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PA

G

E

7

P32/42 C

HASSIS

P32/42 Rev. 12/98

D

Crankcase ventilation system.

Diesel engine induction and injector pump system is certified to be in compliance with
the Federal Vehicle Emission Standards and/or Noise Standards.  Any alterations to the
system or components could void compliance and render the vehicle illegal.  System in-
cludes:

D

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.

D

Exhaust system.

D

Crankcase pressure regulation system.

D

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.

D

When a vehicle is equipped with a electronic fuel injection (EFI) engine, it has an
engine control module ECM/PCM/TCM or VCM.  This ECM/PCM/TCM or VCM
must be maintained at a temperature below 185

_

F at all times.  This is most

essential if the vehicle is put through a paint baking process.  The ECM/PCM/TCM
or VCM will become inoperative if its temperature exceeds 185

_

F.  Therefore, it

is recommended that temporary insulation be placed around the ECM/PCM/TCM
or VCM during the time the vehicle is in a paint oven or undergoing another high
temperature process.

Engine starting instruction label location.  Label should be installed 2 in. above driver’s
sunvisor bracket and 2 1/2 in. to the left of the right hand bracket.

The following statement applies to models with remote mounted air cleaners:

The Body Builder must install the air inlet duct such that it provides cool dry air to the air
cleaner.  Radiator baffling must be provided to prevent recirculation of air through the
radiator.  The air inlet must be shielded from water and snow that may come from the
road, tires and through the grille.

The air cleaner position and ducting between the air cleaner and engine should not be
modified.

The following applies to P models with L29/L31/L35 engines:

The relationship of the air cleaner assembly to the Mass Air Flow sensor (MAF) as posi-
tioned by the air cleaner elbow cannot be altered.  The MAF sensor black electronic mod-
ule must remain 30

_

 forward of vertical.

The following statement  applies to P 30032 models with a 6.5L turbo diesel engine.

CAUTION:

Do not run the engine with the air cleaner or ducting to the turbo removed.
Serious personal injury or damage to the engine could result.

Apply a Caution label on the turbo inlet ducting.

Apply Starting Fluid Warning label in a visible area near air intake duct inlet.

Refer to information in the Loose Parts Box for labeling and air inlet duct part numbers.

Section 7 – Transmission

Light duty models equipped with manual transmission have a clutch-operated start safe-
ty switch.  Starter should operate whenever the ignition is turned to start and the clutch
is fully depressed.  The clutch-operated start safety switch is integral with the clutch mas-
ter cylinder push rod.  It is 

not adjustable.

Models equipped with automatic transmissions and column shift control have a steering
column mounted neutral/park start safety mechanical lockout feature, which interfaces
with the steering column ignition switch.  Starter will only operate when gear shift lever
is in the neutral or park position.  Re-adjust the shift linkage if necessary as outlined in
the Truck Service Manual.

Transmission shift cable must be routed and clipped properly to avoid contact with hot
surfaces such as exhaust manifold or EGR pipe.

NOTE:

Remove the shift cable clearance tag from the EGR tube after shift cable
routing.

Models equipped with brake-transmission shift interlock (BTSI) must fully apply the regu-
lar brakes before you can shift from park when the ignition key is in the run position.

Models equipped with manual transmission use a hydraulic clutch actuator.  Check fluid
level as outlined in the vehicle owners manual.  Attach manual transmission shift lever
boot to floor using four 11514843 screws or equivalent.

It is mandatory that no change be made to the clutch master cylinder location, clutch
master cylinder push rod length, or pedal position.

After installation of the body, vehicles with automatic transmissions should have the shift
linkage checked and adjusted if necessary as outlined in the Truck Service Manual.

Summary of Contents for P32

Page 1: ...st be taken to protect all ve hicle components especially brake fuel lines front suspension air cylinders and fuel tank assembly electrical wiring and ECM PCM TCM VCM or ABS To avoid electronic compon...

Page 2: ...body assembly attach ments It is imperative that the body assembly structure be integrated to the chassis through the above parts to ensure vehicle structural integrity If this design criteria is not...

Page 3: ...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...

Page 4: ...a large variation in completed vehicle front weight due to differences in body weight and equipment the front suspension alignment caster camber and toe must be checked and reset if necessary after t...

Page 5: ...Floorboard and toe pan position cannot be altered as it will interfere with brake and ac celerator pedal movement or cause driver discomfort The floor may be covered with normal pad and carpeting only...

Page 6: ...sioner In this type of system degrees of pulley wrap belt tension andpulleyalignmentareverycriticalfactors Modificationisnotrecommended Due to the critical nature of the accelerator system anyone maki...

Page 7: ...elationship of the air cleaner assembly to the Mass Air Flow sensor MAF as posi tionedbytheaircleanerelbowcannotbealtered TheMAFsensorblackelectronicmod ule must remain 30_ forward of vertical The fol...

Page 8: ...ls hoselengthsandtheirlocation exceptasdescribed in the fuel fill system modifications section could void compliance The system includes D Fueltank fuellevelsender fuelfillandventhosesandpipes emissio...

Page 9: ...ns in the fuel system These valves are only to be opened when siphoning water and contaminants from the fuel sys tem Fuel Tank For vehicles with full frames the tank must have a minimum clearance of 2...

Page 10: ...n 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...

Page 11: ...nce of not more than 450 mm In this clipping they shall not have a free movement that will allow rubbing on any vehicle component either fixed or moveable D All clips used must be of the rubber lined...

Page 12: ...h must be off when connecting or disconnecting battery cables or hangers jumper cables Failure to do so may overstress or damage the ECM PCM TCM VCM ABS or other electronic components Modifications ad...

Page 13: ...rea with the top approximately the same height as the radiator fill cap The bottle must be sup ported by the two attaching embossments at the top and also by the rib at the bottom of the bottle to pre...

Page 14: ...PAGE 14 P32 42 CHASSIS P32 42 Rev 12 98 P 30032 General Arrangement Diesel Engine Option L65 6 5L Turbo HO...

Page 15: ...PAGE 15 P32 42 CHASSIS P32 42 Rev 12 98 P 30032 General Arrangement Diesel Engine Option L65 6 5L Turbo HO...

Page 16: ...PAGE 16 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement Diesel Engine Option L57 6 5L HO w FL6 Independent Front Suspension...

Page 17: ...PAGE 17 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement Diesel Engine Option L57 6 5L HO w FL6 Independent Front Suspension...

Page 18: ...PAGE 18 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement Gas Engine Option L31 5 7L V8 w FK4 I Beam Front Suspension...

Page 19: ...PAGE 19 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement Gas Engine Option L31 5 7L V8 w FK4 I Beam Front Suspension Option FK4...

Page 20: ...PAGE 20 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement Gas Engine Option L31 5 7L V8 w FL6 Independent Front Suspension...

Page 21: ...PAGE 21 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement Gas Engine Option L31 5 7L V8 w FL6 Independent Front Suspension...

Page 22: ...PAGE 22 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement Gas Engine Option L35 4 3L V6 w FK4 I Beam Front Suspension...

Page 23: ...PAGE 23 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement Gas Engine Option L35 4 3L V6 w FK4 I Beam Front Suspension...

Page 24: ...PAGE 24 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement Gas Engine Option L35 4 3L V6 w FL6 Independent Front Suspension...

Page 25: ...PAGE 25 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement Gas Engine Option L35 4 3L V6 w FL6 Independent Front Suspension...

Page 26: ...PAGE 26 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement Gas Engine Option L35 4 3L V6 w FL5 FL6 Independent Front Suspension...

Page 27: ...PAGE 27 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement Gas Engine Option L35 4 3L V6 w FL5 FL6 Independent Front Suspension...

Page 28: ...PAGE 28 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement Diesel Engine Option L57 6 5L HO w FK4 FK5 I Beam Front Suspension...

Page 29: ...PAGE 29 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement Diesel Engine Option L57 6 5L HO w FK4 FK5 I Beam Front Suspension...

Page 30: ...PAGE 30 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement H Point Locations w I Beam Front Suspension Options FK4 FK5 without I Beam Front Suspension Options FL5 FL6 FL7...

Page 31: ...PAGE 31 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 General Arrangement School Bus Application Option B3D B3M L57 L57 L57...

Page 32: ...PAGE 32 P32 42 CHASSIS P32 42 Rev 12 98 P 30032 Auto Apply Park Brake Harness Ground...

Page 33: ...PAGE 33 P32 42 CHASSIS P32 42 Rev 12 98 P 30000 Instrument Cluster Location...

Page 34: ...PAGE 34 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 Body Mounting Hole Location P 30000 Battery Mounting Hole Location...

Page 35: ...PAGE 35 P32 42 CHASSIS P32 42 Rev 12 98 P 30000 Chassis Data...

Page 36: ...PAGE 36 P32 42 CHASSIS P32 42 Rev 12 98 P 30032 Taperleaf Suspension...

Page 37: ...PAGE 37 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 Gas Engine 5 7L V8 Option L31...

Page 38: ...PAGE 38 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 Gas Engine 4 3L V6 Option L35...

Page 39: ...PAGE 39 P32 42 CHASSIS P32 42 Rev 12 98 P 30032 Gas Engine 7 4L V8 Option L29...

Page 40: ...PAGE 40 P32 42 CHASSIS P32 42 Rev 12 98 P 30032 Diesel Engine 6 5L Turbo Ho Option L65...

Page 41: ...PAGE 41 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 Diesel Engine 6 5L HO Option L57...

Page 42: ...P 300 32 42 Engine Removal Space Requirements and Deaeration Cooling System Engine Removal Space Requirements Deaeration Cooling System Diesel Vent Line Heater Tank Inlet Connection Crossover Pipe Wat...

Page 43: ...PAGE 43 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 Air Conditioning Fittings...

Page 44: ...PAGE 44 P32 42 CHASSIS P32 42 Rev 12 98 P 30042 Air Conditioning Compressor Locations...

Page 45: ...PAGE 45 P32 42 CHASSIS P32 42 Rev 12 98 P 300 32 42 Fuel Filler Neck...

Page 46: ...PAGE 46 P32 42 CHASSIS P32 42 Rev 12 98 P 30000 Fuel Tank Arrangement...

Page 47: ...PAGE 47 P32 42 CHASSIS P32 42 Rev 12 98 P 30000 Temporary Fuel Tank Arrangement...

Page 48: ...PAGE 48 P32 42 CHASSIS P32 42 Rev 12 98 P 30000 Center High Mounted Stop Lamp CHMSL...

Page 49: ...PAGE 49 P32 42 CHASSIS P32 42 Rev 12 98 P 300 32 42 Lamp Mounting P 30032 P 30042...

Page 50: ...PAGE 50 P32 42 CHASSIS P32 42 Rev 12 98 P 300 32 42 Instrument Panel Cut Out...

Page 51: ...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 wi...

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