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2015-18 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL

Pa g e |

FUEL SYSTEMS

FUEL SYSTEM PRECAUTIONS

General

Modifications in the fuel system are not recommended, either in the circuit or the components.

WARNING:

When replacing fuel line parts, be sure to observe the following:

•

Put a

“CAUTION:

FLAMMABLE”

sign in the workshop.

•

Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher.

•

Do not smoke while servicing fuel system. Keep open flames and sparks away from the
work area.

WARNING:

•

Before removing fuel line parts, carry out the following procedures:

•

Put drained fuel in an explosion-proof container and put the lid on securely. Keep the
container in safe area.

•

Release fuel pressure from the fuel lines. Refer to the

Fuel Pressure 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  the  fuel  tube  quick  connectors,  make
sure  the  quick  connectors  are  secure.  Ensure  that  the
connector  and  resin  tube  do  not  contact  any  adjacent
parts.

•

After installing tubes, make sure there is no fuel
leakage at connections in the following steps:

•

Apply fuel pressure to fuel lines by turning ignition
switch ON (with engine stopped). Then check for fuel
leaks at connections.

•

Start the engine and rev it up and check for fuel
leaks at connections.

•

Use only a Genuine OEM fuel filler cap as a replacement.
If an incorrect fuel filler cap is used, the MIL may come
on.

•

For servicing Evaporative Emission System parts, refer to
the EC section in the service manual.

•

For servicing On Board Refueling Vapor Recovery
(ORVR) parts, refer to the EC section in the service
manual.

Содержание CHEVROLET CITY EXPRESS CARGO VAN 2015

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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