Polaris GEM E Series Service Manual Download

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ELECTRICAL 5 - 50

November 2007

GEM Service Manual

POWER DISTRIBUTION

Summary of Contents for GEM E Series

Page 1: ...GEM Service Manual REV 1 4 19 2012 November 2007 1 INTRODUCTION 1 1 2 SUSPENSION AND STEERING 2 1 3 DRIVETRAIN 3 1 4 BRAKES 4 1 5 ELECTRICAL 5 1 6 WHEELS AND TIRES 6 1 7 BODY 7 1 ...

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Page 3: ...Manual November 2007 CONTENTS INTRODUCTION 1 2 GENERAL WARNINGS 1 2 VEHICLE IDENTIFICATION SAFETY CERTIFICATION LABEL 1 3 FASTENER USAGE 1 3 PARTS AND LUBRICANT RECOMMENDATION 1 5 MAINTENANCE SCHEDULES 1 5 HOISTING AND JACKING 1 6 ...

Page 4: ...icle integrity by their choice of methods tools or parts GENERAL WARNINGS Observe the following safety precautions whenever you are working on your vehicle Always wear safety glasses for eye protection Use safety stands whenever a procedure requires you to be under the vehicle Be sure that the ignition switch is always in the OFF position and that the key is removed Be sure to switch the 72 volt m...

Page 5: ...sure Fig 1 VIN Certification Label Fig 2 VIN Certification Location 1 VIN Certification Label Location Typical 2 passenger model shown NOTE The last six digits of the VIN are also located on the rear frame support under the bench seat cushion FASTENER USAGE DESCRIPTION WARNING USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY Fasteners and torque specifications referen...

Page 6: ...pension frame to frame lower M12 x 1 75 YES 60 Front suspension frame to frame upper 3 8 16 YES 30 Ball joint pinch bolt M6 1 YES 30 Motor to differential 20 YES 65 Rack pinion to frt suspension frame M8 x 1 25 NO 225 Rear suspension frame to frame M12 x 1 75 NO 60 Seat belt D ring to frame NO 60 Seat belt end to frame NO 60 Seat belt latch assembly to frame NO 60 Seat belt latch assembly to brack...

Page 7: ...uality Fig 3 NLGI Symbols 1 Wheel bearing lubrication 2 Chassis lubrication 3 Chassis and wheel bearing lubrication DESCRIPTION DIFFERENTIAL Use 30 SAE engine oil 12 44 1 14 76 1 16 oz DESCRIPTION BRAKE FLUID Use only DOT 3 brake fluid from an unopened container when filling the master cylinder to prevent contaminants from entering the brake system MAINTENANCE SCHEDULES Perform the following inspe...

Page 8: ... POINTS PROVIDED ARE FOR A COMPLETE VEHICLE WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST CAUTION Do not attempt to lift a vehicle with a floor jack positioned under an axle tube body side panel or sill or front control arm W...

Page 9: ... WITH BUSHINGS 2 7 REAR SUSPENSION 2 8 REAR SUSPENSION FRAME AXLE 2 4 PASSENGER ONLY e2 e4 eS eL 2 8 REAR SUSPENSION FRAME AXLE 6 PASSENGER LONG BACK EXTRA DUTY e6 e6S eLXD 2 9 REAR HUB AND BEARING SPINDLE 6 PASSENGER LONG BACK EXTRA DUTY e6 e6S eLXD 2 10 STEERING 2 11 STEERING WHEEL 2 13 STEERING COLUMN ASSEMBLY 2 15 STEERING GEAR 2 16 OUTER TIE ROD END 2 17 STEERING KNUCKLE 2 18 ...

Page 10: ...gnment is essential for proper vehicle handling and passenger safety Front end damage or replacement of any steering or front suspension component will require inspection of the alignment to determine if it is still within specifications CAUTION Never attempt to modify suspension or steering components by heating or bending Before starting wheel alignment the following inspection and necessary cor...

Page 11: ...ications Vehicle pulls to one side Tire pressure Tire Worn wheel bearings Loose or worn ball joints Weak or broken spring shock absorber assembly Adjust tire pressure Rotate front tires side to side Replace front knuckle assembly Replace ball joints as necessary Replace spring shock absorber Check for proper front end alignment Vehicle pulls to one side while braking Brakes worn or out of adjustme...

Page 12: ... of the tread at the front of the left front tire 6 Subtract the front measurement from the rear measurement If the front measurement is less than the rear the vehicle has toe in and is shown with a plus sign 1 16 If the front measurement is greater than the rear the vehicle has toe out and the difference is shown with a minus sign 1 16 ADJUSTING TOE 1 Center the front wheels 2 Inspect the positio...

Page 13: ...ght of the vehicle when the fasteners are tightened This will maintain vehicle ride comfort and prevent premature bushing wear TORQUE SPECIFICATIONS Description Thread Size Use Loctite 242 Inch Pounds Foot Pounds Brake line to wheel master cylinder NO 37 Control arm to frt Suspension frame M10 x 1 5 NO 30 Differential to frt Suspension frame 5 16 18 NO 225 Front suspension frame to frame lower M12...

Page 14: ...inder four or five times The action throughout each stroke should be smooth and even CAUTION The shock absorber bushings do not require any type of lubrication Do not attempt to stop bushing noise by lubricating them Grease and mineral oil based lubricants will deteriorate the bushing REMOVAL FRONT SHOCKS 1 Raise and support the vehicle on a suitable hoist 2 Using a 3 4 inch wrench and socket remo...

Page 15: ...nnecting control arm to front frame and the steering knuckle 6 Remove the control arm assembly INSTALLATION 1 Install the control arm assembly to the frame and steering knuckle Tighten just snug 2 If installing the upper control arm only install the spring shock absorber lower mounting bolt Tighten just snug 3 Install the tire and wheel assembly Tighten the lug nuts to 65 ft lbs 4 Install the hubc...

Page 16: ...icle ride comfort and prevent premature bushing wear REAR SUSPENSION FRAME AXLE 2 4 PASSENGER ONLY e2 e4 eS eL DESCRIPTION The rear suspension frame is attached to the rear of the vehicle frame by bolts in bushings OPERATION The rear suspension frame provides a platform for the rear shocks and acts as an axle for the rear wheels and brakes REMOVAL 1 Raise and support the vehicle on a suitable hois...

Page 17: ... 6 Make sure to properly support the rear Frame Axle assembly 7 Remove the bolts securing the brake lines to the axle 8 Remove the rear hub and bearing 9 Remove the rear spindles 10 Note Support the backing plate assemblies to protect the brake lines and parking brake cables 11 Remove the lower spring shock bolts with a 3 4 inch wrench and socket 12 Remove the bolts attaching the frame axle assemb...

Page 18: ...ear hub and bearing Tighten 1 Assy Brake LH Rear 2 Assy Hub Rear 3 Install the hub and bearing Torque to 165 ft lbs 3 Spindle Rear 4 Drum 5 Bolt 4 Install the dust cap 5 Dust Cover 6 Hex Nut 5 Install the brake drum 7 Hex Bolt 6 Install the tire and wheel assembly Tighten just snug 8 Lock Washer 7 Tighten the lug nuts to 65 ft lbs 8 Install the hubcap 9 Lower the vehicle to the floor 10 Tighten th...

Page 19: ...ng column transmits rotation of the steering wheel to the pinion in the steering gear Rotation of the pinion moves the gear rack in the steering gear from side to side This lateral action of the rack pushes and pulls the tie rods that are attached to the steering knuckles Steering knuckles pivot on ball joints that are mounted on the control arms Wheel and brake assemblies are mounted to the steer...

Page 20: ...g wheel does not want to return to center position Incorrect tire pressure Lack of lubrication suspension components Worn coil spring shock assembly Adjust tire pressure Inspect and lubricate suspension components Replace steering gear Inspect and or replace coil over shock assy Excessive play in steering wheel Loose or worn steering or suspension components Worn or loose wheel bearings Steering g...

Page 21: ...ts through the steering wheel Figure 11 and thread them into the U shaped plate Thread them in far enough to go through the U shaped plate Figure 12 9 Use appropriate wrench to turn the large bolt down against the threaded end of the steering shaft 10 Tighten large bolt on puller until the steering wheel comes loose 11 Remove steering wheel 1 Remove the mounting screws located on the underside of ...

Page 22: ...align steering wheel to steering shaft and place on shaft 2 Replace washer and attaching nut on end of shaft and tighten to press wheel completely on splines Back off nut and tighten to 20 ft lbs 3 Replace steering wheel cover and attach with mounting screws TORQUE SPECIFICATIONS Description Thread Size Use Loctite 242 Inch Pounds Foot Pounds Steering wheel to steering shaft NO 20 ...

Page 23: ...s attaching steering column to dash frame 10 Remove steering column CLEANING AND INSPECTION Rotate steering shaft in bearing feeling for roughness of action If roughness is detected replace steering shaft Inspect steering shaft u joints and pinion mating surface for wear or damage Replace shaft if necessary INSTALLATION 1 Position the steering column assembly in dash and install the mounting bolts...

Page 24: ...er Tie Rod End in this section 5 Remove the pinch bolt that joins the steering column shaft and the steering gear Slide the steering shaft up to disconnect it from the gear 6 Remove the bolts and washers that attach the steering gear bracket on the front suspension frame and remove the steering gear 7 Remove the steering gear bracket Fig 14 Steering Gear Attaching Bolts 1 Attaching bolts with up t...

Page 25: ...he wheel and tire assembly 4 Loosen the tie rod jam nut 5 Remove the nut from the bottom of the rod end stud where it attaches to the steering knuckle 6 Use a 2 jaw puller to separate the tapered stud from the knuckle 7 Count and mark the thread locations of tie rod end at tie rod 8 Remove the outer tie rod end from the tie rod INSTALLATION 1 Thread the new end into the tie rod to approximately th...

Page 26: ...ws the vehicle to be steered REMOVAL 1 Raise and support the vehicle using a suitable hoist 2 Remove hubcap 3 Remove the tire and wheel assembly 4 Remove the cotter pin and loosen the half shaft retaining nut 5 Remove front brake assembly See Front Brake Assembly in Brake section 6 Remove nut from the bottom of the tie rod end stud where it joins the knuckle 7 Use a 2 jaw puller to separate tie ro...

Page 27: ...DRIVETRAIN 3 1 November 2007 GEM Service Manual CONTENTS DRIVETRAIN 3 2 HALFSHAFT 3 2 DIFFERENTIAL 3 4 ...

Page 28: ...king noise in turns which indicates that the outboard joint is damaged Batteries power the motor The accelerator pedal potentiometer controls the motor speed The motor is connected to a differential The power is transferred from the differential through two constant velocity CV drive shafts halfshaft to the wheel hubs A thump or clunk when accelerating from coasting which points to a faulty inboar...

Page 29: ...fferential and is not damaged 4 Install the inner end of the halfshaft over the splined shaft on the differential Press inward toward differential until spring clip snaps into place 5 Connect the lower control arm and install the king pin pinch bolt 6 Install upper front shock mounting bolt just snug 7 Install washer and nut on halfshaft outer end 8 Add Loctite 242 and torque halfshaft nuts to 65 ...

Page 30: ...ct the differential to the suspension frame 6 Remove the differential by sliding it out the right passenger side INSTALLATION 1 Add oil to new differential Use 30 SAE engine oil 16 oz 2 Make sure that the spring clips are on the splined differential shafts 3 Position differential between front suspension frame and mounting plate 4 Install mounting brackets and bolts 4 through the lower mounting br...

Page 31: ... ASSEMBLY 2 4 PASSENGER ONLY e2 e4 eS eL 4 7 REAR BRAKE ASSEMBLY 6 PASSENGER LONG BACK EXTRA DUTY e6 e6S eLXD 4 9 BRAKE PEDAL ASSEMBLY 4 11 MASTER CYLINDER ASSEMBLY 4 12 PARK BRAKE LEVER ASSEMBLY 4 13 PARKING BRAKE CABLE ASSEMBLY 4 14 PARKING BRAKE CABLE ASSEMBLY 6 PASSENGER ONLY 4 16 PARK BRAKE CABLE TENSION ADJUSTMENT 4 17 ...

Page 32: ...into the front brake calipers and the rear wheel cylinders through the brake lines The pistons in each caliper and wheel cylinders are forced out causing the front brake pads and rear brake shoes to come into contact with the front brake rotor and the rear brake drum When the park brake lever is pulled up tension is placed on park brake cables attached to the rear drum brake assemblies thereby act...

Page 33: ...s If the condition is allowed to continue rotors and drums can become so scored that replacement is necessary BRAKE CHATTER Loose or worn components or glazed burnt linings usually cause brake chatter Additional causes of chatter are rear brake linings not securely attached to the shoes loose wheel bearings and contaminated brake linings THUMP OR CLUNK NOISE Thumping or clunking noises during brak...

Page 34: ... fluid stream is clear and free of bubbles 7 Then move in turn to the left rear right front then left front and repeat steps 1 6 PRESSURE BLEEDING 1 Follow the bleeder unit instructions for attachment and usage 2 Always ensure that the brake fluid reservoir in the master cylinder is kept at the MAX fill line while bleeding 3 Bleed the system at all four wheels Starting at the right rear and contin...

Page 35: ...plate 7 Remove 15 16 drive shaft cotter pin and retaining nut 8 Remove the hub and rotor assembly 9 Remove the four screws and the rotor assembly INSTALLATION 1 Install the rotor on the hub and install the four screws Apply Loctite 242 to the threads and tighten the screws to 15 ft lb 2 Install the rotor and hub assembly onto the vehicle 3 Install and tighten snugly the 15 16 drive shaft retaining...

Page 36: ...e Use Loctite 242 Inch Pounds Foot Pounds Brake line to wheel master cylinder NO 37 Brake drum assembly to steering knuckle M8 x 1 25 NO 20 Half shaft to drum brake assembly M10 x 1 5 YES 65 Wheel lug nuts 12mm NO 65 Rotor to Hub YES 15 Caliper NO 20 Wheel Cylinder to Backing Plate NO 115 ...

Page 37: ...es the brake shoes to press against the brake drum The friction of the shoes against the drum causes the drum and wheel to stop turning REMOVAL 1 Raise and support the vehicle on a suitable hoist 2 Remove the hubcap 3 Remove the tire and wheel assembly 4 Remove the cotter pin and clevis pin attaching park brake cable to actuator lever on brake drum 5 Remove the park brake cable from actuator lever...

Page 38: ...ting bolt and tighten 4 Install the lower spring 5 Position trailing shoe first 6 Position leading shoe NOTE Make sure the pads properly engage wheel cylinder pistons 7 Replace upper spring 8 Replace shoe retention pins and clips 9 Replace lower pivot point spacer with narrow side up then replace retainer with rounded side down Attach with bolt and nut 10 Install the drum and attach with Allen hea...

Page 39: ...ure pushes the pistons out causing the brake shoes to press against the brake drum When the park brake lever is engaged it pulls on the cables to the park brake actuator lever which engages the two brake shoes Movement of the park brake actuator forces the brake shoes to press against the brake drum The friction of the shoes against the drum causes the drum and wheel to stop turning DISASSEMBLY 1 ...

Page 40: ...ttach 17 mm brake line to wheel cylinder 10 Install the drum NOTE Be sure you have the correct RH or LH drum brake assembly 11 Install the tire and wheel assembly Tighten the lug nuts to 65 ft lbs 12 Install the hubcap 13 Bleed the brakes See Brake Bleeding instructions in this section 14 Adjust the parking brake cable See Parking Brake Cable Tension Adjustment in this section NOTE If only servici...

Page 41: ...ng pressure in master cylinder REMOVAL 1 Remove upper and lower dash panels See Dash Upper Panel and Dash Lower Panel in Body section 2 Remove the four bolts attaching pedal assembly to dash support frame 3 Remove the brake pedal assembly TORQUE SPECIFICATIONS Description Thread Size Use Loctite 242 Inch Pounds Foot Pounds Brake pedal assembly to frame 5 16 18 NO 225 Brake pedal to push rod 3 8 16...

Page 42: ...electrical connectors from the master cylinder 4 Using a flare nut wrench remove the brake lines from master cylinder Cap the brake tube connections to prevent fluid loss or dirt contamination 5 Remove two mounting bolts attaching master cylinder to cowl 6 Remove master cylinder and mounting gasket INSTALLATION 1 Install master cylinder and mounting gasket on cowl 2 Install the two mounting bolts ...

Page 43: ...CIDENTAL CONTACT WITH BATTERY TERMINALS CAN RESULT IN DAMAGE OR PERSONAL INJURY TWO PASSENGER SHORT BED UTILITY LONG BED UTILITY COUPE MODELS 1 Chock wheels 2 Remove lower seat See Bench Seat in Body section 3 Switch master disconnect switch OFF and cover battery terminals to prevent electrical contact 4 Release park brake 5 Locate threaded adjusting rod cable at the end of the lever 6 Using 1 2 o...

Page 44: ...onnect switch ON FOUR PASSENGER SIX PASSENGER SEDAN MODELS 1 Position the park brake lever assembly 2 Install the mounting bolts through park brake lever brackets 3 Connect the park brake switch wires to proper terminals on switch Red White on center terminal and Tan on upper most forward terminal 4 Insert adjusting rod into park brake cable equalizer replace adjusting and jam nuts 5 Adjust tensio...

Page 45: ...rking Brake Cable Attachment 1 Cable mounting bracket 2 Cable end 3 Cotter pin 4 Clevis pin 5 Actuator lever Fig 13 Parking Brake Cable Mounting 1 Mounting bracket 2 Parking brake cable 3 Retaining ring INSTALLATION 1 Install park brake cable into retainer on frame attach with retaining rings 2 Position cable end over park brake actuator lever on rear brake assembly Insert clevis pin to attach ins...

Page 46: ...p 4 Drill out 3 rivets per side and remove the parking brake cable INSTALLATION 1 Position parking brake cables and install Fig 14 Parking Brake Cable Assembly 2 Join the parking brake cables at front frame to the brake backing plate 1 Equalizer 2 Brake backing plate 3 Connect the parking brake cables to the tension equalizer 3 Rivets 3 per side 4 Install the rear brake shoes See Rear Brake Assemb...

Page 47: ...ut forward or backward as needed to adjust tension 6 Tighten rear nut against adjusting nut to lock in place 7 Apply park brake and test by attempting to roll vehicle forward by pushing it If vehicle moves repeat tension adjustment procedure Fig 15 Park Brake Cable Tension Adjustment 1 Park brake cables to rear wheels 2 Jam nuts 3 Adjusting rod cable assembly 4 Tension equalizer NOTE The vehicle m...

Page 48: ...T PEDAL 5 17 BATTERY 5 18 CHARGER 5 27 MOTOR CONTROLLER 5 32 DC CONVERTER 5 33 MAIN CONTACTOR 5 34 MOTOR 5 35 MOTOR MAGNET AND SPEED SENSOR TACHOMETER 5 37 LIQUID CRYSTAL DISPLAY LCD 5 38 PSDM 5 39 ACCESSORY SYSTEM 5 41 ACCESSORY SYSTEM COMPONENT REPLACEMENT 5 46 ELECTRICAL OVERVIEW 5 48 INDEX 5 49 HARNESS AND CONNECTOR DRAWINGS 5 76 ...

Page 49: ...em is divided into three groups the Power System the Drive System and the Accessory System WARNING Always turn off the Master Disconnect Switch and allow a few minutes for the system to discharge before servicing the electrical system Never wear loose jewelry rings or watches Always use insulated tools to prevent shorting NOTE The master disconnect switch is located in the lower dash unit of the f...

Page 50: ...cid batteries and provide a total power supply voltage of 72 volts OPERATION The battery charger automatically recharges the battery to 100 charge when plugged into a standard 110 volt 15 amp breaker outlet When the charger is active logic in the motor controller prevents the vehicle from being operated The battery charger monitors battery temperature by means of a temperature sensor If the batter...

Page 51: ...l drive power Power and drive system operation is monitored by the motor controller status information is displayed on the LCD display The basic operation procedures described in the Owner s Manual must be followed for the drive system to operate properly If the drive system does not operate verify the following steps have been completed Master disconnect switch see figure 4 is shown in the ON pos...

Page 52: ...RVICE THE VEHICLE WITH THE MASTER DISCONNECT SWITCH TURNED OFF IF THE MASTER DISCONNECT SWITCH IS ON TO MEASURE VOLTAGE USE EXTREME CAUTION DANGEROUS VOLTAGE IS PRESENT REMOVE ALL JEWELRY SUCH AS RINGS WATCHES OR NECKLACES THAT COULD CONTACT ELECTRICAL CONNECTIONS AND CONDUCT ELECTRICITY SEVERE INJURY BURNS OR EVEN DEATH COULD OCCUR IF CAUTION IS NOT USED NOTE The information provided in this sect...

Page 53: ...sition Symptom Fuse F5 No display Vehicle Moves Fuse F9 No display No Movement Fuse F13 No display No Movement Fuse in DC DC Converter NOTE Not available in 2007 models No display No Movement 05 Start switch failed to close Check start switch circuit from motor controller to start switch Start switch may be defective Refer to the Motor Controller Circuit Diagram for troubleshooting the start switc...

Page 54: ... try running the headlights for a little while to drain the battery charge If the voltage is below 86 VDC there is a problem with the sensing circuit in the motor controller 21 Problem with the accelerator pedal wiring See Accelerator Pedal Diagnosis and Testing 23 Motor field current is too high when the start switch is closed and the reverse drive mode is selected Replace the motor controller 24...

Page 55: ...ck wiring between the motor controller and the motor field connections F1 and F2 If the connections are good replace the motor controller 51 Motor controller is not getting 72 volts First go through the Drive and Power System Troubleshooting Chart A If directed back to the Drive and Power System Error Code Chart perform the following procedure Note Between each step if the code appears the code wi...

Page 56: ... 57 does appear the controller has failed because of a shorted motor Replace both motor and controller 64 Control detects that the line driver input P2 P17 is less than 12 battery volts when the key switch is turned ON Open wire to Pin 17 Shorted line driver transistor See Troubleshooting Diagram A 65 Current limit in the line contactor coil is exceeded during run mode The line contactor will drop...

Page 57: ...ceeds 280 amps for 3 5 seconds and the accelerator pedal is calling for maximum performance in the control mode Continued operation of vehicle in high motor current condition Operating control at stall motor current for more than 3 5 seconds Function 16 is incorrectly adjusted for control on time Adjust function per OEM instructions See Trouble Shooting Diagram C Shut off key switch and set emerge...

Page 58: ...5 11 ELECTRICAL GEM Service Manual November 2007 Troubleshooting Diagram A Troubleshooting Diagram B Troubleshooting Diagram C ...

Page 59: ...em Troubleshooting Chart A Note All DC voltage measurements should be taken with respect to motor controller B 72 VDC or chassis ground 12 VDC Step Action Yes No 1 Prior to turning the key switch to the ON position verify the following Vehicle battery charger is not connected to AC power Master disconnect switch is turned on Accelerator pedal is not depressed Are all conditions met Proceed to Step...

Page 60: ...e for open condition by measuring the voltage at the fuse connection at the PSDM cable side in the battery compartment If the fuse is open replace the fuse If the fuse opens again contact the GEM Service Department 3 If no voltage is present at the Main fuse use the Main Contactor Circuit Diagram and a voltmeter to check all battery connections 4 If voltage is present at the main fuse use the Main...

Page 61: ... contactor Are all critical inputs good Replace the motor controller Troubleshoot circuit s suggested in Steps 9a through 9c 9a With the key and the master disconnect switch in the ON position measure the voltage between pin 1 of the 23 pin connector on the top of the motor controller and the 72 volt negative terminal on the controller Is the voltage approximately 72 VDC Proceed to Step 9b Use the...

Page 62: ...p 10e Replace the wire harness between the motor controller and electric motor 10e Measure resistance between pin A and B of the motor temperature switch Is the resistance approximately 0 ohms Proceed to step 10f Replace motor temperature switch 10f Measure resistance between pin B of the motor temperature switch and pin H of the PSDM Is the resistance approximately 0 ohms Proceed to step 11 Repla...

Page 63: ...ies again If they will not charge go to the next step Battery charger will not charge battery and voltage to battery charger 110 VAC has been verified Observe the indicator lamps on the charger Refer to Charger Fault codes Battery charger will not charge battery voltage to battery charger 110 VAC has been verified and temperature sensor has been verified Verify voltage of each battery is greater t...

Page 64: ...es not vary as described replace the accelerator pedal If the resistance is a constant very low resistance possible short circuit or constant high resistance open circuit there could be a problem with the wiring harness between the motor controller and the accelerator pedal module or there could be a faulty accelerator pedal 3 Using an ohmmeter measure the resistance between pins 9 and 8 The resis...

Page 65: ...plied with the GEM electric vehicle are deep cycle marine batteries They are designed to handle discharges down to 20 30 of their rated capacity without doing any internal damage Since the batteries in the electric vehicle must supply 100 of the energy required for operation they are subject to deep discharges and then must be recharged to restore their capacity In comparison the standard automoti...

Page 66: ...15 seconds and the voltage should not drop below 10 5 volts and with no more that 1 2 0 5 of a volt difference between batteries Trojan 30XHS or SCS225 liquid lead acid CCA 665 CA 820 130 AH BCI group size 30H Test at 330 amps Deka 8G31 Gel sealed CCA 550 0 degrees F CA 780 32 degrees F 97 6 AH BCI group 31 Test at 275 amps Deka EV31 liquid lead acid CCA 650 Test at 325 amps 110 AH 20 amps Group s...

Page 67: ...replaced WARNING ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTORS WARNING BATTERY FLUID IS A CORROSIVE ACID SOLUTION AND CAN BURN OR EVEN BLIND YOU DON T ALLOW BATTERY FLUID TO CONTACT EYES SKIN OR CLOTHING IF ACID SPLASHES IN EYES OR...

Page 68: ... Access Panel e6 models 1 Middle seat access panel Fig 12 Middle Seat Access Panel Removed e6 models 1 Battery Fig 13 Front and Rear Batteries e6 models 1 Front batteries 2 Rear batteries ALL 5 Disconnect the negative battery cable 6 Remove the hold downs 7 Disconnect all cables for all front or rear batteries noting connections and locations 8 Remove each battery 9 Lift batteries out using proper...

Page 69: ...g or vegetable oil Eye contact Flush with water for 15 minutes Get prompt medical attention There are many tools that may help in properly caring for and maintaining batteries Below is a list of basic items that GEM recommends for this task WARNING ALWAYS WEAR PROTECTIVE CLOTHING GLOVES AND GOGGLES WHEN HANDLING BATTERIES AND ELECTROLYTE WARNING DO NOT SMOKE NEAR BATTERIES RECOMMENDED EQUIPMENT Wr...

Page 70: ... 8 Correct the readings to 80 F Add 0 004 to readings for every 10 above 80 F Subtract 0 004 for every 10 below 80 F 9 Compare the readings 10 Check the state of charge using Table 1 The readings should be within the factory specification of 1 277 0 007 If not follow the steps below 1 Check and record voltage level s 2 Put battery s on a complete charge 3 Take specific gravity readings again If an...

Page 71: ...lt discharge machine part number 0615 00 can be acquired The discharge units are intended for use on vehicles equipped with the standard 6 12 volt battery configuration See Fig 14 though is capable of operation on vehicles equipped with 9 8 volt battery configuration DISCHARGE PROCEDURE 1 Fully charge the batteries 2 Turn the master disconnect switch to OFF 3 Connect the discharge unit s to the ba...

Page 72: ...fter fully charging the battery Prior to charging there should be enough electrolytes to cover the plates If the battery has been discharged partially or fully the electrolyte level should also be above the plates Keeping the electrolyte at the correct level after a full charge will prevent having to worry about the level at other state of charge Depending on the local climate charging methods app...

Page 73: ...ry remains healthy and ready for use NOTE Storing charging or operating batteries on concrete is perfectly OK SMC STORAGE MARTS CYCLE NOTE Your GEM is equipped with a SMART charge capability Simply leave the vehicle plugged into a standard 110 VAC 15 A power outlet The charger unit will automatically power on once every 2 weeks for gel batteries and once every 7 days for flooded run a charge cycle...

Page 74: ...d extension cord and should not exceed 25 feet in length 12 gauge or heavier OPERATION Insert the proper extension cord into the battery charger receptacle and into a standard 110 volt A C 15 amp breaker outlet GFI is recommended If using a GFI protected charger cord plug into a standard circuit breaker that is NOT GFI protected NOTE Make sure the master disconnect switch is in the ON position Whe...

Page 75: ...quence for two seconds If the charger is used with the master disconnect switch OFF and is waiting to be connected to the battery pack the charging algorithm number will be displayed for 11 seconds see Check Change Charging Algorithm before ultimately displaying an under voltage fault until AC is cycled 3 Once a minimum battery voltage is detected the charger will enter the bulk charging constant ...

Page 76: ...pre loaded with charge algorithms as detailed in Table 1 Each time AC power is applied with the battery pack NOT connected the charger enters and algorithm display mode for about 11 seconds During this time the current algorithm is indicated by the number of blinks of the 80 LED and Remote LED A single digit Algorithm is indicated by the number of blinks followed by a pause A 2 digit Algorithm is ...

Page 77: ...ting this algorithm connect the charger to the battery without interrupting AC power After about 10 seconds the charger will begin charging Use of the PRC algorithm is indicated by the 80 and 100 LEDs flashing together When the PRC charge completes or AC power is removed and reconnected the charger will revert to the DEKA NC algorithm ...

Page 78: ...k Relay Circuit 3 Red to the Contactor left terminal 4 White to black spade from the rear harness temp sensor harness 2 Black wire detail Connect the black wire to the negative terminal on the controller Torque to 50 in lbs 3 Red wire detail Connect the red wire to the left terminal on the contactor As sitting in driver s seat this is the left terminal of the contactor Torque to 120 in lbs ...

Page 79: ... motor controller is accomplished by actuation of the devices such as the accelerator pedal and the drive mode switch DIAGNOSIS AND TESTING The motor controller function is critical to every aspect of the drive system If a fault occurs with the motor controller you should see an error code on the liquid crystal display LCD Use the Drive and Power System Error Codes section starting on page 5 6 Ele...

Page 80: ...nverter functions automatically when the master disconnect switch is in the ON position DIAGNOSIS AND TESTING Diagnosis and testing of the DC DC converter is covered in the Accessory System Troubleshooting Chart The circuit diagrams provided in this manual are also useful in isolation of problems associated with the DC DC converter REMOVAL 1 Turn the master disconnect switch OFF 2 Open the hood as...

Page 81: ...should be supplied to the drive motor The motor controller will not activate the main contactor if an error condition exists See Drive and Power System Error Codes chart REMOVAL 1 Turn the master disconnect switch OFF 2 Remove upper and lower dash 3 Locate main contactor 4 Remove electrical connections noting connection and orientation for each wire 5 Remove screws that mount contactor to the fron...

Page 82: ...Switch 2 Motor Armature 2 A2 3 Speed Sensor Tachometer 4 Motor Armature 1 A1 5 Motor Field 2 F2 OPERATION Motor activation and speed are controlled by the motor controller based on the signal from the potentiometer located in the accelerator pedal in the cab A splined cup in the motor is connected to a splined shaft on the pinion gear in the differential Rotational motion of the motor s cup transm...

Page 83: ...sts for reassembly and then pull straight out INSTALLATION 1 Make sure to put a resilient bumper inside motor spline socket The cupped end of the bumper will face outward Be sure bumper is all the way in the spline socket 2 Put a very light coating of Valvoline Special Moly Ep grease or equivalent on the splined differential shaft not necessary Too much grease will cause motor problems 3 Install m...

Page 84: ...in the center of the motor s end panel Fig 22 Speed Sensor Tachometer Assembly 1 Speed Sensor Tachometer Assembly OPERATION When the motor s armature rotates the magnet rotates also The sensor detects the magnet s motion and transmits a signal through its pigtail to the motor controller REMOVAL 1 Disconnect and remove screw attaching wire harness to motor see figure 20 2 Remove sensor pigtail asse...

Page 85: ...s remaining battery capacity The remaining battery capacity is displayed in a bar type graph For example 8 green bars indicate 80 charge 1 yellow bar indicates 10 charge and 1 red bar indicates less than 10 charge REMOVAL 1 Remove upper dash panel See Upper Dash in Body section 7 2 Remove lower dash panel See Lower Dash in Body section 7 3 Remove RH and LH pod covers See Pod Covers in the Body sec...

Page 86: ... Remove all connectors and cables noting connection and orientation for each wire 4 Remove the 4 nuts that secure the PSDM to the mounting plate 5 With a small screwdriver lightly pry around mounting studs working back and forth between all studs INSTALLATION 1 Position the PSDM and install the 4 nuts that secure the PSDM to the mounting plate Tighten mounting nuts to 72 in lbs 2 Connect all conne...

Page 87: ...ELECTRICAL 5 40 November 2007 GEM Service Manual ...

Page 88: ...5 41 ELECTRICAL GEM Service Manual November 2007 ACCESSORY SYSTEM DESCRIPTION Fig 26 Accessory System Diagram ...

Page 89: ...des a single continuous tone when the horn button is pressed The horn button is located on the left side of the instrument pod The heater operates by the heater switch located in the center lower dash panel figure 27 item 1 The heater blower motor operates by receiving 12 VDC from the fuse protected DC DC converter The heater element runs on 72 VDC fused direct feed from the batteries through the ...

Page 90: ...erter pin 12 and there is no voltage at pin 7 or 8 with the key switch ON replace the DC DC converter If there is 12 VDC at the DC DC converter pins 7 and 8 with the key switch ON and there is no voltage at the PSDM J4 pins A and B check the wiring between the DC DC converter and the PSDM J4 using the DC DC Converter Circuit Diagrams If there is 12 VDC at the PSDM J4 pins A and B with the key swit...

Page 91: ...orn switch is OK check the horn horn ground and voltage circuit Use the Horn Power Outlet Circuit Diagram and a voltmeter to isolate the problem Heater does not work Visually inspect fuse F2 or measure with an ohmmeter to determine if it is open Heater switch Blower motor Replace the fuse if open Use the Heater Circuit Diagram and a voltmeter to check the wiring connections the heater switch and t...

Page 92: ...ork The wiper motor has overload protection and may stop working for a short period of time if the windshield is very dry Wait a moment and try operating the wipers again If the wipers fail to operate visually inspect fuse F7 or measure with an ohmmeter to determine if it is open Wiper switch part of the multifunction switch Wiper motor Replace the fuse if open Check for voltage at the wiper motor...

Page 93: ...TOR LAMP REPLACEMENT 1 Open hood 2 Remove lock nut from light and disconnect the red and black wires 3 Replace light assembly 4 Reverse the removal procedure to install REAR TURN INDICATOR LAMP REPLACEMENT 1 Remove two Phillips head screws holding lens in place 2 Remove lens 3 Twist bulb counterclockwise to remove noting type of bulb and replace 2057 2067 4 Reverse the removal procedure to install...

Page 94: ...ectrical connector 4 Loosen retaining nut and remove key switch 5 Reverse the removal procedure to install ACCESSORY WIRING CHART S1 F3 S2 F2 S3 F8 S4 F6 S5 FLASHER HAZARD JUMP TO S4 S6 F10 S7 F12 S8 F11 TURN SIGNAL SWITCH REPLACEMENT 1 Remove the upper and lower dash panels See Body section 7 2 Remove the RH and LH POD covers See Pod Covers in Body section 7 3 Remove the 2 screws 4 Disconnect ele...

Page 95: ...ELECTRICAL 5 48 November 2007 GEM Service Manual ELECTRICAL OVERVIEW ...

Page 96: ...5 55 MOTOR CONTROLLER SYSTEM 5 56 PARK BRAKE CIRCUIT 5 53 POWER DISTRIBUTION 5 50 REAR LIGHTING 5 70 SECURITY LIGHT BAR 5 65 TURN SIGNAL REMINDER CIRCUIT 5 74 WIPER WASHER 5 75 HARNESS TYPE ABBREVIATION DC DC Converter Harness DCCH Headlight Harness HH Front Harness FH Instrument Panel Harness IP Controller Harness CH Rear Harness RH Tail Light Harness TLH Charger Wiring C Battery Temperature Sens...

Page 97: ...ELECTRICAL 5 50 November 2007 GEM Service Manual POWER DISTRIBUTION ...

Page 98: ...5 51 ELECTRICAL GEM Service Manual November 2007 CHARGING SYSTEM ...

Page 99: ...ELECTRICAL 5 52 November 2007 GEM Service Manual CHARGING SYSTEM CONTINUED e6S eLXD OPTION ...

Page 100: ...5 53 ELECTRICAL GEM Service Manual November 2007 PARK BRAKE CIRCUIT ...

Page 101: ...ELECTRICAL 5 54 November 2007 GEM Service Manual DC DC CONVERTER ...

Page 102: ...5 55 ELECTRICAL GEM Service Manual November 2007 MAIN CONTACTOR ...

Page 103: ...ELECTRICAL 5 56 November 2007 GEM Service Manual MAIN CONTACTOR CONTINUED e6S eLXD OPTION ...

Page 104: ...5 57 ELECTRICAL GEM Service Manual November 2007 MOTOR CONTROLLER SYSTEM ...

Page 105: ...ELECTRICAL 5 58 November 2007 GEM Service Manual MOTOR CONTROLLER SYSTEM CONTINUED ...

Page 106: ...5 59 ELECTRICAL GEM Service Manual November 2007 DISPLAY RD ...

Page 107: ...ELECTRICAL 5 60 November 2007 GEM Service Manual DISPLAY CONTINUED ...

Page 108: ...5 61 ELECTRICAL GEM Service Manual November 2007 DISPLAY CONTINUED ...

Page 109: ...ELECTRICAL 5 62 November 2007 GEM Service Manual HORN POWER OUTLET ...

Page 110: ...5 63 ELECTRICAL GEM Service Manual November 2007 HEATER ...

Page 111: ...ELECTRICAL 5 64 November 2007 GEM Service Manual DASH FAN ...

Page 112: ...5 65 ELECTRICAL GEM Service Manual November 2007 SECURITY LIGHT BAR ...

Page 113: ...ELECTRICAL 5 66 November 2007 GEM Service Manual AUDIO SYSTEM ...

Page 114: ...5 67 ELECTRICAL GEM Service Manual November 2007 FRONT LIGHTING EXCEPT NEW YORK HI LO BEAM OPTION ...

Page 115: ...ELECTRICAL 5 68 November 2007 GEM Service Manual FRONT LIGHTING EXCEPT NEW YORK ...

Page 116: ...5 69 ELECTRICAL GEM Service Manual November 2007 FRONT LIGHTING NEW YORK ...

Page 117: ...ELECTRICAL 5 70 November 2007 GEM Service Manual REAR LIGHTING EXCEPT NEW YORK ...

Page 118: ...5 71 ELECTRICAL GEM Service Manual November 2007 REAR LIGHTING NEW YORK ...

Page 119: ...ELECTRICAL 5 72 November 2007 GEM Service Manual REAR LIGHTING ...

Page 120: ...5 73 ELECTRICAL GEM Service Manual November 2007 REAR LIGHTING CONTINUED ...

Page 121: ...ELECTRICAL 5 74 November 2007 GEM Service Manual TURN SIGNAL REMINDER CIRCUIT ...

Page 122: ...5 75 ELECTRICAL GEM Service Manual November 2007 WIPER WASHER ...

Page 123: ...007 GEM Service Manual HARNESS AND CONNECTOR DRAWINGS CONVERTER HARNESS CONVERTER HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector 1 DC DC Converter 12 2 3 72 Volt Ground 12 Volt Ground 1 4 PSDM J4 6 ...

Page 124: ...ervice Manual November 2007 PIN LOCATIONS FOR CONVERTER HARNESS CONNECTORS Connector Illustration Connector Number Connects To Number of Pins in Connector 1 DC DC Converter 12 2 3 72 Volt Ground 12 Volt Ground 1 4 PSDM J4 6 ...

Page 125: ...ADLIGHT HARNESS HEADLIGHT HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector 1 Headlight Harness 6 2 Headlamp Left 1 3 Lamp Turn Left 1 4 Lamp Turn Left Ground 1 5 Headlamp Right 1 6 Lamp Turn Right 1 7 Lamp Turn Right Ground 1 ...

Page 126: ...al November 2007 PIN LOCATIONS FOR HEADLIGHT HARNESS CONNECTORS Connector Illustration Connector Number Connects To Number of Pins in Connector 1 Headlight Harness 6 2 5 Headlamps Power 1 3 6 Turn Lamps Power 1 4 7 Turn Lamps Ground 1 ...

Page 127: ...Manual FRONT HARNESS FRONT HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector 1 PSDM J1 10 2 3 4 Motor Wiper 1 5 6 Horn 1 7 Front Harness 6 8 Switch Brake Level Fluid 2 9 10 Switch Brake Pressure 1 11 12 Volt Ground 1 ...

Page 128: ...IONS FOR FRONT HARNESS CONNECTORS Connector Illustration Connector Number Connects To Number of Pins in Connector 1 PSDM J1 10 2 3 4 5 6 9 10 11 Horn Motor Wiper Switch Brake Pressure Charger 1 7 Front Harness 6 8 Switch Brake Level Fluid 2 11 12 Volt Ground 1 ...

Page 129: ... HARNESS IP HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector 1 PSDM J2 12 2 PSDM J3 16 3 Display D2 12 4 Display D1 10 5 6 Switch Light 1 7 Switch Multifunction 10 8 Switch Key 3 9 10 11 12 Switch Drive Mode 1 13 14 Switch Trip Odometer 1 ...

Page 130: ... HARNESS CONNECTORS Connector Illustration Connector Number Connects To Number of Pins in Connector 1 3 Display D2 PSDM J2 12 2 PSDM J3 16 4 Display D1 10 5 6 9 10 11 12 13 14 Switch Drive Mode Switch Trip Odometer Switch Light 1 7 Switch Multifunction 10 8 Switch Key 3 ...

Page 131: ...7 GEM Service Manual CONTROLLER HARNESS CONTROLLER HARNESS CONNECTIONS Connector Number Connects to Number of Pins in Connector 1 Module Motor Controller 23 2 Switch Accelerator Pedal 10 3 Tachometer 3 4 Sensor Motor Temperature 2 ...

Page 132: ...AL GEM Service Manual November 2007 CONTROLLER HARNESS CONTINUED CONTROLLER HARNESS CONNECTIONS Connector Number Connector to Number of Pins in Connector 5 6 Main Contactor Coil 1 7 PSDM 72 Volt Ground 1 8 PSDM J5 8 ...

Page 133: ...ce Manual PIN LOCATIONS FOR CONTROLLER HARNESS CONNECTORS Connector Illustration Connector Number Connects To Number of Pins in Connector 1 Module Motor Controller 23 4 Switch Accelerator Pedal 10 5 Tachometer 3 6 Switch Motor Temperature 2 ...

Page 134: ...5 87 ELECTRICAL GEM Service Manual November 2007 Connector Illustration Connector Number Connects To Number of Pins in Connector 9 PSDM 72 Volt Ground 1 10 PSDM J5 8 ...

Page 135: ...MAIN HARNESS PASSENGER REAR HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector 1 PSDM J6 8 2 72 Volt Ground 1 3 PSDM Disconnect Switch 1 4 PSDM BATT 1 5 12 Volt Ground 1 6 Charger Battery Temp Sensor 1 7 8 Switch Park Brake 1 ...

Page 136: ...INUED PASSENGER REAR HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector 9 Lamp CHMSL 1 10 Lamp CHMSL Ground 1 11 Lamp License 1 12 Lamp Back Up 1 13 Taillight Harness 4 14 15 Battery Temperature Sensor 1 16 BATT 1 17 BATT 1 18 Main Harness 1 ...

Page 137: ...tion Connector Number Connects To Number of Pins in Connector 1 PSDM J6 8 2 5 12 Volt Ground 72 Volt Ground 1 3 4 16 17 PSDM Disconnect Switch PSDM BATT BATT 1 BATT 6 1 6 7 8 9 10 11 12 14 15 Charger for BTS Switch Park Brake Lamp CHMSL Lamp License Lamp Back Up Lamp License Ground Battery Temperature Sensor 1 ...

Page 138: ...5 91 ELECTRICAL GEM Service Manual November 2007 Connector Illustration Connector Number Connects To Number of Pins in Connector 13 Taillight Harness 4 ...

Page 139: ...GEM Service Manual TAIL LIGHT HARNESS Underneath Side of the Flat Bed TAIL LIGHT HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector 1 Rear Harness 4 2 3 4 Lamp Taillight Left 1 5 6 7 Lamp Taillight Right 1 ...

Page 140: ...007 PIN LOCATIONS FOR TAIL LIGHT HARNESS CONNECTORS Connector Illustration Connector Number Connects To Number of Pins in Connector 1 Rear Harness 4 2 3 5 6 Lamp Taillight Left Lamp Taillight Right 1 4 5 Lamp Taillight Left Lamp Taillight Right 1 ...

Page 141: ...4 DIAGNOSIS AND TESTING PRESSURE GAUGES 6 5 DIAGNOSIS AND TESTING TREAD WEAR INDICATORS 6 5 DIAGNOSIS AND TESTING TIRE WEAR PATTERNS 6 5 DIAGNOSIS AND TESTING TIRE NOISE OR VIBRATION 6 6 REPAIRING LEAKS 6 6 ROTATION 6 6 WHEELS 6 6 DIAGNOSIS AND TESTING WHEEL INSPECTION 6 7 WHEEL INSTALLATION 6 7 November 2007 GEM Service Manual ...

Page 142: ...ity 795 lbs 900 lbs 1200 lbs 1047 lbs TIRE CHART Two Passenger e2 eS Option KENDA ProTour Two Passenger Four Passenger Short Bed Long Bed e2 e4 eS eL Standard NANKANG NY361 Six Passenger Long Bed e6 e6S eLXD Standard SONAR S 780 Four Passenger Six Passenger Long Bed e4 e6 e6S eL eLXD Option ULTREX AS4 Touring Size 205 50 10 165 70R12 77T 185 70R13 86H 185 60R14 82T Construction Bias ply Steel belt...

Page 143: ...all four tires TIRE INFLATION PRESSURES Proper tire inflation pressure is essential to the safe and satisfactory operation of the vehicle Under inflation will cause rapid shoulder wear tire flexing and possible tire failure Over inflation will cause rapid center wear and loss of the tire s ability to cushion shocks Both under and over inflation affect the stability of the vehicle and can produce a...

Page 144: ...E COMPONENTS TO WEAR OUT PREMATURELY AND MAY CHANGE THE VEHICLE S RIDE HANDLING AND STEERING BEHAVIOR IN ADDITION IT MAY AFFECT THE ACCURACY OF THE SPEEDOMETER ODOMETER USING TIRE SIZES OTHER THAN SPECIFIED COULD CAUSE LOSS OF CONTROL RESULTING IN SERIOUS PERSONAL INJURY OR DEATH WARNING NEVER USE A TIRE SMALLER THAN THE SIZE SPECIFIED USING A SMALLER TIRE COULD RESULT IN TIRE OVERLOADING AND FAIL...

Page 145: ...STING TREAD WEAR INDICATORS Tread wear indicators are molded into the bottom of the tread grooves When tread depth is 1 6 mm 1 16 in the tread wear indicators will appear as a 13 mm 1 2 in band Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs Fig 1 Tread Wear Indicators DIAGNOSIS AND TESTING TIRE WEAR PATTERNS November 2007 GEM Service Manu...

Page 146: ... mounting tire on wheel make sure all rust is removed from the rim bead and repaint if necessary Fig 2 Tire Repair Area 1 Repairable area ROTATION Tires on the front and rear operate at different loads and perform different steering driving and braking functions For these reasons they wear at unequal rates and tend to develop irregular wear patterns Rotating the tires at 500 miles or as needed The...

Page 147: ... lesser quality or a substitute design Before installing the wheel be sure to remove any build up of corrosion on the wheel mounting surfaces Ensure wheels are installed with good metal contact Improper installation could cause loosening of wheel nuts This could affect the safety and handling of your vehicle To install the wheel first position it properly on the mounting surface All wheel nuts sho...

Page 148: ...ARDS CONTINUED 7 9 BODY BACK PANEL 7 10 FLOOR PANELS 6 PASSENGER ONLY 7 11 BENCH SEATS 7 12 BUCKET SEAT 7 13 MUDGUARD 7 14 MUDFLAP 7 15 HOOD 7 16 HOOD LATCH ASSEMBLY 7 17 DASH 7 18 DASH UPPER PANEL 7 18 DASH LOWER PANEL 7 19 POD COVERS 7 20 SPAT 7 21 UTILITY BED 7 22 TRUNKBACK GOLFBACK CLIP IN STAKE BED 7 23 PACK LATCH ASSEMBLY 7 24 TRUNKBACK GOLFBACK CLIP IN STAKE BED LEG POCKET 7 26 MIRROR CENTE...

Page 149: ...eb 2 Scores across web 3 Obvious signs of wear on web at buckle 4 Corrosion of any of metal parts or fasteners If any of these signs are present locate and correct cause and replace seat belt assembly TORQUE SPECIFICATIONS Description Thread Size Use Loctite 242 Inch Pounds Foot Pounds Seat belt latch assembly to bracket bucket seat 60 Seat belt retractor to bracket bucket seat NO 60 D Ring to sea...

Page 150: ...aching retractor assembly to seat back support 7 Remove the body foot bracket that attaches the seat back support and body support arm 8 Remove seat belt assembly 9 Remove bolt attaching seat belt latch assembly to seat back support 10 Remove seat belt latch assembly INSTALLATION 1 Attach seat belt latch assembly to seat back support with mounting bolt Tighten to 60 ft lb 2 Attach D ring to seat b...

Page 151: ... sill plate if equipped See Scuff Guards in this section 7 Remove the bottom body side bolts 8 Remove the body back panel Torx bolts and nuts 5 per side 9 Remove side panel 10 If replacing panel remove front and rear trim locks and transfer them to the new side panel INSTALLATION 1 Locate side panel on tub floor pan making sure to match up holes and attaching back trim lock to back panel 2 Install...

Page 152: ... Remove the scuff guard sill plate if equipped 2 Remove the 10 body side rivets 3 Remove the center side panels 4 To install reverse this procedure REAR 1 Remove the swivel pack or utility box See Swivel Pak or Utility Box 2 Remove the rear bench seat cushion See Bench Seat in this section 3 Remove the scuff guard sill plate if equipped See Scuff Guards in this section 4 Drill out 5 rivets from th...

Page 153: ...rom bolt number three on the front side panel 3 1 2 inches 2 Mark the hole location Measure inch from the seam of the panel to get front bolt hole location Drill out the hole to accommodate the bolt 3 Place the scuff guard Set the scuff guard on the car and insert the front bolt that has just been drilled November 2007 GEM Service Manual ...

Page 154: ...Insert the bolt Put on the nuts Tighten the fasteners just tight enough to not deform the scuff guards 5 Finished e2 6 4 Pass Once the panels and tub are bolted together the scuff guards can be assembled Measure down from bolt number 3 on the front side panel 5 inches GEM Service Manual November 2007 ...

Page 155: ...front hole location Drill out the hole to accommodate the bolt 8 Locating the scuff guard Insert the front bolt to locate the scuff guard 9 Finishing the scuff guard 1 Drill out the remaining two boltholes Insert the bolts Tighten the fasteners just tight enough to not deform the scuff guards November 2007 GEM Service Manual ...

Page 156: ...7 9 BODY INSTALLATION OF SCUFF GUARDS CONTINUED 10 Finish e4 GEM Service Manual November 2007 ...

Page 157: ...dy Side Panel in this section 5 Remove bench seat base and seat back See Bench Seats in this section 6 Remove two 2 Tek screws holding the mounting brackets to the back panel attached to the frame rails using a 3 8 driver 7 Disconnect taillight brake light electrical if necessary for brake chimsel light and taillights 8 Remove body back panel INSTALLATION 1 Install the body back panel 2 Install th...

Page 158: ...park brake lever assembly See Park Brake Lever in Brake System 7 Drill out 4 rivets 8 Remove floor panel 9 To install reverse this procedure MIDDLE REAR 1 Remove the center side panels 2 Remove the middle and rear floor mats 3 Remove the bolt from the seat belt D ring 4 Remove the front seats See Bucket Seat in this section 5 Remove the floor access panel 6 Drill out 6 rivets 7 Remove floor panel ...

Page 159: ...The seat back is attached to the back panel and seat back support by screws through the bottom of the seat back Fig 6 Bench Seat new style 1 Bench seat back 2 Bench seat cushion 3 Hand hold 4 Friction latch female 5 Friction latch male 6 Seat cushion REMOVAL 1 Pull up on front edge of seat cushion until friction latch is disengaged 2 Lift seat cushion up and away to remove 3 Remove the 2 Tek screw...

Page 160: ...g bolts 5 Remove three point seat belt D ring from hanger of rear rail 6 Remove the bucket seat assembly INSTALLATION 4 PASSENGER 1 Position bucket seat assembly over seat belt bracket aligning rear mounting holes of seat over mounting holes of seat belt bracket 2 Insert the 4 mounting bolts through bucket seat track seat belt bracket into mounting holes in raised front seat portion of floor panel...

Page 161: ...ttaching the mudguard to body side panel 2 Remove the mudguard INSTALLATION 1 If installing a new mudguard drill four 1 4 holes through mudguard if necessary Use old mudguard to determine hole locations 2 With hood closed position mudguard against body side panel so that the mudguard forms a clean line and fit with the fender portion of the hood assembly 3 Install the mudguard and install the four...

Page 162: ...then 1 8 Trim as necessary for proper fit 2 Mark the first hole 1 inch from the top the remaining holes are spaced at 5 inches starting from the top hole Space all holes on the mud flap evenly from the edge NOTE If the vehicle originally had mud flaps use the existing holes in the vehicle to mark the mud flaps 3 Using a 3 16 drill bit drill holes in the mud flap 4 Using a suitable clamp secure the...

Page 163: ...mp assembly 9 Right turn signal lamp assembly REMOVAL 1 Open hood 2 Remove mounting bolts from front of hood through hinge brackets 3 Remove hood INSTALLATION 1 While supporting the hood attach hinge bracket to hood with mounting bolts Bolts should be loose enough to allow adjustment of hood for fit but tight enough to hold hood in adjusted position 2 Adjust hood latch mounting bracket until latch...

Page 164: ...nt bushing to the hood 3 Remove the latch 4 Remove the upper dash panel See Dash in this section 5 Remove the bolt attaching mounting bracket to windshield lower support 6 Remove the mounting bracket DISASSEMBLY 1 Remove the 2 Phillips head screws attaching striker plate to mounting bracket 2 Remove the striker ASSEMBLY 1 Position the striker on mounting bracket 2 Attach with the 2 Phillips head m...

Page 165: ...e box door 3 Storage tray REMOVAL 1 Open hood 2 Remove the two T27 Torx head screws located immediately below the windshield toward the outer edges 3 Lift upper dash assembly out taking care to disconnect any electrical connections 4 Disconnect the heater ducts at heater assembly if equipped NOTE Take care not to scratch steering column instrument pod covers INSTALLATION 1 Connect heater ducts at ...

Page 166: ...ift lower dash panel out taking care to disconnect any electrical connections and heater ducts Then up until lower tabs are clear of the slots in the floor pan NOTE Take care not to scratch steering column instrument pod covers INSTALLATION 1 Insert panel lower tabs into slots in floor pan 2 Connect any electrical connections then slowly lower and rock lower panel forward into place NOTE Take care...

Page 167: ...d lower dash assemblies See upper and lower dash in this section 2 Remove the 2 screw covers on front of the instrument Pod 3 Remove the 2 front pod cover screws 4 Remove the 4 screws located on the sides and remove the Pod covers INSTALLATION 1 Install 4 screws in located on the sides and remove the Pod covers 2 Install the 2 front pod cover screws 3 Install the 2 screw covers on front of the ins...

Page 168: ...cushion above rear batteries and disconnect 3 Remove the 10 hex head bolts plastic caps 4 Remove the 10 3 8 hex bolts that attach spat to mounting brackets 5 Carefully remove spat INSTALLATION 1 Carefully position spat on vehicle 2 Install the 10 3 8 hex bolts that attach spat assembly to mounting brackets 3 Install the 10 hex bolts plastic caps 4 If vehicle is equipped with license plate light an...

Page 169: ...osed cargo carrier or bed cover if equipped 2 Remove rear seat cushion 3 Disconnect the rear tail light wire harness and license plate light 4 Remove the 4 front bolts 2 each side 5 Remove the 6 bolts 3 each side from the utility bed support bracket 6 With the help of an assistant remove the utility bed INSTALLATION 1 With the help of an assistant position the utility bed 2 Install the 4 front bol...

Page 170: ...ds All available back options can be used on the 2 4 and 6 passenger models They are not available on the short bed or long bed utility models All back units have two legs that fit into pockets mounted on each frame rail Each attaches to a locking latch assembly mounted at the top of the body back panel REMOVAL 1 Use key to unlock the latch handle 2 Unlatch unit by turning handle counterclockwise ...

Page 171: ...andle 1 Locking handle Fig 25 TRUNKBACK GOLFBACK CLIP IN STAKE BED Latch Assembly 1 Turnbuckle bracket 2 Turnbuckle 3 Latch assembly Fig 26 TRUNKBACK GOLFBACK CLIP IN STAKE BED Striker Assembly 1 Latch striker 2 Latch striker bracket OPERATION The keyed locking mechanism in the handle prevents unauthorized unlatching of the pack unit for removal When unlocked turning the handle pulls on the thread...

Page 172: ...proper alignment is attained 4 Tighten mounting bolts 5 Install bench seat REMOVAL 1 Remove bench seat See Bench Seat in this section 2 Remove nut that attaches the turnbuckle assembly bracket to the handle then disengage bracket from handle 3 Remove the 2 screws attaching handle assembly to body back panel 4 Remove handle 5 Remove the 2 self drilling screws attaching the latch mounting bracket to...

Page 173: ... 3 Mounting bolts 4 Install Trunkback Golfback Clip In Stake Bed See Trunkback Golfback Clip In Stake Bed in this section MIRROR CENTER REAR VIEW DESCRIPTION The center rear view mirror assembly is mounted in the center of the upper windshield support It is not serviceable and is replaced as a unit REMOVAL 1 Remove the 2 Phillips head screws at either end of the mounting bracket 2 Remove the Phill...

Page 174: ...s the mirrors are mounted on the doors Damaged mirrors must be replaced as they are not serviceable REMOVAL 1 Using small screwdriver pry out lower screw cover on base of mirror 2 Position the rubber boot to access the upper mounting screw 3 Remove the 2 Phillips head screws attaching mirror to roof rail door 4 Remove mirror assembly and mounting gasket INSTALLATION 1 Install mirror assembly and m...

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