCHES 3016 66 118 77 C30943 SHOW 226 0 8 90 UNLESS OTHERWISE TOPOF CROSSMEMBER SPECIFIED A DIMENSIONS 1000 TO INSIDE TOP OF FRAME 5280 ARE TO INSIDE OF METAL CK Rev 12 98 Rev 11 99 5655 0 C K Truck CuRRENT 1063 4 K 30943 Crew Cab Pickup Crossmember Arrange
83. 441 0 2441 0 1961 0 77 20 96 10 96 10 77 20 549 0 681 0 681 0 549 0 21 61 26 81 26 81 21 61 B 1998 0 2478 0 2478 0 1998 0 78 66 97 56 97 56 78 66 E 1154 0 1154 0 45 43 45 43 1827 5 2307 5 2307 5 1827 5 71 95 90 85 90 85 71 95 2095 0 2575 0 2575 0 2095 0 82 48 101 38 101 38 82 48 3595 0 3340 0 3950 3925 0 141 50 131 50 155 51 154 5 7 1064 0 1419 0 1419 0 1064 0 41 89 55 87 55 87 41 89 194 2 397 0 397 0 194 2 7 65 15 63 15 63 7 65 5550 9 5420 9 6030 0 5880 9 218 54 213 42 237 40 231 53 1056 5 1181 5 1181 5 1056 5 41 59 46 52 46 52 41 59 35 0 35 0 35 0 35 0 1 38 1 38 1 38 1 38 Rev 12 98 Rev 11 99 C K Truck CURRENT C K 109 209 06 Suburban Interior Sheet Metal 1524 53 52 15 SR 1 1 1213 64 1125 77 1150 0 190 87 l 177 44 24 45 51 7 51 Sy 1 12 1632 0 1299 05 1664 04 p 65 51 64 25 51 14 SECTION C C SECTION A A SECTION B B 15 4 60 0 2 37 LJ LJ 237 0 48 70 7 120 3 A 4 74 gt D I VIEW IN CIRCLE E ROOF BOW 3 PLACES DAT T 254 0 1078 17 10535 58 BB 42 45 pn Em 89 73 3 53 Y Lo vr d T
84. 55 oO Q pol _ _ J Am 916 0 26 06 CUT Ly 181 4 252 4 134 3 7 14 9 94 5 29 1 30 0 05 K30943 ABOVE INSIDE METAL TO TOP OF FRAME 357 5 31 7 1 25 30943 14 07 BELOW INSIDE METAL TO TOP OF CONVERTER N 2 Muse d eS J i I EL e 58 4 2 31 C30943 91 4 3 60 30943 INSIDE METAL 15 3 0 60 C30943 OF FRAME TO TOP 348 0 48 3 1 90 K30943 OF SHIELD 13 70 INSIDE METAL TO TOP OF CONVERTER C30943 amp L31 L29 SHOWN INCHES UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO INSIDE OF METAL CK Rev 12 98 Rev 11 99 C K Truck CuRRENT C K 310 314 03 Chassis Cab 10 000 and 12 000 15 GVWR 5 7L Gas Engine Option 131 and 7 4L Gas Engine Option 129 2311 1 90 99 CK310 2921 1 115 00 CK314 1674 4 635 0 65 92 25 00 5 E _ 702 4 27 65 1020 2 40 65 293 3 11 55
85. 57 10 10000 DW ves 15 75 t 9 14 7 124 K 20953 8600 SW JB7 JD7 12 48 52 78 83 106 52 106 K 30953 9200 SW JB8 15 48 46 70 80 104 50 101 K 30943 9200 SW JB8 15 48 75 100 96 124 75 124 30953 10 000 DW JB8 12 48 59 86 89 116 59 SW Single Wheel JB5 and JB essel Vacuum Powered Diaphragm Booster DW Dual Wheel 8 5 Hydraulic Boosters C G Center of Gravity Brake System lt lt a C 10953 C 20953 C 30903 C 30903 C 30943 C 30943 C 30943 C 30953 C 30953 6200 ii ng dd a 48 FMVSS 106 Brake Hoses This vehicle when altered will conform to FMVSS 106 providing no alterations are made which affect the function physical or mechanical properties environment loca tion or vital spatial clearances of the components assemblies or systems identified below Hoses and hose end fittings Labeling requirements FMVSS 108 Lamps reflective Devices and Associated Equipment This vehicle when altered will conform to FMVSS 108 if it is completed with a body over 80 inches wide providing the following conditions are met 1 Each of these devices must be properly installed on the completed vehicle and meet all the requirements of FMVSS 108 a The following devices when provided located and or wired by General Motors meet the requirements of th
86. 7 E 340 0 13 39 SPECIFIED ALL DIMENSIONS 1346 0 BOTTOM OF MUFFLER ARE TO INSIDE OF METAL 4 52 99 TO INSIDE TOP OF pu DE TOP OF CAB FRAME legem cT TO INSIDE TOP INSIDE METAL TOP OF FRAME 5 C Een OF FRAME CENTERLINE OF REAR AXLE 764 5 y Te Aa eS COME OS eS NN Lay J IN FA H S 348 0 os 13 70 CK Rev 12 98 Rev 11 99 C K Truck CURRENT 310 314 03 Chassis Cab Regular Cab 2 Wheel Drive 10 000 11 000 GVWR w 6 5T Diesel Engine 4109 5 161 79 C310 4719 5 185 81 C314 2203 0 86 73 C310 _ 609 6 2820 3 BBC gt OF REAR AXLE CROSSMEMBER 2813 0 110 75 C314 24 00 111 03 F ARRANGEMENT 1575 5
87. 7 5 125 25 131 31 138 88 141 41 146 46 151 51 1315 123 23 127 27 132 32 137 37 141 41 146 46 135 5 122 22 127 27 131 31 135 35 140 40 144 44 1415 121 21 125 25 130 30 134 34 138 88 142 42 155 5 119 19 123 23 127 27 131 31 135 35 139 39 159 5 119 19 123 23 126 26 130 30 134 34 138 38 183 5 116 16 120 20 123 23 126 26 129 29 Example Wheel base When mounting equipment with the center of gravity 30 inches ahead of the front axle centerline on a truck with 131 5 wheelbase the chart indicates the front rear percent ages to be 123 23 If the front mounted accessory weighs 150 Ibs the front axle is equal to 150x1 23 or the weight is decreased by 23 or 150x0 23 which equals 33 lbs In effect the weight on the front axle is increased by the weight of the equip ment and payload plus the weight transferred from the rear Rear Mounted Accessories Front Rear Weight Distribution for Equipment Mounted Behind Rear Axle Wheel Overhang Center of Rear Axle to the Equipment Center of Gravity base 30 36 42 48 117 5 25 125 31 131 38 138 41 141 46 146 51 151 131 5 23 123 27 127 32 132 37 137 41 141 46 146 135 5 22 122 27 127 31 131 35 135 40 140 44 144 141 5 21 121 25 125 30 130 34 134 38 138 42 142 155 5 19 119 23 123 27 127 31 131
88. 8 15 94 Bis INSIDE TOP OF RAIL BOTTOM OF SHIELD BASED ON C31003 amp 129 amp C5B INCHES CK Rev 12 98 Rev 11 99 114 D ENTERLINE HICLE QC lt 58 38 57 09 _ 29 135 1000 e 406 5 560 4 22 06 n E 16 00 OUTSIDE METAL NORMAL 4 55 OUTSIDE TOP OF OF FRAME FRAME TO BOTTOM OP E 15 20 c 427 3 OF TAN 15 527 OUTSIDE T P OF FRAME TO BOTTOM OF SHIELD e 500 Em E FT 7 500 JG A 5 59 Jes UE 29 5 GALLON s Ll 10 68 29 4 GALLON DRAW CAPACITY OUTSIDE OF METAL OF FRAME AT OF AXLE CK Rev 12 98 Rev 11 99 C K Truck CURRENT 115 K 10706 4 Wheel Drive Utility fe ENTERL INE HICLE QC lt
89. 9 K310 REPER TO 5 2203 0 86 73 310 298 609 6 CROSSMEMBER 2813 0 110 75 K314 24 00 1575 5 346 0 890 8 one 62 03 PT 13 62 35 07 171 4 145 0 6 75 5 71 e 796 0 mE Eg 2 EN NE 31 34 1 aN l Jon 1 8 IN 2 L7 4 T Sh f a la 1 2 Lr 1 HN c od pum 4 GAS N r pj 2 HILL 151 0 Jf J N88 s FRONT T WHEELS D REFER TO FUEL 2 00 TANK DRAWING 956 0 orn m CK Rev 12 98 Rev 11 99 18 0 DIA HOLES BODY MOUNTING OF REAR AXLE 1 2820 3 111 03 ie
90. A 316 5 12 46 222 6 INSIDE OF METAL 8 76 TO CENTERLINE INSIDE METAL NOTES OF TAILPIPE TOP OF FRAME 1000 2 3832 gt INCHES MUFFLER UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO INSIDE OF METAL CK Rev 12 98 Rev 11 99 C K Truck CURRENT 29 EXHAUST DRAWING REFER TO FRAME DRAWING REFER TO SPARE IRE CARRIER DRAWING REFER TO HITCH DRAWING REFER FUEL TANK DRAWING ER TO BODY DRAWING REAR AXLE FRONT AXLE CK Rev 12 98 Rev 11 99 C K Truck CURRENT Pickup Cargo Box Weight Distribution WB OAL 117 50 194 52 131 50 213 42 1 38 Cab to Pickup Box 35 41 WB OAL 141 50 218 54 155 51 237 43 Pickup Cargo Box Weight Distribution Wheelbase in 117 5 C K 1500 1155 eS ____ _ _______ _____ EL 7 SCS C K 2500 141 5 155 5 R s C K 3500 388 Rev 12 98 Rev 11 99 C K Truck CURRENT Chassis Cab Body Cargo Weight Distribution
91. ARE FOR DIESELS ONLY CK Rev 12 98 Rev 11 99 C K Truck CURRENT K 30903 9200 GVWR Regular Cab 4 Wheel Drive w 6 5T Diesel Engine 3963 0 TIRE CARRIER 156 02 CROSSMEMBER 5299 4 OVERALL 4028 3 208 74 158 59 2820 3 1419 0 83 86 gt T 111 03 55 87 1577 3 sie 346 0 24 00 899 4 TEF 62 10 227 9 13 62 MUFFLER 136 2 35 41 ue 4 m 5 36 gt d 8 97 112 0 5 36 ZCRANK 15 08 REAR FACE 1616 0 T _ TES Ew OFENGINE essa A EE i qs e EI
92. AXLE B SECTION uu Z 256 sasa 1 i i A 71 6 2 82 NOTES TOP OF FRAME _ INSIDE INCHES OF METAL CK Rev 12 98 Rev 11 99 96 C K Truck CURRENT SECTION MODULUS 10 14 IN SECTION MODULUS 21 1 IN SECTION MODULUS 18 86 IN RBM 355 000 IN LB RBM 738 000 IN LB RBM 660 000 IN LB 73 6 T 58 0 2 90 58 0 73 6 2 28 2 28 58 0 92 C gt 2 gt t 57 6 7 6 TYP 7 6 TYP 27 2 97 Reed SEC B B 299 sec c c 299 a 1276 4 50 25 _ FRONT AXLE D FRONT AXLE _ SS C O FRONT AXLE J R A i LL ORR ee P T rh HH lt C31003 ONL D AP iu poe AER de i ps am amp 3 an 20 REINFORCEMENT SUSP BRKT a L 5 AL
93. BE PART NUMBER 12346190 FOURTH ee 12346191 GAL i LUBE CAPACITY 8 5 PINTS 12547885 BULK FIFTH D 75 SERIES C C20903 amp 96 9 TABLE OF POWER TAKE OFF DRIVE GEARS 81 25 3 81 TRANSMISSION MODEL SAE NUMBER OF NORMAL PITCH ANGLE amp NORMAL REDUCTION C20953 amp C6P 97 7 PTO TEETH PITCH DIAMETER HAND OF PRESSURE AT PTO C30953 3 85 OPENING HELIX ANGLE DRIVE GEAR K20903 amp C6P 63 9 30903 2 52 eet 30 7 9366 4 3647 30 RH 22 4987 579 K20953 amp C6P 64 7 Pu 2 99 PTO GEAR PITCH LINE DISTANCE PTO DISTANCE DISTANCE DIRECTION C31003 5 98 1 1000 RPM VELOCITY OF GEAR MOUNTED FROM PAD FROM OUTSIDE OF C31403 C5B 3 86 ise SPEED INPUT PTO 1000 FACE FROM SHAF CENTERLINE CARE MACHINED ROTATION RANS RPM INPUT CENTERLINE OF GEAR SURFACE K31003 C5B 65 1 FT MIN OF OPENING TO PITCH LINE K31403 C5B 2 56 DIM A OF GEAR 12 40 INCHES 579 675 0 488 COUNTER 3 296 Ci FORWARD CK Rev 12 98 Rev 11 99 C K Truck CURRENT 310 314 318 03 Power Take Off PTO Transmission TAKE OFF OPENING LOCATION TRANSMISSION MWS OF FRONT WHEELS L OF TRANSMISSION 50 0 PIPE ASSEMBLY 1 18 EXH MANIFOLD A OF VEHICLE NORMAL TOP OF FRAME 26 7 1 05 C 310 314 318 Ei z N Y 4 C dy
94. C K Truck CURRENT BODY BUILDERS INSTRUCTIONS The Incomplete Vehicle Document IVD is supplied with each incomplete vehicle and provides information that should be used by intermediate and final stage manufacturers in determining conformity to applicable Federal Motor Vehicle Safety Standards FMVSS The IVD also includes information which must be followed in order to ensure that Environmental Protection Agency EPA and California emissions certification requirements and NHTSA Fuel Regulations are met This Body Builders Book contains information that may be used in addition to the for any manufacturer making alterations to a complete incomplete vehicle No alter ation should be made to the incomplete vehicle which either directly or indirectly re sults in any component assembly or system being in nonconformance with any appli cable Federal Motor Vehicle Safety Standard or Emission Regulation Intermediate and final stage manufacturers should be familiar with all Federal Motor Vehicle Safety Standards and Emission Regulations and aware of their specific responsibilities as manufacturers For further assistance contact Upfitter Integration at 1 800 875 4742 Section 0 General Instructions Check for proper clearance between body members and chassis components which may in any way affect the reliability and performance of the vehicle by developing abrasion and wear points from moving parts or degradation from extreme en
95. ERLINE OF C209 W C6P 309 WO C6P DIMENSIONS ARE OPPOSITE ABOUT VEHICLE PICKUP BOX MOUNTING HOLE LOCATIONS MARKED THUS 8 PLACES DIMENSIONS OF MOUNTING HOLES ARE SYMMETRICALLY OPPOSITE ABOUT CENTERLINE OF VEHICLE INCHES C K Truck CURRENT K 1 2 3 0953 Extended Cab Pickup Crossmember Arrangement qc 2 OF FRONT WHEELS OF REAR WHEEL 196 57 m L 4588 0 m NORMAL TOP OF FRAME 180 63 ae 3305 0 5 130 12 126 5 4 4 50 4 98 120 0 C 3147 0 123 0 4 7 48 4 72 M30 MG5 122 72 4 84 M50 MW3 CN 2637 0 j 990 2 38 98 103 82 828 0 E MT1 MW3 24 60 am i 1059 0 41 69 448 5 n T m 208 5 27 035 aa 8 21 575 0 708 0 22 64 27 87 1150 0 OF d gd ep lA OF FRONT WHEELS K209 W C6P 309 K109 209 WO C6P INCHES FRAME OUTLINE DIMENSIONS ARE SYMETRICALLY OPPOSITE ABOUT CENTERLINE OF VEHICLE PICKUP BOX MOUNT INC HOLES ARE MARKED THUS 8 PLACES CK Rev 12 98 Rev 11 99 C K Truck CURRENT 87 36
96. ESEL EXHAUST DIMENSIONS 189 8 85 63 48 43 NORMAL FOR 20753 ONLY OF FRAME 7 47 ENGINE OPTION DIM L56 2301 3 AA 96 57 1 leo 609 6 24 00 NOTES 303 cc INCHES 340 a VIEW IN DIRECTION DD 1243 7 UNLESS OTHERWISE SPECIFIED OF ARROW Z 48 96 ALL DIMENSIONS ARE TO OUTSIDE 346 0 OF METAL 13 62 CK Rev 12 98 Rev 11 99 C K Truck CURRENT K 107 207 53 Extended Cab 4 Wheel Drive w 6 5T Diesel Engine 3430 3 BBC 1064 0 135 05 41 90 899 4 8830 DD EE 175 4 e 35 41 15 08 6 90 MUFFLER REAR AXLE REAR FACE
97. L 1771 0 127 0 274 4 10 80 228 0 8 98 C31803 LT225 70R19 5 15000 DUAL 1771 0 127 0 274 4 10 80 228 0 8 98 MINIMUM GROUND CLEARANCE TO BE CALCULATED BY USING GROSS AXLE WEIGHT AND RECOMMENDED TIRE PRESSURE INCHES CK Rev 12 98 Rev 11 99 106 C K Truck 3500HD Rear Suspension Hanger Bracket Locations Chassis Cab 15 000 GVWR SYMMETRICAL ABOUT CENTERLINE HANGER REAR SPRING FRONT mm F Un REAR AXLE N l d emo sem z A D if FRAME a wry N o mm N HANGER REAR SPRING REAR E SUPPORT REAR 2 N REAR SPRING FRONT 200 4 SUPPORT RE HANGER b SPRING REAR 91 4 _ 7 89 HANGER 5 60 190 4 VIEW IN DIRECTION VIEW IN DIRECTION 7 50 OF ARROW A OF ARROW B 60 0 2 01 30 6 1 20 2 36 gt HB
98. L DIMENSIONS ARE MM INCHES MODEL A B C D FRAME 51005 1562 20561 27 TO eee RAIL C31403 1886 74 25 45 3305 0 130 12 C31803 2496 98 27 45 5305 0 150 12 5915 0 154 13 CK Rev 12 98 Rev 11 99 C K Truck CURRENT 10516 Utility 2 Door Arrangement 26 78 WHEELBASE CENTERLINE 30 OF REAR AXLE RH Pl c 460 8 18 14 921 6 36 28 wo M30 LH le NL 944 5 31 19 e M30 RH 223 0 1035 17 40 75 8 78 MG5 1084 5 42 7 1400 0 746 0 084 5 42 70 55 12 29 37 2660 0 982 5 144 0 104 72 38 68 5 51 INS DE M30 ONLY 2588 0 TO INSIDE METAL LH CENTERLINE 101 89 TOP OF FRAME 5 56 9 2 24 FORWARD OF RH UE IM E EN CENTERL INE 84 70 33 13 OF METAL UNLESS 2680 9 S SPECIFIED 105 55 Rev 12 98 Rev 11 99 98
99. N HOUSING FUEL TANK HOSE FUEL VENT FIGURE 2 LABEL INSTALLATION Pickup Box Removal Fuel Fill System Modifications Diesel Parts are provided through your Chevrolet GMC Dealer to convert the fuel fill and vent 1 The fuel fill and vent system must be installed such that there is adequate clear system to meet the packaging requirements of the particular bodies that are installed ance between the fuel fill and vent system and the tires under all operating condi on the chassis See pages 40 and 42 for part numbers and diagrams tions Body attachment brackets and U bolts must also be located such that there is adequate clearance to all fuel system components such as the fuel lines and Certain guidelines must be adhered to in modifying the fuel fill and vent system to en the fuel level sending unit under all operating conditions sure that the completed product meets the manufacturers requirements CK Rev 12 98 Rev 11 99 C K Truck CURRENT 2 Splice joint tube 2 0 inches dia x 3 0 inches long may be used to adjust the length and orientation of hose between the two 90 bends To do this the hose should be cut the required length removed and the remaining two sections of hose reassembled using the splice joint The hose sections must be pushed over the retaining bend and up to the stop bead in the center of the splice joint The two clamps are to be placed between the retaining beads and the stop bead Fig ure 1 The
100. NSIDE METAL TO CENTERLINE TO BOTTOM OF TAILPIPE OF MUFFLER C318 amp L29 SHOWN INCHES UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO INSIDE OF METAL CK Rev 12 98 Rev 11 99 124 C K Truck CURRENT C K 10516 w 5 7L Gas Engine Option L31 1915 5 LL 5588 75 41 di 22 00 1076 3 595 0 42 37 gt r 23 43 577 6 250 3 q 22 74 9 85 i 9 85 T A X9 916 0 I 36 06 E zo 102 6 177 5 4 04 6 99 2 1 0 08 C10516 7 0 0 27 35 1 1 38 K10516 40 0 1 58 INSIDE METAL K10516 TO TOP OF INSIDE METAL MUFFLER TO TOP OF CONVERTER 3 Nd Ss 316 5 5 0 0 20 10516 12 46 38 0 1 50 K10516 INSIDE METAL TO TOP OF CONVERTER 10516 8131 SHOWN INCHES UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO INSIDE OF METAL CK Rev 12 98 Rev 11 99 C K Truck CURRENT 125 C K 10706 w 5 7L Gas Engine Option L31
101. OF ARROW Y ALL DIMENSIONS ARE TO OUTSIDE OF METAL C K Truck CURRENT 20953 amp 8600 GVWR C 30953 9000 GVWR Extended Cab 2 Wheel Drive w 6 5T Diesel Engine te 4638 3 E CRANK 182 61 2656 3 609 6 3430 3 REAR AXLE 104 58 d 24 00 n 135 05 g 899 4 ES 1243 7 La 3460 S 1419 0 NORMAL TOP 48 96 13 62 55 85417 22 REAR FACE 55 87 gt OF FRAME 7 OF ENGINE 1296 8 301 4 175 4 916 0 15 08 15247 51 06 11 87 161 8 6 91 36 06 NE ditm 48 81 221 8 6 37 136 0 c 156 3 660 0 8 73 a Eo 5 35 1 59 8 6 15 25 98 EE Te 1 2 35 I i PEE
102. ONAL p s l DUAL REAR TIRE 1 E r 1 1 FOR ADDITIONAL INFOR 19494 OVERALL INSIDE 1572 0 MAION SEE CAB PAGE 7675 WIDTH 1620 0 WIDTH 61 89 CHASSIS AND 63 78 CHASSIS 53 MODEL 2 FLANGE H 1656 0 BETWEENISTAKE g i 65 20 POCKETS 1632 5 INCHES BETWEEN 1 64 72 1679 0 STAKE 66 10 POCKETS 1644 0 64 72 M 49 0 e ee uL s Y 1 93 gt f _ n J 53 0 ALL STAKE POCKET 2 09 OPENINGS ARE APPROX 134 5 1154 0 1153 5 37 7 X 53 7 5 30 45 43 45 41 1 48 2 11 124 3019 7 TAIL GATE 118 89 OPENING TOP i 2441 0 1574 4 96 10 L506 61 98 W204 LI ue 55 87 49 06 W201 22 397 0 550 0 T 45 63 21 65 25 35 0 681 1 38 779 85 35 26 81 po o 277 1545 154 5 85 5 up TOP OF 3 37 deir 7 10567 ee 8 0 597 BEAD 2 i 41 60 0 31 all _ 253 0 ee a 9 96 Er O 2 N N 1 0 43 H504 SS TT 3f m q ud 400 V ii 19 29 __ AM Y I ge IH503 68 7 4 GAS FILLERDOOR 2 70 1530 0 RR STAKE GROUND LINE 1443 60 24 im 5 68 1636
103. PECIFIED ALL DIMENSIONS ARE TO INSIDE OF METAL CK Rev 12 98 Rev 11 99 C K Truck CURRENT C K 1 2 07 09 03 53 Pickup 5 0L Gas Engine Option L30 _ 635 0 AR 25 00 687 9 222 9245 Gea 27 10 604 5 23 82 7 916 0 5 36 09 I TV D E oo 48 1 VEHICLE MODEL AA 249 1 132 8 1690 4 5 23 9 81 5 23 C K10703 66 55 1 20753 5057 335 9 13 22 INSIDE METAL l AS E OF FRAME TO BOTTOM a 9 0 F MUFFLER 55 4 INSIDE TOP OF FRAME 10953 104 54 OF CONVERTER ME r cob e G OF REAR AXLE M 76 5 3 01 C FRAME 13 71 109 5 4 31 K FRAME FRONT WHEELS 0 7 0 07 C FRAME 33 7 1 33 K FRAME CK Rev 12 98 Rev 11 99 C K Truck C K 1 2 07 09 03 53 Pickup 5 7L Gas Engine Option L31
104. R MAX GROWN TIRE WIDTH ON WIDEST RIM RPO ROS DUAL REAR WHEELS TRACK SERIES TIRES GVW RANGE REAR WHEEL TRACK DIM A DIM B DIM C DIM D DIM E DIM DIM G C2500 LT225 75R16 7200 SINGLE 616 0 13 0 855 0 377 0 50 0 253 0 384 0 239 0 LT245 75R16 7200 SINGLE 616 0 13 0 872 0 360 0 41 5 270 5 400 0 256 0 K2500 LT225 75R16 7200 SINGLE 622 0 50 0 861 0 383 0 53 0 223 5 384 0 239 0 LT245 75R16 7200 SINGLE 622 0 50 0 878 0 366 0 44 5 238 0 400 0 256 0 C2500 LT245 75R16 8600 SINGLE 624 0 7 0 880 0 386 0 53 5 221 0 400 0 256 0 K2500 LT245 75R16 8600 SINGLE 624 0 7 0 880 0 386 0 53 0 212 5 400 0 256 0 C2500 LT245 75R16 8600 SINGLE 652 8 7 0 908 8 414 8 67 9 221 0 400 0 256 0 K2500 LT245 75R16 8600 SINGLE 652 8 7 0 908 8 414 8 67 9 212 5 400 0 256 0 C3500 LT245 75R16 9000 9600 SINGLE 634 0 7 0 890 0 396 0 58 0 221 0 400 0 256 0 K3500 LT245 75R16 9200 SINGLE 634 0 7 0 890 0 396 0 58 0 212 5 400 0 256 0 C3500 LT225 75R16 10000 DUAL 853 0 127 0 2343 0 363 0 60 0 171 0 384 0 236 0 490 0 7 50 X 16LT 10000 DUAL 853 0 127 0 2343 0 363 0 60 0 201 5 430 0 236 0 490 0 K3500 LT225 75R16 10000 DUAL 853 0 127 0 2343 0 363 0 60 0 161 5 384 0 236 0 490 0 7 50 X 16LT 10000 DUAL 853 0 127 0 2343 0 363 0 60 0 192 0 430 0 236 0 490 0 CK Rev 12 98 Rev 11 99 C K Truck CURRENT C K 300 Rear Axle Tire Data Chart Chassis Cab
105. R15 6800 SINGLE 500 0 8122 So Wiz 7200 SINGLE 500 0 Yu EE 7 T7455 239 0 9 41 C20053 LT245 75R16 7200 SINGLE 500 0 7 0 209 3 18500 256 0 10 08 LT245 75R16 8600 SINGLE 607 0 1 38 204 2 8 04 256 0 CIO 053 C20906 LT245 75R16 8600 SINGLE 607 0 FO 219 7 18 64 256 0 10 08 1225 7 75516 0000 DUA B35 0 27 D 194 1 7 64 22900 19 4 c30900 LT2457 7 R10 3000 SINGLE 607 0 EE 204 2 8 04 25B 0 10 08 7 50 18LT 0000 DUA 27 0 228 8 15 93 244 0 8 6 12257 I 9600 SINGLE B07 0 TD 189 3 7 45 239 0 9 4 0000 DUAL 635 0 27 0 188 6 7 43 254 0 See LT245 75R16 9000 SINGLE 607 0 7 0 201 5 17 55 256 0 10 08 7 20 A 0000 DUA 635 0 27 0 222 1 158 74 244 0 9 6 mmm LT225 75R16 10000 11000 DUA 6350 27 0 Sint 7 52 2540 Sse T EDIBE 10000711000 UA SEN 27 0 222 18 74 244 0 18 8 m LT225 75R16 10000711000 DUA 635 0 FA BIST X7152 234 0 15 2 Zar 10000711000 635 0 2750 222 1 15 74 244 0 8 8 CK Rev 12 98 Rev 11 99 104 C K Truck CuRRENT K 1500 2500 3500 Front Axle Tire Data Chart 4 Wheel Drive DERI TIRE WIDTH lt amp
106. RY LEFT SIDE 5 16 2 19 0 BRED 2 5 0 RUST S2 FUSIBLE LINK 50 0 BLK 50 0 5 0 RUST FUSIBLE LINK 2 TO TACH IN CLUSTER SEE SHEET 7A REGULATOR TO ALT TT 12052641 12162000 IN CLUSTER SEE SHEET 7A 12047950 13 0 RED 2 M8 OR 5 16 90 0 BLK 2 3 0 RUST 2 52 0 DIESEL GLOW PULL IN PLUG MODULE AU SOL ON TRL WRG FOEDE UN START MTR 777 6 5 0 PPL AUTO 6 5 0 PPL MAN PRIMARY BATTERY RIGHT SIDE STRAP UNDERHOOD EQUIV TO 50 0 CABLE ELECTRICAL CURRENT CAPACITY CENTER 50 0 BLK 55505550555 25525555552 SESSION ae 9900090 525525505550 XXX XXX XX ENGINE GROUND RFRAME BODY GROUND GROUND CK Rev 12 98 Rev 11 99 134 Controls If itis desirable to activate the OEM A C system compressor from secondary mote switch care must be taken to insure that the OEM pressure switches are still active in the system to maintain proper compressor cycling action and ov
107. Truck CURRENT K 30943 Crew Cab 4 Wheel Drive 4968 3 _ 195 61 Ja 3985 1 609 6 156 89 24 00 945 0 346 0 37 21 13 62 185 4 7 30 BODY DRAWING 6 83 I lt 1 5 ae T ES J l i A 916 0 me 36 06 jr y L 9 5 M D 1 FK __ _ C 1 Le a IN jz J ENS _ J aa REFER TO FUEL TANK DRAWING NOTES 4280 0 WHEELBASE INCHES 911 4 2860 0 1420 0 35 88 112 60 55 91 383 0 OF ENGINE _ UNLESS OTHERWISE 508
108. acturers of complete Light Duty Trucks prior to sale and delivery to the ultimate purchaser This explanation is contained in a letter from C N Freed of the EPA to M M McBride of the Recreation Vehicle Industry Association dated July 13 1979 A portion of this letter states secondary manufacturers are not manufacturers under the act when the following conditions are met 1 The vehicles produced by a secondary manufacturer conform in all material re spects to the design specification in the original manufacturer s application for certifi cation hereafter application and 2 The weight of the vehicles produced by a secondary manufacturer including the weight of fuel at nominal tank capacity is no more than 500 105 above the maximum vehicle weight No frontal area restrictions will apply to secondary manufacturers who comply with the conditions above However every vehicle sold to an ultimate purchaser must be covered by the Emission warranty mandated by Section 270 a of the Act Secondary manufacturers who do not meet the above conditions will be considered manufactur ers under the Act and will be required to ensure that the vehicles they produce are covered by a certificate of conformity The maximum vehicle weight for a given vehicle is determined by A Subtracting 300 105 from the highest loaded vehicle weight see 40 CFR 86 079 2 for loaded vehicle weight definition and the table at 40 CFR C K
109. ad p a 120 2 415 1 181 4 16 34 4 73 6 1 0 24 C310 C314 39 1 1 54 K310 K314 INSIDE METAL TO TOP OF CONVERTER HEAT SHIELD T w s ces NM mE 15 3 0 60 C310 C314 48 3 1 90 K310 K314 INSIDE METAL TO TOP 432 5 17 03 3722 OF CONVERTER INSIDE METAL 14 65 MUFFLER C314 amp L31 L29 SHOWN INCHES UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO INSIDE OF METAL CK Rev 12 98 Rev 11 99 C K Truck CURRENT 3500HD Chassis Cab 15 000 GVWR 7 4L Gas Engine Option 129 2312 3 91 10 C310 2922 3 115 14 C314 3532 3 139 17 C318 1824 11 Ww 635 0 1550 5 I _ 702 4 61 08 0277 1125 4 44 31 415 1 16 34 T 4 NP a L 2 7 2 Dese DLL dl L 4 176 4 E 6 94 un 120 1 HEAT SHIELD 4 6 0 18 TOP OF FRAME TO TOP OF CONVERTER 372 1 199 14 65 INSIDE METAL I
110. amp maxifuse marked Stop from the long row of maxi fuses This will effectively remove the stop lamp input from the steering column so that the rear turn signal lamps will be turn only instead of stop turn MAXIFUSE FRT FENDER i 2 AG i AS ee 02 AN IZ NADIA ELS SES SY 3 Verify proper operation of turn and stop lamps and CHMSL if so equipped Continuous Powered Memory Circuits Diesel If a Master Battery Disconnect Switch is required for a specific vehicle application it will be necessary to add a wiring circuit to the vehicle to connect direct fused bat tery power to the powertrain control module PCM to maintain the continuous pow ered memory circuits To maintain PCM memory the 18 gauge 0 8 metric orange wires that are terminated in cavities C 13 and D 13 of the blue 32 pin Micro Pack connector at the PCM must be removed from the connector and their ends insulated and taped back on the har ness Body Builder added direct battery feed circuit wires that are protected by a 20 amp fuse and have been properly terminated should then be inserted into both of these cavities CK Rev 12 98 Rev 11 99 C K Truck CURRENT Secondary lock Blue connector To direct battery circuit Step 4 The terminal ends should be installed into slots C13 and D13 to enable PCM memory Step 1 Remove glove box door assembly Step 2 Remove blue c
111. any portion of the vehicle impinging upon or causing distortion to the fuel system with suffi cient energy to puncture or separate the fuel system Care should be taken that the structural integrity of the vehicle is restored following any modification of the structure FMVSS 302 Flammability of Interior Materials This vehicle when altered will conform to FMVSS 302 providing no alterations or sub stitutions are made which affect any materials parts or components identified below and installed on the Chassis Cab by General Motors Seat cushions Sunvisors Seat backs Curtains Seat belts Shades Headlining Wheel housing covers Arm rests Head restraints Floor covering Engine compartment covers Console Instrument panel Compartment shelves All trim panels including door front rear and side panels Any other interior materials including padding and crash deployed elements that are designed to absorb energy on contact by occupants in the event of a crash C K Truck CURRENT Canadian Motor Vehicle Safety Standards CMVSS 1101 Emission Device CMVSS 1102 Crankcase Emission CMVSS 1103 Emission CMVSS 1104 Opacity Diesel Engine Only CMVSS 1106 This vehicle when altered will conform to the above standards except 1106 providing no alterations are made which affect the function physical or mechanical properties environment locations or vital spatial clearances of the components identified b
112. bber matted backing is supplied When performing any operation around air bag components or wiring including but not limited to any operations around the instrument panel electrical wiring and fuse block steering column wheel and the engine compartment you must disable the air bag system prior to the operation If the vehicle is equipped with an SDM you must disable the air bag system prior to upfitting Note Striking or dropping a powered SDM may cause air bag deployment The air bag system must be enabled after operation completion This must be verified before shipping the vehicle Instructions for disabling and enabling the air bag system can be found in the GM service manual for the specific product line the vehicle frame front bumper system front sheet metal or other front structure roof structure doors floor pan driveline or contents of the engine compartment by any subsequent manufacturer which would result in any difference from the modified vehicle s deceleration if the modified vehicle were to be subjected to bar rier impact tests conducted per FMVSS 208 The rear seat belts provided by General Motors will conform to FMVSS 208 pro viding no alterations are made to the number location or configuration of the des ignated seats seating positions or to the number placement installation or model number of the seat belt assemblies of this incomplete vehicle c the instrument panel or its mounting the steering column
113. components could void compliance and render the vehicle illegal System includes Fuel system throttle body injector TBI or central port injector CPI and associated tubes hoses and pipes air cleaner outside air hose and spacer heat stove and heat stove pipe fuel pump and inlet manifold fuel vapor canister e Exhaust system Ignition system distributor and initial spark timing setting spark plugs spark plug wires e Crankcase ventilation system CK Rev 12 98 Rev 11 99 C K Truck CURRENT Diesel engine induction and injector pump system is certified to be in compliance with the Federal Vehicle Emission Standards and or Noise Standards Any alterations to the system or components could void compliance and render the vehicle illegal Sys tem includes e Fuel system Injection pump injector lines and injectors fuel return hoses and pipes air cleaner outside air hose fuel pump fuel filter fuel heater assembly and intake manifold Exhaust system Crankcase pressure regulation system Charge air cooler system External engine components such as air cleaner crankcase pressure regulator valve alternator injection pipes fuel return hoses from injectors exhaust manifolds oil fill pipe etc must be provided with sufficient clearance for engine roll and torque e When a vehicle is equipped with a electronic fuel injection EFI engine it has an engine control module ECM PCM TCM or This
114. de Impact Protection GVWR of 10 000 Pounds or Less This incomplete vehicle when completed will conform to FMVSS 214 providing no alterations are made to the cab roof floor side pillars fuel system chassis structural components and door assemblies FMVSS 216 Roof Crush Resistance GVWR of 6000 Pounds or Less This vehicle conforms to FMVSS 216 providing no alterations are made to the cab roof side pillar structural components and door assemblies FMVSS 219 Windshield Zone Intrusion GVWR of 10 000 Pounds or Less This incomplete vehicle when completed will conform to FMVSS 219 providing no alterations are made to the cab and front end structural components the hood and hood mounts the vehicle does not exceed the Chassis Cab unloaded vehicle weight specified in Table A and during a 30 m p h frontal barrier impacttest 1 no compo nent installed by any manufacture shall prevent the hood from folding upward along the lateral centerline and 2 no component installed by any manufacturer shall pene trate the windshield or protected zone FMVSS 301 Fuel System Integrity MPV S Trucks and Buses GVWR of 10 000 Pounds or Less This vehicle when altered will conform to FMVSS 301 providing it is completed in accordance with the following specific conditions by the final stage manufacturer 1 The following items when installed by General Motors will conform providing no alterations are made which affect the funct
115. e This is nec essary to avoid chaffing fretting rubbing etc which may cause wear to the pipes or hoses Fuel fill hose clamps are to be tightened to 19 25 Ibs in torque 7 Fuel fill vent hose clamps are to be tightened to 13 18 Ibs in torque 44 TAIL LP HARN EXT TAIL LAMP ASM Part Description Part Number Lamp Assembly Left hand and Right hand 15684994 5 2 Bolt Screw 15965179 3 Harness Assembly 15302486 11501906 11501869 6 Bolt Screw 11504585 7 Bolt Screw C K Truck CuRRENT Tail Lamp Assembly Federal Motor Vehicle Safety Standards FMVSS 101 Controls and Displays This vehicle when altered will conform to FMVSS 101 providing no alterations are made which affect the size location identification or illumination of the controls and displays identified below or the location travel and type of seat If the seat is installed by the final stage manufacturer the visibility and operation of the controls and displays listed below must meet the requirements of paragraph S5 of the standard Vehicle and system controls and displays including Hazard warning signal control and tell tale Engine coolant temperature display High beam control and indicator Steering wheel Service brake Accelerator Horn control Clutch Ignition control Gear position display Headlamp control Turn signal control and display Brake failure warning display Illumination intensity co
116. e seat assemblies FMVSS 203 Impact Protection for the Driver from the Steering Control System GVWR of 10 000 Pounds or Less Conformity with FMVSS 203 is not substantially affected by the design of this incom plete vehicle and General Motors makes no representation as to the conformity with this standard FMVSS 204 Steering Control Rearward Displacement GVWR of 10 000 Pounds or Less This vehicle when altered will conform to FMVSS 204 providing no alterations are made to the cab and front end sheet metal and structural components roof hood hood mechanism doors fenders pillars fender reinforcement cowl bumpers and bumper mounting system frame frame reinforcement front suspension and front cross member or steering control system or other components that would affect the steering control system displacement in a 30 m p h fixed barrier impact FMVSS 205 Glazing Materials This vehicle when altered will conform to FMVSS 205 providing no alterations are made which affect the physical or chemical properties of the glazing material or the monogram or the visibility of the monogram 50 FMVSS 206 Door Locks and Door Retention Components Not Applicable to Bus This incomplete vehicle when completed will conform to FMVSS 206 providing no alterations are made which affect the function physical or mechanical properties en vironment location or vital spatial clearances of the components assemblies or sys
117. ed to be specified as it is controlled within the FMVSS 105 test procedure by specific instructions as to how ballast is to be placed while height is not controlled it is as sumed that for test purposes it would be reasonable For Body Builder s use the center of gravity location can be approximated by the fol lowing formula Wb 150 10 000 Wie Wib 150 W B Wi hyWe h Wb 10 000 Wi horizontal distance from front wheels to completed vehicle center of gravity inches vertical distance from ground to completed vehicle center of gravity inches rear component of bare chassis weight pounds rear component of body weight pounds vehicle wheelbase inches total weight of chassis body pounds plus 400 pounds center of gravity height from ground of the bare chassis selected from the following values by model C K 28 G 32 M L 28 P30 24 total weight of Bare Chassis pounds center of gravity height of body from ground inches total weight of body pounds rear component of 400 pounds from lightly loaded definition 400 pounds from lightly loaded definition multiplied by its vertical center of gravity height assumed of 25 inches NOTE An alternate method of center of gravity calculation may be found in the current issue of the General Motors Body Builders Book in the gen eral instruction section and in SVIE Bulletin 39 C K Truck CuRRENT Allowable Center o
118. eight as specified K Model The following statement applies to C3500 HD Models with I Beam Front Axle The front crossmember steering gear attachment is weldment Under no conditions may the flanges be cut or notched out in any manner Any alteration would severely affect steering attachment capabilities Section 4 Rear Suspension Clearance to body should be provided for the suspension axle driveshaft and tires under the following conditions 1 Axle in full jounce against metal to metal stop 2 Axle at 4 5 roll with one side of axle in full jounce at the metal to metal stop and 3 Axle at design position Allowance for the tire chain clearance shown on a maxi mum grown tire must allow for 42 2 mm 1 66 in clearance to the sides of the tire and 63 5 mm 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 and any other related components must not be placed where they cross the path of motion of the rear axle driveshaft axle brake pipes hoses spring or tires Such crossing could result in rupture wear through or separation due to normal axle motion See chassis data information for additional clearances and for assistance in calculat ing trim heights NOTE Concerns regarding the additio
119. elow Carburetor and choke controls A I R system Crankcase emission control system Engine assembly Ignition system Exhaust emission control system P C V system ntake system Exhaust system Catalytic converter Fuel system Evaporative emission control system Transmission assembly Axle Tires Fan and drive Diesel fuel injection controls Turbocharger and associated controls When completed it should conform to CMVSS 1106 providing no alterations are made to the noise attention components identified thus in the above list Canadian Radio Frequency Interference Regulations This vehicle when altered will conform to the above regulations providing no alter ations or substitutions are made which affect any parts of components identified be low Distributor Ignition wires Spark plug wires CK Rev 12 98 Rev 11 99 C K Truck CURRENT U S EPA and California Exhaust and Evaporative Emission Requirements Light Duty trucks Light and Medium Duty in California are certified by the primary manufacturer and the vehicle is labeled as being in compliance with emission and fuel economy requirement In addition all gasoline powered Federal California Light Duty Medium Duty and Heavy Duty vehicles are required to have an approved fuel evaporative emission con trol system Vehicle certified to Heavy Duty emission standards also require special evaporative emission labeling In order to assure that
120. er pressure protection M SPLICE 1 0 GREEN BODY BUILDER ADDED DIODES 1 0 GA BROWN y SWITCH SPLICE COMPRESSOR CYCLING SWITCH TO COMPRESSOR FROM IGNITION 2 1 OEM A C CONTROL HEAD CONNECTOR SPDT RELAY In order to connect a remote HVAC switch controller into the base OEM system it will be necessary to tie into the circuit that runs between the OEM control head and the compressor cycling switch This is the light green wire that exits cavity 10 of the OEM controller connector A 12 volt DC ignition signal must be applied to this circuit when requesting the HVAC compressor to turn on The Body Builder may obtain this signal by splicing into the brown wire that exits cavity 5 of the OEM controller connec tor It will be necessary to incorporate either diodes or an isolation relay into this circuit to prevent damage to the OEM controller due to unwanted electrical feedback Note The compressor cycling switch circuit that must be spliced into by the Body builder is an extremely low current circuit and will require the use of a low energy switch to prevent future system malfunctions that can be caused by a film build up on the switch contacts C K Truck CURRENT lt PANEL k HVAC Contro connector Ignition Power Feed Interfacing A veh
121. eterne 660 6 1 4 1 18 if gt Tx Ah VL i Z A m 936 1 2598 ZENGINE H te Oh E 916 0 999 j 86 06 N E i 4 E i i 1 FH uu 1 1 550 32 mi i HI gt 7 gt bf a meaa HI H EI EET ESSE M i i H p _ L A eer up a S 1 N 1 172 N i 7 221 gt k 132 0 E j ESL i 5 20 n Lh t L 1 m VEHICLE HER H E 29 0 4G P 432 2 1 14 he B 5 maa 1702 TOP OF CONVERTER 345 4 lt 13 60 3544 161 OUTSIDE METAL 637 13 91 FRONT WHEEL OUTSIDE METAL 6 89 MUFFLER TO CENTERLINE OF 3340 0 WHEELBASE TAIEPIEE 2338 0 131 50 lt A 92 05 NOTES 1575 0 1565 0 INCHES 62 01 gt 61 61 ALL EXHAUST DIMENSIONS ARE FOR DIESEL ENGINE L65 ONLY UNLESS OTHERWISE SPEICIFIED ALL 314 0 DIMENSIONS ARE TO OUTSIDE OF METAL 12 36 339 0 13 35 Z CK Rev 12 98 Rev 11 99 C K Truck CURRENT 107 207 53 Extended Cab 2 Wheel Drive w 6 5T Diesel Engine ET CC 3430 3 BBC 1064 0 938 5
122. eum 1 5 20 2 432 2 17 02 FRONT TRANSFER CASE WHEFIS lets 20125 79 23 LA OF REAR AXLE 2948 0 116 06 2185 0 1565 0 86 02 6161 7 CK Rev 12 98 Rev 1 P 4573 0 TIRE CARRIE 1 99 CROSSMEMBER s 180 04 la 5909 4 OVERALL Er REDE 232 65 Le 3430 3 BBC 1419 0 Le m 135 05 gt T 55 87 899 1 35 41 OF ENGINE i 1348 0 53 07 cS 383 0 1331 8 15 08 I 660 3 52 43 26 00 ee _ m 208 5 m 191 3 8 21 7 53 8 73 n 31 QS Ee ODE ew eee gt Dog 90 see x 347 7 13 67 ZOF FRONT 003 IOP OF FRAME WHEELS NORMAL TOP 352 2 13 87 OF FRAME TOP OF FRAME 3950 0 WHEELBASE TO CENTERLINE 155 50 OF TAILPIPE DIESEL EXHAUST DIMENSIONS K10953 amp 156 K20953 amp 165 315 3 DIM L56 L65 DIM 156 65 12 41 57 2656 3 945 0 i 104 58 DD 37 20 609 6 346 0 BB 24 00 13 62 eee 4638 3 x 182 61 1540 UNLESS OTHERWISE SPECIFIED VIEW IN DIRECTION
123. f Gravity Chart C G of vehicle in FMVSS unladen condition Curb 400 Ibs must be inside shaded area that is it must be within the trapezoid formed by the coordinates A B C D plus it must be to the rear of vertical line E and forward of vertical line F CK Rev 12 98 Rev 11 99 C K Truck CURRENT Pickup Box Removal Vehicles Coordinates of Allowable C G C G Limit Variation at FMVSS Unladen Curb 400 Ibs Forward Rearward a E 6200 sw JB 15 48 5 8 93 124 52 124 7200 sw 7 22 s z vw e s D LJ sw ves 5 59 6 4 10000 DW 2 as a8 75 59 100 _ j D L LD DL LL Lj 9000 SW JB8 15 45 50 76 87 113 54 109 9600 SW JB8 15 45 50 76 87 113 54 109 10000 DW JB8 15 48 75 100 96 124 75 124 1111111 111 9000 Sw 15 48 7 8 w 5 t 10000 DW 2 48 59 ne 59 ne NENNEN __ D bL jj LJ K 10953 sw JB vo 1 5 124 52 1 4 10953 6600 sw JB Jb 15 54 9 tw 5 121 L DL LL D LL LL LL 9200 sw ves 1 s 6 4 85 L LL DL LL LL Lj 0903 1000 DW ves 32 48 5 76 t
124. h that there is adequate clearance to all fuel system components such as the fuel lines and the fuel level send ing unit under all operating conditions C K Truck CuRRENT Fuel Tank For vehicles with full frames the tank must have a minimum clearance of 2 in top front rear and sides to body and other supports Tank may be pressurized to 1 25 PSI maximum to check for final line leakage or for forcing fuel through the system Pressures greater than this amount may be detrimen tal and affect tank durability The use of auxiliary fuel tanks is not recommended f an auxiliary fuel tank is add ed the alterer must take responsibility for compliance with affected motor vehicle safety standards Also if an auxiliary fuel tank is added to a gasoline powered ve hicle the fuel must be drawn through a pipe at the top of the tank balance line be tween tanks is not permitted Gasoline fueled vehicles are now equipped with a fuel pump return line If an auxiliary tank is added the tank selector valve must include a return port which returns fuel to the tank from which the fuel is being drawn In gasoline engines the fuel pump is located in the fuel tank The battery must be dis connected before starting any work on the fuel system Gaseous Fuel Conversions All truck gasoline engines may be converted to use liquified petroleum gas LPG or natural gas NG GM only approves the conversion of vehicles with option KL5 in combination w
125. he existing bat tery cables Ifthe battery requires relocation and longer cables are required a propor tionately larger gauge wire must be used If in relocating the battery the negative ground cable is attached to frame rail a cable of similar gauge be provided between the frame rail and the engine This is required due to the heavy electrical loads im posed by the starting circuit To ensure proper operation of the battery cables the fol lowing chart on length gauge and materials must be strictly adhered to Combined length of positive and negative Cable in Inches Cable Gauge 4 66 o ___________ 7 ______ _____0 ______ ___ gt _____ If the battery is remotely mounted other than in the engine compartment the sense circuit in the generator regulator shall be used The sense circuit consists of a 7 76 OHM 1 4 watt resistor connected in series between the S terminal of the generator and the B terminal of the battery Auxiliary Battery Gasoline Engines Only If an auxiliary battery is to be retro fitted the electrical schematic for option TP2 is recommended as a guide This will result in the auxiliary battery being connected to the vehicle load and charging circuit when the ignition switch is on fuse block termi nal Acc lgn Fused When the ignition switch is turned off the interlocking relay is disengaged and the auxiliary battery is disconnected from the vehicle ci
126. his vehicle when altered will conform to FMVSS 124 providing no alterations are made which affect the function physical or mechanical properties environment loca tion or vital spatial clearances of the components assemblies or systems identified below Accelerator control systems including but not limited to Lever throttle or accelerator and supporting bracket Cable or rod throttle or accelerator and support bracket including seals Electronic throttle control assembly and related wiring Cruise control module wiring and cable if so equipped Spring s throttle or accelerator return Pedal throttle or accelerator and attachments Floor covering material must not be installed under pedal nor within 1 inch of side of pedal Attachment pin hole or ball stud to carburetor port fuel injection unit throttle lever CK Rev 12 98 Rev 11 99 FMVSS 201 Occupant Protection in Interior Impacts GVWR of 10 000 Pounds or Less This vehicle when completed will conform to FMVSS 201 providing no alterations are made which affect the function physical or mechanical properties environment location or vital spatial clearances of the components assemblies or systems identi fied below Instrument panel Seats Interior compartment doors Sunvisors Arm rests FMVSS 202 Head Restraints GVWR of 10 000 Pounds or Less This vehicle when altered will conform to FMVSS 202 providing no alterations or sub stitutions are made to th
127. hould be no larg er than 19 mm 0 75 in in diameter Holes are to be drilled no closer than 63 5 mm 2 5 in apart For holes drilled forward of the rear axle centers are to be no closer than 63 5 mm 2 5 in from the top or bottom flanges and no closer than 89 mm 3 5 in from any suspension attachments For frame holes drilled rearward of the rear axle hole centers are to be no closer than 51 mm 2 0 in from the top or bottom flange and no closer than 89 mm 3 5 in from suspension attachments No additional holes or notching of either top or bottom frame flanges is allowed Section 3 Front Suspension Since there is a large variation in completed vehicle front weight due to differences in body weight and equipment the front suspension alignment must be checked and reset if necessary after the vehicle is completed Caster and camber should be set with reference to the A dimensions On C3500 HD trucks with camber and caster is designed into the axle suspension and cannot be adjusted CK Rev 12 98 Rev 11 99 3 See Truck Service Manual for complete alignment procedure specifications and measurement of the A dimension under Diagnosis and Front Alignment section C K Models are designed such that camber and caster do not need adjustment unless severe road impact or accident deformation occurs Toe should be reset after the ve hicle is completed and while at normal operating load with trim h
128. ic 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 Holes Holes to mount brackets supports and out riggers must be drilled in the vertical side rail web with the following restrictions e Material between edge of hole and inside of upper or lower flange must not be less than 37 mm 1 50 in for low carbon steel 36 000 PSI yield e The minimum edge distance between any two 2 holes must be larger than twice the diameter of the larger hole 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 When welding low carbon steel side rails crossmembers and brackets 32 000 36 000 PSI yield strength emphasis is placed upon weld application techniques to avoid stress risers that may adversely affect frame operating stresses CK Rev 12 98 Rev 11 99 C K Truck CURRENT When welding is performed anywhere on the vehicle precautionary measures should be taken to prevent damage to electrical system wiring or components Prior to any welding parts or components wh
129. ich 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 are cool careful ly inspect wiring and electrical components for shorts or other damage which could draw excessive currents and possibly cause an electrical system short when the bat tery 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 affected MVSS and for warranty on items such as driveshafts universal joints center bearings and rear transmission tailshaft transfer case and transmission case frac tures output shaft bushings bearings brakes fuel systems and any other related component failures Additionally the customer must be alerted in the modifier s own ers manual that parts for the reworked area are not available through the General Mo tors 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 in 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 s
130. icle ignition power feed circuit may be obtained by the Body Builder by connect ing to an ignition circuit terminal the OEM convenience center The convenience center is located in the passenger compartment on the left side of the dash panel outboard of the steering column A wire of an appropriate gauge size should be prop erly terminated and inserted into cavity C of a Delphi Packard Electric 280 Metri Pack connector Part Number 12110777 dark green in color The connector should then be inserted into the 3 way connector cavity in the convenience center marked spare This circuit may be used for circuit loads of one 1 ampere or less If power greater than the one ampere maximum limitation is required this circuit can still be used but only as a signal source to energize a Body Builders supplied relay PWR WDOS LKS STS AWD VAN E C MIR RR DEF CONVENIENCE CENTER 1 HARNESS CK Rev 12 98 Rev 11 99
131. if 1 No alterations are made to the cab and front end structural components including roof hood and hood mechanism doors fenders pillars fender reinforcement cowl bumpers and bumper mounting system windshield and windshield mount ing system and frame frame reinforcement 2 The maximum weight of the body and or equipment installed must be such that the completed vehicle s unloaded vehicle weight does not exceed the values spe cified in Table A page 54 3 The center of gravity for the respective body type of the installed body and acces sories does not exceed the maximum center of gravity height specified in Table A page 54 4 The height above the frame of the body or accessories does not exceed the maxi mum body height specified in Table A page 54 5 The clearance between the rear most part of the cab and the front of the body is not less than the minimum cab to body clearance specified in Table A page 54 6 The minimum vertical clearance between the cab roof and any portion of the installed body or accessories that extends over the cab roof must not be less than eight inches CK Rev 12 98 Rev 11 99 51 7 The maximum body weight does not exceed the value specified in Table A 54 8 During 30 m p h frontal barrier impact test component installed by any sub sequent manufacturer shall move forward from its permanently mounted position FMVSS 214 Si
132. ing Aeroquip connecting fittings attached to pre charged lines This allows a one time only connection to the O E M charged A C system with out having to discharge evacuate and recharge for the connection of a rear A C sys tem A modification to the A C system which causes the A C plumbing lines to increase in length such as the addition of a rear after market evaporator and blower assembly will necessitate the following changes e Lubrication PAG refrigerant oil must be added to rear system to provide lubrication for compressor Refer to Service Manual for specifications Refrigerant Add R 134A refrigerant to system based on sizing of new tubes hoses and evaporator Contact your A C supplier for recommended charge C K Truck CURRENT e Label Revise modify GM charge label located on top of front evaporator or A C bottle from factory recommended charge for a front system only to body builder s new recommended dual system per SAE J639 This is important for servicing the A C system so that the technician knows the correct amount to add to the modified system Section 2 Frame Hole drilling welding modifications or alterations to the frame assembly are the re sponsibility of persons performing these operations These same individuals assume complete responsibility for frame assembly reliability performance after alterations and compliance to applicable FMVSS requirements The following procedures and specif
133. ion physical or mechanical properties environment location or vital spatial clearances of the components assemblies or systems identified below Fuel feed pipes front rear and intermediate Fuel return pipes front and rear Fuel feed and return hose front rear and intermediate Fuel tank assembly Fuel vapor lines and cannister Fuel tank cap assembly Fuel tank filler neck screws Fuel tank filler neck hose Fuel tank filler neck vent hose Fuel tank filler neck vent hose clamp strap 52 Fuel tank meter assembly Fuel tank filler neck hose clamp clamp assembly Fuel tank filler neck assembly upper Fuel filter Fuel tank shields cage Fuel tank filler neck plate Fuel hose shield 2 This incomplete vehicle when completed will conform to FMVSS 301 Fuel Sys tem Integrity if a No alterations are made to the fuel system and attaching or protective structure b The unloaded cab chassis vehicle weight of the completed vehicle does not ex ceed the weight listed in Table A page 54 c Any subsequent manufacturer completes the fuel filler neck installation according to the instructions available in the current year s Body Builders Book d During all barrier impact tests 1 No component installed by any subsequent manufacturer impinges or causes distortion to the fuel system with sufficient energy to puncture or separate the fuel system 2 No vehicle modification by any subsequent manufacturer results in
134. ipes emission canisters fuel feed fuel return and vapor lines purge control solenoids fuel fill cap canister vent solenoid For these reasons NO ALTERATION OF THE FUEL SYSTEM IS RECOMMENDED Fuel Fill It is recommended that when mounting the fuel filler pipe assembly and vent hose that a minimum of 3 0 in clearance be provided to any body component to prevent contact between hoses and or mating parts and that retention be provided to ensure routing and prevent failure due to wear and fatigue Both the fill and vent hoses must be routed and supported if needed such that there are no sags or kinks As viewed from the filler neck pipes and hoses must have a downward slope toward the tank 6 There should be a minimum of 4 of downward slope in the fill and vent pipe at any location No fuel traps are allowed Alterations of fuel routings could affect the ability of the completed vehicle and are therefore not desirable 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 must allow the vehicle to meet enhanced evaporative emissions requirements Fuel Lines Fuel line routing precautions 12in minimum clearance to exhaust system is required or a metal shield must be provided e Fuel lines should be clipped to chassis to prevent chafing Metal clips must
135. is protected by a 30 amp Maxi fuse inside the fuse center If more than 30 amp is required the battery should be used as a pow er supply source CK Rev 12 98 Rev 11 99 C K Truck CURRENT 9 3 Fan clutches not conforming to the original equipment specifications may not ate correctly and may stay on continuously never come on or cycle on and off ex FUSE RELAY cessively This will result in a reduction of fuel economy engine overheat at times MCN and annoying cycling respectively 4 Heavy duty cooling equipment is required when air conditioning auxiliary belt driven equipment snow plows winches etc are installed 5 Continuous coolant flow is necessary from heater connection on engine to heater B connection radiator to control transmission oil temperatures during closed ther ene gt mostat warm up operation Do not alter this flow as it may result in premature en Battery power gine or transmission failure output studs 222 gt ail lt 6 If a heater unit is not installed in the vehicle or a heater shut off valve is required a line connecting the heater connection on the engine to the heater connection on the radiator must be installed When a shut off valve is required in heating system it must be teed into the system in such a manner as to maintain continuous flow be tween engine heater connection radiator heater connection at all times Do not install any
136. is standard Headlamps and or foglamps Front cab roof clearance and identification lamps Front side marker reflex reflectors Rear reflex reflectors Front side marker lamps Tail lamps Front turn signal lamps Stop lamps Turn signal operating unit Turn signal flasher Vehicle hazard warning signal operating unit Vehicle hazard warning signal flasher Mud flaps w reflectors Tractor only License plate lamp Rear turn signal lamps Back up lamps Center high mounted stop lamp Rear cab conspicuity reflectors Tractor only b No part of the completed vehicle shall be installed so as to prevent any of the de vices listed in a above from meeting their required photometric output at the spe cified test points If such interference exists the applicable devices may have to be relocated or additional devices added to meet the requirements of FMVSS 108 Any FMVSS 108 part shall not be painted c The following additional devices must be installed on the van body and meet all the requirements of this standard Rear side marker reflex reflectors Front and rear identification lamps Rear side marker lamps Front and rear clearance lamps d The following additional devices must be installed on the van body and meet all the requirements of this standard if the overall vehicle length is 30 feet or greater Intermediate side marker lamps Intermediate side reflex reflectors C K Truck CURRENT e C K 300 03 Chassis Cabs with Roof Ma
137. ith engine L31 5 7L However some conversions may cause harmful effects to the engine Such fuel systems may require assurances from alternate fuel system manufacturers and or installers that the equipment will not cause damage to the engine or the exhaust system In the use of dual fuel systems the vehicle operator should strictly adhere to the manufacturer s procedures for switching from gasoline to gaseous fuel operation Improper switching procedures may result in overheating and damage to the exhaust system and the vehicle The gaseous fuel tank should not be mounted in an enclosed area of the vehicle such as the passenger compartment truck etc and the system should be vented to the outside of the vehicle In addition vehicles converted to gas eous fuels should not be stored in enclosed places such as garages Further General Motors cautions purchasers that the design location and installation of any type of fuel storage system involves significant technical and engineering considerations and that these statements on gaseous fuel conversions should not be interpreted to be an approval by General Motors of any modification to the original equipment fuel system CK Rev 12 98 Rev 11 99 C K Truck CURRENT Conversions to gaseous fuel should be made in conformance with applicable Federal and State regulations Removal of emission control components or the addition of gaseous fuel systems which could damage or reduce the longevity of
138. iting from this same switch The splice should be made in an area that is protected from the environment and should also be sealed to be weather resistant Note This circuit is pulled to ground whenever the automatic transmission lever is in Park or Neutral The maximum body builder electrical load that can be added to this circuit is one 1 ampere The body builder should incorporate a relay into the system if the added load will exceed the one ampere maximum limitation The OEM circuit can then act as a ground signal for the Body Builder relay coil whenever the transmission selector is in Park or Neutral The High side of the relay coil should be powered by an ignition switch controlled power source so that the relay will not be energized when the ignition key is in the Off position If the body builders finds it necessary to electrically interface to the park neutral circuit of the OEM neutral safety switch it should be accomplished as follows e Locate the neutral safety switch on the automatic transmission SORS OH 4 m B RO T NEUTRA START BACKUP TRANS CONN HARN CK Rev 12 98 Rev 11 99 C K Truck CURRENT Procedure for installation of the Electronic Interface of Power Take Offs PTO on 1998 Model Year Gasoline Engines with On Board Diagnostics Il This procedure is intended as a guide to aid in safely installing an Electronic inter face to the 1998 C K Full S
139. ize truck from General Motors in 1998 Model Year with ON BOARD DIAGNOSTICS II This procedure is predicated on a 1998 Vehicle Computer Module VCM in a Full Size Truck and the OEM PTO manufacturers instructions for installation It should be recognized that generalized procedures cannot anticipate all situation The following steps are to be followed in making the modifications Using Packard Elecite fools modify terminal sedi by remor ing the seal tower from cavity 2 of connector Note Tools 1 Perform a safety inspection of the existing body builders vocation available through Pioneer Standard 1 800 PACKARD application Open the hood and remove both the positive and nega tive cables from the batteries Crimp terminal P N 12084912 on to an 18 gauge wire using tool P N 12125080 Also available through Pioneer Stan 2 Shut off all power from the vehicle 3 Install the Power Take Off device and the associated hardware i e a Hydraulic Pump or Kits 4 Remove the 24 pin black connector from the VCM and open the wire dress cover to expose rear of connector 020040559 8 Insert terminated lead into cavity 2 of Are jo 255 connector until fully seated Noc 9 Reinstall TPA close wire dress cover and plug connector into VCM 10 Protect wire and route clip to suitable location at PTO control switch This end of the wire should be switched to ground when ever the PTO system is engaged to bypass OBD II diagnostic
140. k or money order made payable to the mentioned companies Credit Card orders can be made by phone on the listed toll free phone numbers Electrical System Interfacing Guidelines General Discussion General Motors recognizes that the completion of manufacture of some cab chassis vehicles by Body Builders for specific vocational needs will require interfacing with portions of the OEM chassis electrical system The manner in which these interfacing modifications are made can have an adverse affect on chassis electrical operations in addition to causing problems with the Body Builder electrical system In some cases a no start condition can occur Additionally an improper interface can cause the engine control computer to set and store fault codes and illuminate service telltale lights For these reasons extra care must be taken to ensure that these types of modi fications are performed using reliable processes and components The following pages describe some of the known electrical system modifications which are being done by ambulance manufacturers and provides a general definition of the recommended interfacing between the OEM chassis and Body Builder hard ware to minimize the impact to the OEM chassis electrical system C K Truck This is not a How To manual It assumes the reader has technical expertise in the area It is ultimately the responsibility of the Body Builder to design the interface to the OEM
141. lation guidelines and instructions e Calculation of weight distribution for the front and rear axles The loaded vehicle with driver passengers aftermarket accessories snow plows spreader and cargo must not exceed Gross Vehicle Weight Rating GVWR Front and Rear Gross Axle Weight Ratings Ballast Compensating Weight The use of ballast weight may be required to prevent exceeding the Gross Axle Weight Rating of the front axle Ballast should be securely attached in the pickup box or be hind the rear axle of vehicle 1999 Snowplow Prep Package Option VYU GMTG Chevrolet GMC Pickups Chassis Cabs K20753 K20903 K20953 K30903 K30953 K20903 K30903 K31003 K31403 Extended Regular Extended Regular Extended Regular Regular Regular Regular 141 5 131 5 155 5 131 5 155 5 131 5 131 5 135 5 159 5 Pickup Box Length GVWR 65 8 8 8 J 8600 8600 9200 9200 8600 9200 12000 12000 GAWR Frt 4500 4500 4500 4500 4500 4500 4500 4500 4500 Engine Availability with VYU Opt Code Gas V8 350 CID Vortec 5700 i 8 8 8 8 8 8 8 Gas V8 454 CID Vortec 7400 L29 N A A N A N A N A A A A A Diesel V8 395 CID 6 5T e A NA NA NA A A A CK Rev 12 98 Rev 11 99 C K Truck CURRENT 37 Pickups Chassis Cabs Model K20753 K20903 K20953 K30903 K30953 K20903 K30903 K31003 K31403 Cab Extended Regular Extended
142. lt assemblies provided and C K Truck CURRENT ering if so equipped air bag crash sensors Sensor Diagnostic Module SDM in C K and all air bag system wiring Do not relocate or move the SDM Do not obstruct the path of air bag deployment see restricted area reference in appendix Do not mount any components that produce more than a 20 Gauss magnetic field as measured at the SDM Speakers magnets must be located at least 5 inches from the SDM You must disconnect the SDM before doing any welding on the vehicle other wise do not disconnect the SDM If the sunshade is removed or altered a new Inflatable Restraints System Caution label must be installed per the sketch found in Part Ill of this document A label has been shipped loose In order to be in compliance with FMVSS 208 no other label shall be installed on the same side of the sunvisor as the Inflatable Restraint Caution Air Bag label Instrument panel temporary warning label must not be removed NOTE Most air bag wiring is wrapped with yellow tape and all air bag components have yellow connectors CAUTION To help avoid Personal Injury Due to unwanted air bag inflation observe the following precautions Do not weld solder braze hammer machine drill heat electrical splice add onto remove relocate test paint loosen or in any way alter air bag components or wiring or fuses Carpet may be put over the SDM if an appropriate moisture barrier such as a ru
143. ment ik 143 11 41 87 E 2923 0 m 115 08 1043 0 2218 4 EET NC 7 M30 MG5 M50 87 34 BOX MTG SLOT 990 2 38 98 E pu 1059 0 41 69 16 58 er vat c EE 30 0 w EOF 1 18 NENG INE 932 0 36 69 INSIDE TO VEHICLE n s MESI fetal ere sassa J 32 80 BOX 4280 0 wore BRACKET 638 0 25 12 168 50 WHEELBASE BOX MTG SLOT 208 5 r118 817 8 21 I M TO I M n 107 5 i 4 23 EEG I M TO INSIDE METAL i TOP OF FRAME En T f pa 1 3 5 195 5 0 14 7 70 TOP OF BOX MOUNTING BRACKET TO INSIDE TOP 908 0 OF FRAME 114 49 TOP OF CROSSMEMBER TO _ 1000 INSIDE TOP OF FRAME p Jo K5094 5 SHOW UNLESS ALL DIMENSI INSIDE OF RWISE SPECIFIED ONS ARE TO ETAL CK Rev 12 98 Rev 11 99 C K Truck CURRENT 1 2 0906 Suburban Crossmember Arrangement
144. n of leafs or modifying the Rear Suspension on the C 3500 HD Models refer to Brakes Section 5 for additional information Section 5 Brakes See Truck Service Manual for brake specifications 4 Due to critical nature of brake systems anyone making modifications ations must assume complete responsibility for system reliability performance and certification to FMVSS 105 or FMVSS 121 Itis mandatory that no change be made to the brake main cylinder location brake ped al 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 Check power steering fluid level for models equipped with hydroboost brake Refer to Owner s Manual Added floor covering or carpeting must not restrict service or parking brake pedal trav el from released position to full pedal travel No body part or chassis mounted component may be located within 2 0 in of brake hose routing in all wheel and axle positions All exhaust system components must also have a minimum of 2 0 in clearance to brake hoses in closest positions Be sure to account for brake hose travel with suspension Body builder is to verify that the brake warni
145. nd or submit a written statement to the EPA Administrator that the Hydrocarbon storage system has been upgraded according to the requirements of 40 CFR 86 088 35 g 2 In addition compliance with applicable fuel evaporative emission regulations will be maintained if no alterations are made to the fuel filler neck s and any subsequent manufacturer completes the fuel filler neck installation s and fuel level sender installation s according to the instructions which are furnished in the current year s Body Builders Book CK Rev 12 98 Rev 11 99 53 Specifications for Fill Pipes and Openings of Motor Vehicle Fuel Tanks appli cable only to California gasoline powered vehicles This vehicle will conform to Title 13 California Administrative Code Chapter 3 Air Re sources Board Subchapter 7 Specifications for Fill Pipes and Openings of Motor Ve hicle Fuel Tanks if no alterations are made to the fuel filler neck s and any subsequent manufacturer completes the fuel filler neck installation s according to the instructions which are furnished in the current year s Body Builders Book 54 Table A C K Truck CURRENT These Pickup vehicles when altered will conform to FMVSS 212 219 301 providing the following conditions are met i ini 9 Body Weight Maximum Body Minimum Cab to ari a Height Body Clearance Unloaded Pounds x General Body Type x Ctr of heelbase ravi
146. ng switch is operative The brake warning switch on models equipped with vacuum hydraulic brakes is located adjacent to the master cylinder vacuum unit This includes both the brake system differential pres sure and parking brake actuator switch Section 6 Engine For additional information refer to Body Section 1 Air conditioning and auxiliary belt driven equipment installation recommendations No alterations or additions to the accessory drive belt system will be warranted on ser pentine belt systems The serpentine belt type of drive is designed as a total system incorporating a single poly V belt and an automatic tensioner In this type of system degrees of pulley wrap belt tension and pulley alignment are very critical factors Modification is not recom mended In some single belt serpentine systems belt tension is determined by the automatic tensioner and its position relative to the belt No adjustment required C K Truck CURRENT Due to the critical nature of the accelerator system anyone making modifications or alterations assumes complete responsibility for system reliability performance and compliance to FMVSS 124 Caution must be exercised so that the accelerator cable is properly routed Specifications are as follows e Route cable to maximize all bend radii In no case should bend radii be less than in 76 mm Minimum distance from exhaust manifold to be 6 0 in 150 mm unless a heat shield i
147. ns with pipe surface temperatures slightly less than this Extreme care must be used when placing body components in the proximity of the exhaust system so as not to exceed the rated temperature limits of the components Due to variants in underbody configu rations 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 heat radiated from the engine How much is retained in the area will depend on how well this area is ventilated in your individual designs Here again temperature checks of interior areas surrounding the engine should be made to determine if your insula tion is adequate This is the same engineering practice we have followed on our com plete vehicles incorporating these exhaust systems CK Rev 12 98 Rev 11 99 7 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 Heat shields are mounted to the underbody and or exhaust system components cat alytic converter and muffler Shields for the propshaft hanger bearings are als
148. nstalling aftermarket systems should provide information as to where and how to obtain service and replacement parts When installing a Power Take Off PTO with hydraulic lines the following care should be exercised e Route and secure all hydraulic lines so that they are not in close proximity to any parts of the exhaust system Keep all fittings and connections away from the exhaust system Make sure connections and fittings cannot leak on the exhaust system e Exhaust system heat can damage and degrade hydraulic lines and components Oils and hydraulic fluid coming in contact with a hot exhaust system could result in a fire Section 1 Body Accessory items such as refrigerator hot water heater furnace etc which operate on liquid propane gas should be located and protected to prevent exposure to any flame Body structures interior and accessory arrangements must be designed into the ve hicle to provide for proper load distribution on both axles and not to exceed any gross axle weight ratings Lateral load equalization must also be maintained The resultant Center of Gravity of the unladen vehicle must be within the limits tabulated in the FMVSS 105 section of the Incomplete Vehicle Document Body insulation provided by General Motors should not be removed This includes any thermal or underbody heat shields This insulation is provided to protect the ve hicle body and occupants from excessive heat and or provide noise atte
149. ntrol Fuel level display Windshield wiper control Windshield washer control Oil pressure display Electrical charge display Manual choke control Tail lamps control Rear window defrosting and defogging controls Manual transmission shift lever except transfer case Heating system controls including fan Air conditioning system controls including fan Engine start control Engine stop control Hand throttle control Clearance lamp control Side marker lamp control Identification lamp control Windshield defrosting and defogging controls Speedometer display Odometer must be metric Trip recorder must be metric Hub odometer must be metric Automatic vehicle speed control Seat belt tell tale Anti lock brake failure warning display Air bag tell tale if so equipped If the alterer installs any of the aforementioned controls and displays those controls will also have to meet the requirements of this standard For Canada MVSS only when Canadian option is specified CK Rev 12 98 Rev 11 99 C K Truck CURRENT FMVSS 102 Transmission Shift Level Sequence Starter Interlock and Trans mission Braking Effect This vehicle when altered will conform to FMVSS 102 providing no alterations are made which affect the function physical or mechanical properties environment loca tion or vital spatial clearances of the components assemblies or systems identified below Transmission control and identification system
150. nuation Any replacement material internal to the occupant compartment must be certified for FMVSS 302 Flammability of Interior Materials Areas of specific concern but not lim ited 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 Conversions Engine cover insulation A minimum of 10 departure angle should be maintained if frame and or body is ex tended If body builder installs seating other than that supplied with vehicle it is the body build ers responsibility to ensure that the seating and restraint systems comply with FMVSS requirements The restraint systems supplied with the vehicle were designed to accommodate the seating reference points and seat travel of the original equip ment seats only Air Conditioning For additional information refer to Engine Section 6 NOTE Air conditioning systems using R 134A refrigerant are equipped with metric fittings to prevent interchange with R 12 refrigerant components Do not interchange R 134A components refrigerant oil or service equipment with R 12 components refrigerant oil or service equipment Rear Air Conditioning This unit may be equipped with A C quick connect fittings Option YF7 on the liquid tube high pressure and the suction low pressure return tube These fittings are designed to accept match
151. o pro vided 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 steering column mast jacket not to be altered Section 10 Tires Check wheel lug nuts for proper torque specifications are provided in the Owner s Manual Substitution of tires of greater capacity than those offered as original equipment by vehicle manufacturer is not approved for use on original equipment wheels Any usage of higher capacity tires must be accompanied by higher capacity wheels How ever the wheel offset and distance from centerline of rim to wheel mounting face must be the same as the replaced original equipment wheelto ensure proper wheel bearing loading and clearance of tires to body and chassis components Increasing tire and wheel capacity does not necessarily increase vehicle GVW ratings Any substitution of tires may affect Speedometer Odometer accuracy It is recommended that tire chain clearance guideline J683 from the Society of Auto motive Engineers be adhered to in designing rear wheelhouse clearance Check tires and inflate to recommended tire pressure according to the tire pressure information provided in Owner s Manual and tire inflation label provided with vehicle 8 Section 12 Electrical Battery and Battery Cables The vehicle battery should be located and positioned to make use of t
152. ode of 1360 RPM It is recommended that an 18 gauge 0 8 metric dark green wire be utilized for this application e Plugging a terminated wire into cavity B 8 of the 24 pin brown Micro Pack connector at the PCM and grounding the other end of this wire lead through a Body Builder installed control switch will enable a high idle mode of 1070 RPM It is recommended that an 18 gauge 0 8 metric light green wire be utilized for this application e f both sets of wires and Body Builder switches are added to the vehicle the grounding of both of these circuits at the same time through their respective switches will result in a high idle mode of 1600 RPM CK Rev 12 98 Rev 11 99 C K Truck CURRENT SECONDARY LOCK SMALL BROWN CONNECTOR ROUTE WIRES TO CONTROL SWITCHES STEP 4 THE TERMINAL END SHOULD BE INSTALLED INTO SLOT B7 OR 88 OR IN BOTH BASED ON THE PRESET STEP 1 REMOVE GLOVE BOX HIGH IDLE SPEED REQUIRED DOOR ASSEMBLY STEP 2 REMOVE SMALL BROWN CENTER CONNECTOR BY PINCHING PRIMARY AND SECONDARY LOCK TOGETHER STEP 3 HOLDING CONNECTOR AND USING SMALLL SCREW DRIVER REMOVE SECONDARY LOCK CK Rev 12 98 Rev 11 99 7 Splice a wire onto the 18 gauge 0 8 metric yellow wire that exits from cavity Neutral Safety Switch Connection A of the 7 way connector at the switch Caution must be exercised to assure that only the yellow wire from cavity A is spliced into as there are two other yellow wires ex
153. onnector b pinching primary and secondary lock together Step 3 Holding connector and using small screw driver Remove secondary lock CK Rev 12 98 Rev 11 99 132 Additionally the vehicle radio clock must be powered continuously to maintain the correct time and radio pre set stations To maintain radio clock memory the 20 gauge 0 5 metric orange wire that is terminated in cavity C 10 of the 20 pin 2 10 pin assem bly connector at the back of the radio must be removed from the connector and its end insulated and taped back on the harness A Body builder added direct battery feed wire that is protected by a 10 amp fuse and properly terminated should be in serted into this cavity RC PANEL L ines RADIO CONNECTOR S The radio may have to be removed from the instrument panel to gain access to the 20 pin connector COMFONENT CARRIER FLAYER w Front C K Truck CURRENT It should be noted that it is the responsibility of the Body Builder to ensure that power feed wires to these devices are properly fused and routed to prevent damage to the OEM electrical system during subsequent vehicle use Auxiliary Electrical Loads When option YF2 is specified for ambulance conversion the cab chassis vehicle will be equipped with a dual generator system Additionally an electrical junction block is provided in the engine compartment mounted to the dash panel on the driv er s side This junc
154. r all operating condi tions Body attachment brackets and U bolts must also be located such that there is adequate clearance to all fuel system components such as the fuel lines and the fuel level sending unit under all operating conditions The fuel fill and vent pipe system available from the dealer includes a number of additional hose retaining beads The pipes can be trimmed at the hose retaining beads to adjust for the various chassis lengths and body widths The pipes must be trimmed only at locations where a hose retaining head is present A hose re taining bead must be present at each pipe to hose interface in a modified fuel fill and vent system Pipe ends must be free of burrs which may be detrimental to satisfactory assembly and or function CK Rev 12 98 Rev 11 99 3 A minimum of 8 0 inches of fill hose must be maintained between the filler neck and the fuel tank as measured in an outboard direction from the tank surface at the fill hose nipple to the outlet end of the filler neck Both the fill and vent hoses must be routed and supported if needed such that there are no sags or kinks Excess hose length may be removed as required pro vided hose does not kink As viewed from the filler neck pipes and hoses must have a downward slope toward the tank There should be a minimum of 4 of downward slope in the fill and vent pipe at any location The fuel fill and vent system should be restrained in the upfit vehicl
155. r to nozzle Defroster outlet to heater assembly adaptor Chassis and instrument panel wiring harness assembly 45 FMVSS 104 Windshield Wiping and Washing Systems This vehicle when altered will conform to FMVSS 104 providing no alterations are made which affect the function physical or mechanical properties environment loca tion or vital spatial clearances of the components assemblies or systems identified below Windshield wiping and washing systems including but limited to Windshield washer fluid reservoir Washer reservoir cap Water reservoir filler assembly Windshield washing system hoses Windshield washer nozzle Chassis wiring harness Windshield assembly Windshield wiper arm assembly Windshield wiper blade assembly Windshield wiper linkage assembly Windshield wiper washer control Windshield wiper washer motor pump assembly Windshield module attachments FMVSS 105 Hydraulic Service Brake Emergency Brake and Parking Brake Services Allowable center of gravity variation C K These charts detail the envelope of allowable center of gravity variation for completed vehicles This is significant for the lightly loaded portion of FMVSS 105 which is de fined as curb plus 400 pounds distributed in the driver passenger area of the vehicle The lightly loaded center of gravity of complete vehicles needs to be restricted so it will meet FMVSS 105 stopping distances The laden center of gravity does not ne
156. rcuit Modifications add on wiring must be carefully reviewed to ensure compatibility with the base vehicle wiring by reviewing system schematics wire routing paths harness connections etc Due to the wide range of modifications that may be required for vocational needs itis notfeasible for the O E M to take into account all potential revi sions For this reason any person modifying existing vehicle wiring must assume re sponsibility that the revisions have not degraded the electrical system performance Any add on wiring must be properly fused and routed to prevent cut pinch and chafe problems as well as avoid exposure to excessive heat Care must be exercised that existing vehicle interfaces do not have their current load capabilities exceeded and C K CURRENT that the respective control devices are not overloaded Added wire size should be at least as large as the the wire to which it is attaching in order for fuse protection to be maintained A Packard electric wiring repair kit is available through Kent Moore GM P N 12085264 Kent Moore P N J38125 4 This kit contains instructions tools and com ponents for making repairs to wiring harness components This kit would also greatly assist in accomplishing necessary add on wiring such as body marker lamps so that system reliability durability is maintained Electrical wiring components can be obtained through your authorized GM dealer Many Packard Electric components
157. rker Lamp Delete Option 9H5 will com ply with Standard 108 provided clearance and identification marker lamps are installed on the completed vehicle 2 No alterations other than any relocation of items in 1 a which may be necessary to conform to the standard should be made which affect the location mounting surfaces function environment or visibility clearance of the above listed devices which have been installed on this incomplete vehicle FMVSS 111 Rearview Mirrors This vehicle when altered will conform to FMVSS 111 providing no alterations or sub stitutions are made to the outside or inside mirrors furnished with the vehicle the driv er s seat location is not altered and the body width is not increased FMVSS 112 Headlamp Concealment Devices Conformity with FMVSS 112 is not substantially affected by the design of this incom plete vehicle and General Motors makes no representation as to the conformity with this standard FMVSS 113 Hood Latch System This vehicle when altered will conform to FMVSS 113 providing no alterations are made which affect the function physical or mechanical properties environment loca tion or vital spatial clearances of the components assemblies or systems identified below Hood latch systems which may include but are not limited to Hood latch catch assembly Hood latch support assembly Hood latch pilot Hood latch striker plate hook FMVSS 114 Theft Proctection
158. s provided Do accelerator cable clips to route wires harnesses or other cables Cable sheath must be clipped so as not to pinch inner cable Cable must not be loose in clip allowing sheath to move when accelerator pedal is applied and released Cable must not be subjected to kinking or routing across any sharp edges Cable routing must be perpendicular to the surface of the front of dash at the dash fitting No objects or routings should force cable to have a bend at the dash fitting Flexible components hoses wires conduits etc 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 1 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 2 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 Federal Vehicle Emission Standards Any alterations to the systems or
159. sary to drain and refill add fluid to transmission such as when installing PTO DO NOT substitute any other lubricant Installation of other lubricants may result in internal transmission damage Castrol Syntrog GL4 is the only synthetic lubricant currently approved for use in the NV4500 This product can be secured through your local GM dealer under GM part number 12346190 per quart e Transmission lubricant capacity is 8 5 pints Models equipped with manual transmission use a hydraulic clutch actuator Check fluid level as outlined in the vehicle owners manual It is mandatory that no change be made to the clutch master cylinder location clutch master or slave cylinder push rod length or pedal position Section 8 Fuel and Exhaust Fuel Systems The fuel evaporative emission control equipment is certified to be in compliance with the Federal and California Vehicle Emission Standards Metal fuel lines and fuel tanks have a surface coating to reduce corrosion on inside and outside surfaces to comply with useful life requirements All fuel hoses are made of alow permeation multi layer material to comply with enhanced evaporative emission requirements Any alter ations to systems or components including materials hose lengths and their location except as described in the fuel fill system modifications section could void com pliance The system includes Fuel tank fuel level sender fuel fill and vent hoses and p
160. tems identified below Door and pillar systems including but not limited to Door lock Door latch striker plate Inside lock control linkage Door hinge Door latch Exterior door handles Door wedges FMVSS 207 Seating Systems This vehicle when altered will conform to FMVSS 207 providing no alterations are made which affect the function physical or mechanical properties environment loca tion and vital spatial clearances of the components assemblies or systems provided and identified below Seating systems including but not limited to Seat adjuster assembly Folding seat or seat back latch assembly Seat or seat back latch assembly Seat or seat back latch striker Seat or seat back latch release control Seat riser Seat anchorages brackets reinforcements attachment hardware etc Seat assembly If the intermediate or final stage manufacturer installs any additional seats they will also have to meet the requirements of this standard FMVSS 208 Occupant Crash Protection This vehicle when altered will conform to FMVSS 208 providing it is completed in accordance with the following specific conditions by the final stage manufacturer 1 The front seat belts provided by General Motors will conform to the requirements of FMVSS 208 providing no alterations are made to a the number location or configuration of the designated seating positions and b the number placement installation or model number of the seat be
161. tion block functions as an interconnect between the vehicle batter ies generators and for the purpose of attaching body builder electrical loads The intent of this block is to provide a convenient location for the body builder to incorpo rate the electrical shunt for a vehicle ammeter if required and also to provide a point where a high current lead can be attached for the ambulance accessories Please note that the wiring to this block comes directly from the batteries and that any loads attached at that point would have to have their own circuit protection devices Refer to the electrical diagram for this system DASH PANEL Me JUNCTION BEOCK Also for cab chassis with the 22 option heavy gauge ground straps have been provided between the engine chassis and body sheet metal near the right rear of the engine for the purpose of providing a robust ground return path from the body or chas sis to the battery The body builder must ensure that the ground returns from their loads provide an adequate ground path into these straps such that voltage drops are minimized CK Rev 12 98 Rev 11 99 C K Truck CURRENT M10 OR 3 8 ENG I NE GROUND 1 50 0 BLK SINGLE STUD JUNCTION BLOCK LH FRONT OF DASH 459476 REGULATOR L 121 80 WHT D C 25 80 BRN 8 12047950 SECONDARY BATTE
162. ty Height Inches C K 20903 w C6P 14 0 C K 30903 Low Service C K 20 3 131 5 WB 56 CA High Service C Regular Cab C K 30943 14 0 164 5 WB 56 Y 20 3 Crew Cab C K 20953 w C6P 14 0 C K 30953 Low Service C K 20 3 155 5 WB 56 CA High Service C Extended Cab These dimensions are measured vertically form top of frame directly behind cab Inches Under 62 0 62 0 amp Over Under 62 0 62 0 amp Over Under 62 0 62 0 amp Over Unloaded vehicle weight means the weight of a vehicle with maximum capacity of all fluids neces sary for operation of the vehicle but without cargo or occupants The body weight the vehicle weight must not exceed the Maximum Unloaded Vehicle Weight ehicle Weight Pounds AMinimum Maximum 1 700 3 0 6 470 1 700 3 0 6 470 2 600 1 700 3 0 6 470 299 vehicles of 8 500 pounds GVWR less see the Vehicle Emission Control Information Engine Exhaust Emission Control Information or Important Engine Information Label in the vehicle engine compartment for completed vehicle curb weight requirements A Weight of Pickup Box Note Bumper weight of 35 Ibs is not included CK Rev 12 98 Rev 11 99 C K Truck CURRENT C K Truck Regular Cab Interior
163. v 11 99 C K Truck CURRENT K 109 209 06 Suburban 4 Wheel Drive w 6 5T Diesel Engine 4072 8 160 35 4 2269 8 609 6 89 36 24 00 1781 7 en 346 0 70 15 13 62 ES 2 916 0 j PST 36 06 2 o EN Beg 42 GAL DRAW 1810 123 2 ON CAPACITY 7 24 4 85 a ae m M _ 610 0 24 02 882 0 34 72 CENTERLINE OF FRONT WHEELS HEAT SHIELD 316 5 12 46 INSIDE METAL TO CENTERLINE OF TAILPIPE Ti s iis 196 0 327 2 772 12 88 INSIDE TOP OF INSIDE METAL FRAME TO BOTTOM NOTES TO BOTTOM OF MUFFLER OF PLASTIC SHIELD gt INCHES K10906 amp L31 SHOWN UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO INSIDE OF METAL CK Rev 12 98 Rev 11 99 C K Truck CURRENT 27 C 10516 Utility 2 Wheel Drive 2 Door GAS EXHAUST DRAWING PI
164. v 12 98 Rev 11 99 C K Truck CURRENT C K 1 2 0906 Suburban Side Step Running Boards Option BVE STEP IN HEIGHT AT SILL 618 0 24 33 500 3 z W BOTTOM RUNNING RAMP OVER ANGLE 4340 1 OF BOARD X Y COORDINATE RUNNING 5 1 DIMENSIONS BOARD HEIGHT W x m 72 44 BMERUNC ton Z 42 44 AND REAR AXLES 125 0 52 0 1670 05 RAMP OVER ANGLE POINT 4 92 2 05 65 75 1000 INCHES CK Rev 12 98 Rev 11 99 C K Truck CURRENT C K 10516 Utility Seating Front Rear d N T j A 189 0 189 0 7 44 34 7 44 v m 898 0 m 898 0 25 12 898 55 35 35 35 VIEW IN DIRECTION OF ARROW A CREW Mi DIRECTION GE ABRIR VIEW IN DIRECTION OF
165. viron ment or thermal exposure or may increase interior noise Check headlamp aim and all vehicle illumination systems for proper operation when the vehicle has been completed Re aim headlamps when necessary Check for proper operation of windshield washer wipers and defroster system 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 or any electronic unit associated with an inflat able restraint system See Owner s Manual If arc welding is employed on the chassis precautions must be taken to protect all vehicle components especially brake and fuel lines fuel tank assembly electrical wir ing and ECM PCM TCM or VCM To avoid electronic component damage disconnect battery batteries disconnect the negative cable first followed by the positive To reconnect cables connect the positive first then the negative CK Rev 12 98 Rev 11 99 When welding components to the frame assembly remove the wax coating in the area of the weld in order to obtain secure welds After completion of the weld a compatible corrosion protection should be applied to the affected weld areas 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 Those i
166. will have increased Front GAWR from 4250 Ibs to 4500 Ibs gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt I gt gt gt gt gt gt gt gt gt gt gt gt gt CK Rev 12 98 Rev 11 99 38 PICKUP BOX REMOVAL PROGRAM The following information is for vehicle alterers who intend to remove Pickup boxes from C K Trucks and install second unit bodies on these vehicle This information ap plies only to those vehicles which have a Gross Vehicle Weight Rating GVWR of 6100 Ibs up to and including 10 000 Ibs Vehicles listed in Table A Alterations To Completed Vehicles Persons who alter complete certified Pickup Trucks by removal of the Pickup box should be aware that this type of activity would impose upon them the corresponding responsibility for ensuring that the units as sold are in compliance with all applicable safety and or emissions including noise and RFI requirements Specific questions concerning compliance or certification to these requirements should be directed to the vehicle alterer s legal counsel or the National Highway Traffic Safety Administra tion The Environmental Protection Agency The California Air Resources Board or in Canada The Ministry of Transport or The Canadian Department of Commerce The Environmental Protection Agency has provided an explanation of the policy they will follow regarding the modification by the secondary manuf
167. ype of body should be further advised that a Pickup may require modification in one of the following areas Before a decision is made to alter a C K Pickup Model please be advised of the following consider ations Vehicle Analyze the vehicle specification for product content The option content of a particular vehicle will determine which if any of the four areas of modification might not be applica ble to the vehicle alteration contemplated Service Parts The service parts and related service part numbers as outlined in the four areas of modi fication may be ordered throughout your local Chevrolet GMC Dealer Contact your Dealer s Service Parts Representative for availability and price Areas of Modification 1 Fuel filler neck assembly and housing 2 Tail lamp tail lamp wiring harness and license plate bracket assembly 3 Fuel tank filler pipe ground strap 4 Spare tire mounting CK Rev 12 98 Rev 11 99 39 ltems Description Quantity 1 Pipe Asm L29 L30 L31 L35 without RPO 15728448 1 1 Pipe Asm L29 L30 L31 L35 with RPO NM8 15156558 1 2 Band TY Wrap 790992 1 3 Clamp 3817244 1 4 Clamp 2464901 CK Rev 12 98 Rev 11 99 C K Truck CURRENT Fuel Tank Filler Neck Diesel Items Description Quantity Housing Fuel Tank Upper 15629096 1 Pipe Asm with Engines L56 L65

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