GMC CHEVROLET CITY EXPRESS CARGO VAN 2015 Builder Manual Download

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2015-18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL

Pa g e |

Front Air Bag Modules

—

Driver Side (2017)

1. Side curtain air bag module

(located behind LH side of head-
lining and across windshield
header)

2. Side air bag module (located at

outboard side of driver seatback)

3. Driver air bag module (located in

steering wheel)

Summary of Contents for CHEVROLET CITY EXPRESS CARGO VAN 2015

Page 1: ...Pa g e 1 GENERAL MOTORS UPFITTER INTEGRATION 2015 18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL...

Page 2: ...2015 18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 2 Revision 1 0 Release date October 2 2017...

Page 3: ...nger Air Bag Deployment Width 21 Headlining Cut Front Side Curtain Air Bags Clearance for Bulkhead Installation 22 AIR BAG DEPLOYMENT KEEP OUT ZONES 23 Front Air Bag Keep Out Zones Overhead View 23 Fr...

Page 4: ...w 45 Side Air Bag Inflation Zones Overhead View 46 ALTERED VEHICLES 47 SAFETY INFORMATION 47 Safety Emissions Certification Labels for Altered Vehicles 47 BRAKE COMPLIANCE GUIDELINES 49 Brake Complian...

Page 5: ...67 Cutaway Overhead View 68 D Ring Tie Downs If Equipped 69 SIGN AREA 70 RH Exterior Dimensions 70 LH Exterior Dimensions 71 RH Front Door Exterior Dimensions 72 LH Front Door Exterior Dimensions 73 R...

Page 6: ...REAS 93 Chassis 93 Fuel Filler Pipe and EVAP Canister Location 94 TANK LOCATION 95 Tank Mounting 95 Drilling Precaution Area 96 Fuel Tank Floor Area 96 Drilling Precaution Area continued 97 Drilling P...

Page 7: ...6 REPLACING BOLTS 117 Tightening Torque Table 117 ADD ON EQUIPMENT 118 ANTI CORROSIONPROTECTION 118 SHELVINGANDBULKHEADINSTALLATION 118 Bulkhead 118 H Body Side and D pillar Inner 119 RH Body Side and...

Page 8: ...2015 18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 8 Bulbs 131 Exterior Bulbs 131 Interior lamp Illumination 131 Battery 131 Acronyms 132...

Page 9: ...y Traffic Safety Administration NHTSA the Occupational Safety and Health Act OSHA state local or provincial government laws These regulations and laws may require the installation of additional equipm...

Page 10: ...2015 18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 10...

Page 11: ...M does not assume the responsibility as the final stage manufacturer for modified or altered vehicles General Motors and or the OEM is not responsible for the final certification product liability cla...

Page 12: ...injury caused by unintentional activation of the system Do not use electrical test equipment on any circuit related to the SRS SRS wiring harnesses can be identified by yellow and or orange harnesses...

Page 13: ...2015 18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 13 SUPPLEMENTAL RESTRAINT SYSTEM SRS COMPONENT LOCATIONS...

Page 14: ...moved 6 Instrument Cluster SRS warning light 7 Crash zone sensor view with front grille removed 8 Front LH seat belt pre tensioner RH similar view with lower center pillar cover removed 9 Front side a...

Page 15: ...ir bag or system failure and may increase the risk of serious injury or death in a collision The front passenger seat is equipped with seat weight sensors as part of the supplemental restraints occupa...

Page 16: ...ot interfere with air bag modules or deployment zones Damage to air bag modules may cause serious personal injury or death Objects placed within air bag deployment zones may cause serious personal inj...

Page 17: ...s Overhead View Air Bag Module Locations No modifications in these areas 1 Driver air bag module 2 Side curtain air bag module driver 3 Side air bag module driver 4 Side air bag module passenger 5 Sid...

Page 18: ...r Side Front of vehicle 1 Side curtain air bag module located behind LH side of headlining and across windshield header 2 Side air bag module located at outboard side of driver seatback 3 Driver air b...

Page 19: ...er Side Front of Vehicle 1 Side curtain air bag module located behind RH side of headlining and across windshield header 2 Front passenger air bag module located in RH side of instrument panel 3 Side...

Page 20: ...ARGO VAN BODY BUILDER MANUAL Pa g e 20 Driver Air Bag Deployment Width A Center of the driver air bag module housing B 267 5 mm 10 53 in C Maximum lateral projection of the deployed driver air bag 535...

Page 21: ...Passenger Air Bag Deployment Width A Maximum lateral projection of the deployed front passenger air bag 475 mm 18 7 in B Center of front passenger air bag module housing C 237 5 mm 9 35 in D Reference...

Page 22: ...Clearance for Bulkhead Installation 1 Headlining 2 Driver side curtain air bag module 3 Portion of headlining to be cut off and discarded 4 Passenger side curtain air bag module A 50 mm 1 97 in B 50...

Page 23: ...O VAN BODY BUILDER MANUAL Pa g e 23 AIR BAG DEPLOYMENT KEEP OUT ZONES Front Air Bag Keep Out Zones Overhead View Center of seat Reference point s 1 Instrument panel edge 2 Door glass trim edge 3 Seat...

Page 24: ...EVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 24 Front Air Bag Keep Out Zone Driver Side View A 635 mm 25 in D 405 mm 15 94 in B 510 mm 20 08 in E 915 mm 36 02 in C 685 mm 26 97 in F 355 m...

Page 25: ...BUILDER MANUAL Pa g e 25 Front Air Bag Keep Out Zone Passenger Side View Reference point s 1 Zone follows windshield surface 2 Zone follows instrument panel surface contour A 635 mm 25 00 in B 405 mm...

Page 26: ...oint s 1 Door glass trim edge 2 Maximum inflated driver air bag 3 Vehicle center line 4 Maximum inflated front passenger air bag 5 Door glass trim edge A 150 mm 5 91 in between door glass trim edge an...

Page 27: ...7 Front Air Bag Inflation Zones Overhead View 1 Maximum inflated driver air bag 2 Maximum inflated front passenger air bag 3 Reference point instrument panel seam A 110 mm 4 33 in between instrument p...

Page 28: ...g Inflation Zones Driver Side View 1 Maximum inflated side curtain air bag 2 Maximum inflated side air bag 3 Maximum inflated driver air bag A 760 mm 29 92 in B 750 mm 29 53 in C 350 mm 13 78 in D 550...

Page 29: ...nflation Zones Passenger Side View 1 Maximum inflated side curtain air bag 2 Front edge of front passenger air bag module 3 Maximum inflated front passenger air bag 4 Maximum inflated side air bag A 7...

Page 30: ...O VAN BODY BUILDER MANUAL Pa g e 30 Side Curtain Air Bag Inflation Zones Overhead View A 210 mm 8 27 in B 60 mm 2 36 in between door glass trim edge and air bag C 60 mm 2 36 in between door glass trim...

Page 31: ...ARGO VAN BODY BUILDER MANUAL Pa g e 31 Side Air Bag Inflation Zones Overhead View A 200 mm 7 87 in B 115 mm 4 53 in between door glass trim edge and air bag C 115 mm 4 53 in between door glass trim ed...

Page 32: ...NT AIR BAG MODULE LOCATIONS Front Air Bag Modules Overhead View 2017 Air Bag Module Locations No modifications in these areas 1 Driver air bag module 2 Side curtain air bag module driver 3 Side air ba...

Page 33: ...Pa g e 33 Front Air Bag Modules Driver Side 2017 1 Side curtain air bag module located behind LH side of head lining and across windshield header 2 Side air bag module located at outboard side of driv...

Page 34: ...Side 2017 Air Bag Module Locations No modifications in these areas 1 Side curtain air bag module located behind RH side of headliner and across windshield header 2 Front passenger air bag module locat...

Page 35: ...O VAN BODY BUILDER MANUAL Pa g e 35 Driver Air Bag Deployment Width 2017 A Center of the driver air bag module housing B 267 5 mm 10 53 in C Maximum lateral projection of the deployed driver air bag 5...

Page 36: ...2017 Air Bag Module Locations No modifications in these areas A Maximumlateralprojectionof the deployed front passenger air bag 475 mm 18 7 in B Center of front passenger air bag module housing C 237...

Page 37: ...D INSTALLATION Overhead cutaway view with roof panel removed 1 Headliner 2 Driver side curtain air bag module 3 Portion of headlining to be cut off and discarded 4 Passenger side curtain air bag modul...

Page 38: ...one No modifications in this area Air Bag Inflation Zone 1 Reference point instrument panel edge 2 Reference point door glass trim edge 3 Reference point seat center lines 4 Reference point door glass...

Page 39: ...MANUAL Pa g e 39 Front Air Bag Keep Out Zone Driver Side View Air Bag Deployment Keep out Zone No modifications in this area Air Bag Inflation Zone A 635 mm 25 in B 510 mm 20 08 in C 685 mm 26 97 in...

Page 40: ...one Passenger Side View Air Bag Deployment Keep out Zone No modifications in this area Air Bag Inflation Zone 1 Reference point zone follows windshield surface 2 Reference point zone follows instrumen...

Page 41: ...ass trim edge 2 Maximum inflated driver air bag 3 Reference point vehicle centerline 4 Maximum inflated front passenger air bag 5 Reference point door glass trim edge 6 A 150 mm 5 91 in between door g...

Page 42: ...e 42 Front Air Bag Inflation Zones Overhead View 1 Maximum inflated Driver air bag 2 Maximum inflated Passenger air bag 3 Reference point Instrument Panel Seam A 110 mm 4 33 in between instrument pane...

Page 43: ...Inflation Zones Driver Side View 1 Maximum inflated Side Curtain airbag 2 Maximum inflated Side air bag 3 Maximum inflated Driver air bag A 1 062 mm 41 81 in B 699 mm 27 52 in C 350 mm 13 78 in D 550...

Page 44: ...flation Zones Passenger Side View 1 Maximum inflated side curtain air bag 2 Front edge of front passenger air bag module 3 Maximum inflated front passenger air bag 4 Maximum inflated side air bag A 1...

Page 45: ...BODY BUILDER MANUAL Pa g e 45 Side Curtain Air Bag Inflation Zones Overhead View A 219 mm 8 62 in B 71 6 mm 2 82 in between door glass trim edge and air bag C 71 6 mm 2 82 in between door glass trim...

Page 46: ...ARGO VAN BODY BUILDER MANUAL Pa g e 46 Side Air Bag Inflation Zones Overhead View A 200 mm 7 87 in B 115 mm 4 53 in between door glass trim edge and air bag C 115 mm 4 53 in between door glass trim ed...

Page 47: ...anada Modifiers of motor vehicles are required to affix a permanent label on vehicles that they manufacture bearing a statement of compliance as provided by Section 9 of the Canadian Motor Vehicle Saf...

Page 48: ...permanently attached Shall be affixed adjacent to the original compliance label required by Section 6 The lettering of the label shall be clear indelible indented or embossed or of a color that contra...

Page 49: ...e following systems o parking brake o anti lock brakes o engine vacuum o steering o wheels or tires o brakes o indicator lamps and wiring o brake system reservoir labeling o suspension ride height or...

Page 50: ...2015 18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 50 CENTER OF GRAVITY CG Vehicle Center of Gravity Measurement Process Introduction...

Page 51: ...ight pounds GVW W b W c W l P GVWR Gross Vehicle Weight Rating of the vehicle kg lbs h f Vertical distance between the front wheel center to ground line h R Vertical distance between the rear wheel ce...

Page 52: ...les For safety apply the parking brake Measurement Methods 1 The vehicle should be at its unloaded vehicle condition with full fluids and equipped with spare tire jack and tools 2 Measure the wheelbas...

Page 53: ...5 m 1 6 ft shall be representative value 3 Calculate the CG height by using the following equations Results The center of gravity height GC V obtained is theoretically the same for both cases with th...

Page 54: ...to MaxC 1 050 2 315 1 150 2 535 904 4 1 994 577 3 1 273 1 481 7 3 267 SV 2 925 115 2 1 663 1 3 667 2 155 4 751 657 7 1 450 180 5 398 1 050 2 315 1 150 2 535 905 1 1 995 577 7 1 274 1 482 8 3 269 Maxi...

Page 55: ...26 1 and 135 2 the vertical vehicle center of gravity location can be approximated by following the formula below 1 2 For GVC please use the constant number described on List of Terms The Vertical Cen...

Page 56: ...SS AND CMVSS REGULATION LIST Standards For FMVSS standards refer to the following website www nhtsa gov staticfiles rulemaking pdf FMVSS QuickRefGuide HS811439 pdf For CMVSS standards refer to the fol...

Page 57: ...57 PRECAUTIONS Precautions for Electrical CAN Controller Area Network System Do not modify the CAN system For additional information and identification of CAN system refer to the Service Manual or con...

Page 58: ...specification label 3 Transmission fluid specification label 4 Brake fluid warning label 5 Emission control information label 6 Tire and loading information label 7 Vehicle Identification Number Chas...

Page 59: ...nting Hole Dimensions Warning To avoid rendering the SRS inoperative which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation the f...

Page 60: ...oving or installing the front seats turn ignition switch OFF disconnect both battery terminals and wait at least 3 minutes 2 Place the seat in the vehicle on the mounting stud with the locator pin cor...

Page 61: ...AN BODY BUILDER MANUAL Pa g e 61 RH Front Seat Front Mounting Hole Location 1 Inboard center of hole 2 Outboard center of hole X 874 1 mm 34 4 in X 874 1 mm 34 4 in Y 188 6 mm 7 4 in Y 568 mm 22 4 in...

Page 62: ...AN BODY BUILDER MANUAL Pa g e 62 LH Front Seat Front Mounting Hole Location 1 Inboard center of hole 2 Outboard center of hole X 874 1 mm 34 4 in X 874 1 mm 34 4 in Y 188 6 mm 7 4 in Y 568 mm 22 4 in...

Page 63: ...TY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 63 Seat Position Diagrams SgRP Front Seat Dimension NOTE Seat is in full down and back position A 1 086 5 mm 42 77 in B 625 9 mm 24 64 in C 240 mm 9 44...

Page 64: ...B Maximum length at floor behind seat base 2 103 5 mm 82 8 in C Maximum cargo height 1 330 mm 52 4 in D Height at rear wheel center 1 317 mm 51 9 in E Maximum width at floor Between slide doors 1 480...

Page 65: ...SS CARGO VAN BODY BUILDER MANUAL Pa g e 65 Wheel Well Clearance Cut away side view RH NOTE View from inside of vehicle A Seat position B 296 mm 11 65 in Rear most 856 mm 33 7 in Center 952 mm 37 5 in...

Page 66: ...SS CARGO VAN BODY BUILDER MANUAL Pa g e 66 Wheel Well Clearance Cut away side view LH NOTE View from inside of vehicle A Seat position B 296 mm 11 65 in Rear most 856 mm 33 7 in Center 952 mm 37 5 in...

Page 67: ...DER MANUAL Pa g e 67 Cutaway Wheel Well and Rear Views Rear Left Hand Right Hand Front of Vehicle A 261 8 mm 10 3 in B 1 175 mm 46 3 in C 1 250 mm 49 2 in D 1 260 mm 49 6 in E 725 mm 28 5 in F 271 mm...

Page 68: ...2015 18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 68 Cutaway Overhead View Front of Vehicle A 570 mm 22 4 in B 1 323 mm 52 1 in C 1 432 mm 56 4 in A C A...

Page 69: ...AL Pa g e 69 D Ring Tie Downs If Equipped Front of Vehicle WARNING Do not exceed the maximum total D ring tie down loading of 5 000N 1 124 lbs D ring tie down location A 1 005 mm 39 6 in B 845 mm 33 3...

Page 70: ...r Dimensions A 918 mm 36 1 in B 825 mm 32 5 in C 408 mm 16 1 in D 713 mm 28 1 in E Inset depth 18 mm 0 7 in F 781 mm 30 7 in G 450 mm 17 7 in H 300 mm 11 8 in J 81 mm 3 2 in K 723 mm 28 5 in L 114 mm...

Page 71: ...mm 26 5 in B 836 mm 32 9 in C 987 mm 38 9 in D 1 059 mm 41 7 in E 1 429 mm 56 3 in F 1 587 mm 62 5 in G 210 mm 8 3 in H 322 mm 12 7 in J 383 mm 15 1 in K 760 mm 29 9 in L 1 330 mm 52 4 in M 2 670 mm...

Page 72: ...72 RH Front Door Exterior Dimensions Front of vehicle A 35 0 mm 1 38 in B 132 2 mm 5 20 in C 867 2 mm 34 14 in D 104 7 mm 4 12 in E 384 5 mm 15 14 in F 92 6 mm 3 65 in G 211 4 mm 8 32 in H 546 2 mm 2...

Page 73: ...73 LH Front Door Exterior Dimensions Front of vehicle A 35 0 mm 1 38 in B 132 2 mm 5 20 in C 384 5 mm 15 14 in D 104 7 mm 4 12 in E 867 2 mm 34 14 in F 92 6 mm 3 65 in G 211 4 mm 8 32 in H 788 0 mm 3...

Page 74: ...6 5 in F 200 mm 7 9 in G Inset depth 27 mm 1 1 in H Inset depth 27 mm 1 1 in J 450 mm 17 7 in K 870 mm 34 3 in L Inset depth 14 mm 0 6 in M 75 mm 3 0 in With Glass A 1 450 mm 57 1 in B 941 mm 37 0 in...

Page 75: ...5 LH Slide Door Exterior Dimensions A 1 450 mm 57 1 in D 1 002 mm 39 4 in G Inset depth 27 mm 1 1 in K 870 mm 34 3 in B 941 mm 37 0 in E 165 mm 6 5 in H Inset depth 27 mm 1 1 in L Inset depth 14 mm 0...

Page 76: ...2015 18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 76 Hood Surface Exterior Dimensions A 275 mm 10 8 in B 745 mm 29 3 in C 120 mm 4 7 in D 568 mm 22 4 in E 80 mm 3 1 in...

Page 77: ...EVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 77 Hood Surface Exterior Dimensions continued A Flat surface area 1 026 m2 1 590 in2 B 1 479 mm 58 2 in C 310 mm 12 2 in D 55 mm 2 2 in E 140...

Page 78: ...mm 2 0 in B 61 mm 2 4 in C 580 mm 22 8 in D 796 mm 31 3 in E 128 mm 5 0 in F 75 mm 3 0 in G 36 mm 1 4 in H 54 mm 2 1 in J 70 mm 2 8 in K 628 mm 24 7 in L 30 mm 1 2 in M 255 mm 10 0 in N 643 mm 25 3 in...

Page 79: ...ARGO VAN BODY BUILDER MANUAL Pa g e 79 Back Door Window Opening Sign Area 1 Door gap seam A 128 mm 5 0 in B 426 mm 16 8 in C 455 mm 17 9 in D 488 mm 19 2 in E 438 mm 17 2 in F 750 mm 29 5 in G 782 mm...

Page 80: ...Door Opening Measurements Front of Vehicle Without Door Seal and Interior Trim A 1 191 mm 46 9 in B 870 mm 34 3 in C 1 278 mm 50 3 in D 715 mm 28 1 in E 88 mm 3 5 in With Door Seal and Interior Trim A...

Page 81: ...cle Without Door Seal and Interior Trim A 818 mm 32 2 in B 735 mm 28 9 in C 1 181 mm 46 5 in D 1 181 mm 46 5 in E 27 mm 1 06 in F 1 181 mm 46 5 in With Door Seal and Interior Trim 1 Headlining A 812 m...

Page 82: ...hicle Without Door Seal and Interior Trim A 818 mm 32 2 in B 735 mm 28 9 in C 1 181 mm 46 5 in D 1 181 mm 46 5 in E 27 mm 1 06 in F 1 181 mm 46 5 in With Door Seal and Interior Trim 1 Headlining A 812...

Page 83: ...talled Front of Vehicle Without Door Seal and Interior Trim A 623 mm 24 5 in B 1 181 mm 46 5 in C 622 mm 24 5 in D 624 mm 24 6 in E 27 mm 1 06 in With Door Seal and Interior Trim 1 Headlining A 620 mm...

Page 84: ...talled Front of Vehicle Without Door Seal and Interior Trim A 623 mm 24 5 in B 1 181 mm 46 5 in C 622 mm 24 5 in D 624 mm 24 6 in E 27 mm 1 06 in With Door Seal and Interior Trim 1 Headlining A 620 mm...

Page 85: ...2015 18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 85 Back Door Opening Measurements A 1 175 mm 46 3 in B 1 238 mm 48 75 in C 1 260 mm 49 6 in D 1 250 mm 49 2 in E 193 mm 7 6 in...

Page 86: ...Y BUILDER MANUAL Pa g e 86 Doors and Mirrors Dimensions Overhead View A 3 523 mm 138 7 in B With Mirrors Unfolded 2 010 mm 79 1 in C With Mirrors Folded 1 856 mm 73 1 in D 671 mm 26 4 in E 1 019 mm 40...

Page 87: ...all Dimensions A 4 732 5 mm 186 3 in B 2 925 mm 115 2 in C 968 2 mm 38 1 in D 839 3 mm 33 in E 535 7 mm 21 in F 1 226 7 mm 48 3 in G 1 871 7 mm 73 7 in H 1 729 5 mm 68 1 in Between front fender outboa...

Page 88: ...75 in B 520 mm 20 5 in C 508 05 mm 20 in D 376 94 mm 14 84 in E 68 14 mm 2 68 in F 343 87 mm 13 5 in G 472 97 mm 18 6 in H 844 21 mm 33 23 in J 329 36 mm 12 9 in K 909 28 mm 35 8 in L 383 22 mm 15 08...

Page 89: ...nsions continued NOTE Floor sheet metal removed for clarity Front of vehicle A 1 009 mm 39 7 in B 1 134 mm 44 6 in C 1 250 mm 49 2 in D 1 225 mm 48 2 in E 1 331 mm 52 4 in F 1 275 4 mm 50 2 in G 1 428...

Page 90: ...2015 18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 90 ELECTRICAL Refer to the BODY BUILDER MANUAL 2016 CHEVROLET CITY EXPRESS ELECTRICAL SECTION for detailed electrical information...

Page 91: ...Release Procedure in this section Disconnect the battery negative terminal Always replace O rings and clamps with new ones Do not kink or twist hoses when they are being installed After connecting th...

Page 92: ...mp fuse 20 15A 1 Remove fuel pump fuse 2 located in IPDM E R 1 Refer to the Body Builder Manual 2016 Chevrolet City Express Electrical Section for detailed fuse location information 2 Start engine 3 A...

Page 93: ...2015 18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 93 FILLER NECK AREAS Chassis Front of vehicle 1 B pillar rear edge A 195 mm 7 7 in B 207 mm 8 1 in C 430 mm 16 9 in...

Page 94: ...VAN BODY BUILDER MANUAL Pa g e 94 Fuel Filler Pipe and EVAP Canister Location Front of vehicle 1 EVAP canister assembly 2 Fuel tank protector 3 Fuel tank 4 Front tank strap 5 Clamp 6 Fuel filler hose...

Page 95: ...CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 95 TANK LOCATION Tank Mounting Front of vehicle 1 Fuel tank 2 Rear tank strap 3 Front tank strap 4 EVAP canister assembly A Fuel tank strap...

Page 96: ...lines when drilling through the floor in the area shown or component failure and personal injury may occur Fuel Tank Floor Area All dimensions and reference lines are shown with cargo mat removed Fron...

Page 97: ...g e 97 Drilling Precaution Area continued All dimensions and reference lines are shown with cargo mat removed Front of vehicle 1 Front door jamb front at floor reference line 2 Fuel tank drill precau...

Page 98: ...CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 98 Drilling Precaution Area Filler Neck B Pillar Area Front of vehicle 1 Fuel filler area drill precaution zone A 300 mm 11 8 in B 400 mm 1...

Page 99: ...2015 18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 99 TRAILER TOW Do not tow a trailer with this vehicle This vehicle is not equipped with trailer tow equipment...

Page 100: ...radiator radiator shroud cooling fans liquid cooling circuit etc is allowed Sufficient air passage to the radiator must be maintained therefore do not block the air passage through the radiator grille...

Page 101: ...the HVAC System Changes to the HVAC system are not recommended For liquid connection information service data and specifications refer to the service manual HVAC System Component Locations Manual Air...

Page 102: ...ust system are not recommended 1 Intermediateexhausttube 2 Exhaust bolt springs 3 Ring gasket 4 Front exhaust tube 5 Exhaust bolt springs 6 Ring gasket 7 Gasket 8 Main muffler 9 Ring gasket 10 Exhaust...

Page 103: ...in muffler 4 Rear edge of body channel 5 Front edge of secondary muffler 6 Rear edge of secondary muffler 7 Fuel tank heat shield A 1 470 mm 57 9 in B 745 mm 29 3 in C 670 mm 26 4 in D 120 mm 4 7 in E...

Page 104: ...the nuts on the front and rear of the exhaust tubes Check each part for interference with other components and then tighten the nuts and bolts to specification Inspection after Installation Check exh...

Page 105: ...by the OEM is not recommended Using tires of different make size type or characteristics on the same axle is not allowed Using non recommended tires could affect the performance of the Vehicle Dynami...

Page 106: ...be grounded to any of the suspension components Any new components attached to the steering column or its components must not interfere with the steering column performance during either normal opera...

Page 107: ...lines must be properly retained with adequate clips The shift cable external transmission shift lever and shift cable bracket must not be altered Transmission identification tags must not be removed o...

Page 108: ...revent burns a long sleeve shirt and trousers must also be worn and must not be taken off under any circumstance Before starting repair work be sure to disconnect the negative terminal of the battery...

Page 109: ...ITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 109 High Strength Steel Locations The grey shading in the following illustrations indicate body areas with high strength steel HSS Front Front Left Sid...

Page 110: ...2015 18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 110 Right Side Left Side Rear Left Side Rear Right Side...

Page 111: ...2015 18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e 111 Rear Floor...

Page 112: ...llarreinforcement Other reinforcements 980 1310 MPa Outer sill reinforcement Main back pillar Read the following precautions when repairing HSS 1 Additional points to consider The repair of reinforcem...

Page 113: ...mance in the event of a crash If spot welding is impossible use MIG welding Do not use gas torch welding because it is inferior in welding strength and could have altered performance in the event of a...

Page 114: ...each other leaving no gaps Follow the specifications for the proper welding pitch NOTE The minimum welding pitch varies with the thickness of panels to be welded In general observe the values in the...

Page 115: ...odification to the body that affect the acoustic and thermal insulation the new and or modified insulation must meet or exceed the original specifications Any modifications made by the aftermarket equ...

Page 116: ...sunstarea co m 937 746 8575 Terostat mastic adhesives 06 1273HM Henkel Corporation www henkel com USA 1 248 583 9300 Chemtrec emergency 1 800 424 9300 SA 461 SA 462 SA 463 Masticadhesive PCC 13A EFTEC...

Page 117: ...6 33 65 6 6 48 M14 14 0 1 5 80 8 2 59 100 10 74 7T M6 6 0 1 0 9 0 92 7 80 11 1 1 8 97 M8 8 0 1 25 22 2 2 16 28 2 9 21 1 0 22 2 2 16 28 2 9 21 M10 10 0 1 5 45 4 6 33 55 5 6 41 1 25 45 4 6 33 55 5 6 41...

Page 118: ...r coat and allow to properly dry 4 Apply OEM approved Wax available at a Chevrolet dealer SHELVINGANDBULKHEADINSTALLATION Bulkhead The bulkhead should be attached to the OEM supplied weld nuts in the...

Page 119: ...mm 14 8 in D 255 mm 10 0 in E 1 125 mm 44 3 in F 1 135 mm 44 7 in G 173 mm 6 8 in H 193 mm 7 6 in H Body Side and D pillar Inner RH body side inner as viewed from inside the vehicle Loading should be...

Page 120: ...ll bolts are M8 x 1 25 1 Bulkhead mounting weld nut Mounting point loading not to exceed 10 kg 22 lbs Point may be plugged with M8 bolt 2 Mounting point loading not to exceed 10 kg 22 lbs per point Ma...

Page 121: ...All bolts are M8 x 1 25 1 Mounting point loading not to exceed 10 kg 22 lbs 2 Mounting point loading not to exceed 10 kg 22 lbs per point Total loading across these 2 mounting points not to exceed 20...

Page 122: ...if equipped Loading should be distributed evenly utilizing as many mounting points as possible Front of vehicle Bolt locations for shelving installation All bolts are M8 x 1 25 Mounting point loading...

Page 123: ...eld nut locations All bolts are M6 x 1 0 Mounting point loading not to exceed 5 kg 11 lbs per point Total loading across all 4 weld nuts not to exceed 20 kg 44 lbs Do not exceed a depth of 38 mm 1 5 i...

Page 124: ...ured cargo could cause personal injury To avoid personal injury use care when placing or removing items from the roof rack If you cannot comfortably lift the items onto the roof rack from the ground u...

Page 125: ...exceed a depth of 24 mm 0 9 in for the two front weld nuts A 1 004 mm 39 5 in B 630 mm 24 8 in C 1 117 mm 44 0 in D 1 113 mm 43 8 in E 1 128 mm 44 4 in F 214 mm 8 4 in G 60 3 mm 2 4 in H 800 mm 31 5...

Page 126: ...caution for Fuel 2 For further details refer to Engine Oil Recommendation 3 For further details refer to Engine Coolant Recommendation 4 Available through a CHEVROLET dealer 5 For further details see...

Page 127: ...OEM Long Life Antifreeze Coolant blue and 50 water to provide year round antifreeze and coolant protection The antifreeze solution contains rust and corrosion inhibitors Additional cooling system add...

Page 128: ...0 4 17 Maximum 4 55 4 92 Kingpininclination Degree minute decimal degree LH and RH Minimum 11 10 11 17 Nominal 11 55 11 92 Maximum 12 40 12 67 Total toe in Total toe in distance A B Minimum Out 1 0 mm...

Page 129: ...O VAN BODY BUILDER MANUAL Pa g e 129 Wheel Turning Angle Inner wheel angle A Degree minute decimal degree Minimum 36 55 36 92 Nominal 39 55 39 92 Maximum 40 55 40 92 Outer wheel angle B Degree minute...

Page 130: ...Camber Degree minute decimal degree Minimum 2 0 2 0 Nominal 1 30 1 5 Maximum 1 0 1 0 Total toe in Total toe in distance A B Minimum Out 2 mm 0 079 in Nominal In 3 mm 0 118 in Maximum In 8 mm 0 315 in...

Page 131: ...clearance 2 5 mm 0 10 Bulbs Exterior Bulbs Item Wattage W Bulb No Front combination lamp Turn signal parking lamp 28 8 3457 NAK Headlamp low high 60 55 Halogen H13 Rear combination lamp Stop tail lam...

Page 132: ...Transmission AT AutoTransporter ATV All Terrain Vehicle BCM BodyControlModule BT BusTrailer CAN Controller Area Network CAN H Controller Area Network High CAN L Controller Area Network Low CD C Dolly...

Page 133: ...ns ILSAC International Lubricant Standardization and Approval Committee IPDM E R Intelligent Power Distribution Module Engine Room LDD Load Divider Dolly MH Motor Home MIL Malfunction Indicator Light...

Page 134: ...gineers SB School Bus SgRP Seating Reference Point Acronym Description SRS Supplemental Restraint System SUB Second Unit Body TCD Trailer Converter Dolly TCM Transmission Control Module TPS Throttle P...

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