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G/H Van (GMT 610) 2005

G/H V

AN

(

GMT 610

)

i

P

AGE

BODY BUILDERS INSTRUCTIONS .......................................................................................................................................................... 1

Section 0 – General Instructions ..................................................................................................................................................... 1

Welding ....................................................................................................................................................................................... 2

Labels ......................................................................................................................................................................................... 2

Section 1 – Body................................................................................................................................................................................ 3

Conversions ................................................................................................................................................................................ 3

Air Conditioning .......................................................................................................................................................................... 4

Rear Air Conditioning .................................................................................................................................................................. 4

Section 2 – Frame ............................................................................................................................................................................. 5

Flanges ....................................................................................................................................................................................... 5

Holes ........................................................................................................................................................................................... 5

Alterations ................................................................................................................................................................................... 6

Shear Plate Attachments ............................................................................................................................................................ 6

Trailer Towing .............................................................................................................................................................................. 6

Section 3 – Front Suspension .......................................................................................................................................................... 7

Section 4 – Rear Suspension ........................................................................................................................................................... 7

Section 5 – Brakes ............................................................................................................................................................................ 8

Section 6 – Engine............................................................................................................................................................................. 9

Section 7 – Transmission ................................................................................................................................................................ 11

Section 8 – Fuel and Exhaust ......................................................................................................................................................... 11

Fuel Systems ............................................................................................................................................................................ 11

Fuel Fill ...................................................................................................................................................................................... 12

Fuel Lines .................................................................................................................................................................................. 12

Fuel Tank ................................................................................................................................................................................... 13

Gaseous Fuel Conversions ....................................................................................................................................................... 14

Exhaust System ........................................................................................................................................................................ 14

Section 9 – Steering ........................................................................................................................................................................ 15

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Содержание GMT 610

Страница 1: ...Conditioning 4 Section 2 Frame 5 Flanges 5 Holes 5 Alterations 6 Shear Plate Attachments 6 Trailer Towing 6 Section 3 Front Suspension 7 Section 4 Rear Suspension 7 Section 5 Brakes 8 Section 6 Engin...

Страница 2: ...ea 135 WB G H 134 234 334 27 Sign Area 155 WB G H 137 237 337 28 Window Opening 135 WB G H 134 234 334 29 Window Opening 155 WB G H 137 237 337 30 Glass Area 135 WB G H 134 234 334 31 Glass Area 155 W...

Страница 3: ...Optional E26 135 WB G H 134 234 334 49 Floor without Optional E26 135 WB G H 134 234 334 50 CHASSIS General Arrangement Full Body Van G H 100 200 300 05 06 51 General Arrangement Cutaway G 335 338 33...

Страница 4: ...Location with L H Swing Out Doors opt E26 Full Body Vans 67 Fuel Tank 35 Gallon Mid ship Cutaway 68 Fuel Tank 57 Gallon Rear Mounted behind RR Axle 69 EXHAUST SYSTEMS Exhaust System 135 WB w Vortec 53...

Страница 5: ...ur Web site at http www gmupfitter com Section 0 General Instructions Check for proper clearance between body members and chassis components which may in any way affect the reliability and performance...

Страница 6: ...e sections are made of high strength low alloy steel that could be adversely affected by heating due to welding Also prior to welding the area to be welded and surrounding area must be cleaned of all...

Страница 7: ...ve heat and or provide noise attenuation Any replacement material internal to the occupant compartment may have to be certified for MVSS 302 standard on flammability Some areas of specific interest ar...

Страница 8: ...uick connect fittings on the liquid tube high pressure and the suction low pressure return tube These fittings are designed to accept matching Aeroquip connecting fittings attached to pre charged line...

Страница 9: ...reference pages 38 40 in the Body Builders Manual Flanges Do not drill holes in frame flanges Within 20 mm 0 75 in of radius tangent and 25 mm 1 0 in of raw edge Larger than 12 mm 0 50 in Closer to e...

Страница 10: ...75 in in diameter Holes are to be drilled no closer than 63 5 mm 2 5 in apart For holes drilled forward of the rear axle centers are to be no closer than 63 5 mm 2 5 in from the top or bottom flanges...

Страница 11: ...ovided for the suspension axle driveshaft and tires under the following conditions 1 Axle in full jounce against the metal to metal stop 2 Axle at 4 5 roll with one side of axle in full jounce at the...

Страница 12: ...It is mandatory that no change be made to the brake master cylinder location brake pedal push rod length or pedal position Ensure that the hydraulic brake system is free of air and hydraulic leaks Bl...

Страница 13: ...nger be reconnected if not blocked pinned See the Pin UP procedure outlined in Section 5 Enabling the Park Brake Automatic Adjuster in the G Van Service Manual Section 6 Engine For additional informat...

Страница 14: ...ation remains unchanged Guidelines for accelerator pedal locations are as follows a Ensure that the accelerator can freely operate from idle to wide open throttle position and return Make sure that th...

Страница 15: ...ive 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...

Страница 16: ...revent gasoline vapor from emitting to vents of pilot flamed devices and to body and engine compartment air inlets It is recommended that when mounting the fuel filler pipe assembly and vent hose that...

Страница 17: ...e water drain provisions in the fuel system These valves are only to be opened when removing water and contaminants from the fuel system Fuel Tank The tank must have a minimum clearance of 2 in top fr...

Страница 18: ...ould damage or reduce the longevity of those components could cause the mechanical and emission performance warranty to be voided Exhaust System Particular care should be taken to prevent the possibil...

Страница 19: ...peration of body components The same can be said for the engine compartment Obviously there will be additional heat radiated from the engine How much is retained in the area will depend on how well th...

Страница 20: ...es and inflate to recommended tire pressure according to the tire pressure information provided in the Owner s Manual and tire inflation label provided with the vehicle Any substitution of tires may a...

Страница 21: ...terminal must not cause undue strain at these connections There should be no sharp bends in the cables adjacent to the connections The cables should be routed down from the terminals rather than hori...

Страница 22: ...t exceed 52 C Infrequent peak temperatures to 75 C can be tolerated in soak situations only Shielding may be required to protect the battery from a source of excessive heat 14 Battery Storage Today s...

Страница 23: ...fusible link 3 Fabricate a new fusible link wire approximately 6 to 8 in long from the same wire size as the original link Acceptable fusible link material will be imprinted with the wire size and th...

Страница 24: ...duty cooling equipment is required when air conditioning auxiliary belt driven equipment snow plows winches etc are installed 5 Continuous coolant flow is necessary from the heater connection on the e...

Страница 25: ...ION DESCRIPTION DESCRIPTION G13405 6200 Q4B 135 Cargo Van 7200 C5Z G13405 w YF7 7200 C5Z 135 Cargo Van 10 Series H13405 7200 C5Z 135 Cargo Van H13405 w YF7 7200 C5Z 135 Cargo Van G13406 H13406 7200 C5...

Страница 26: ...DESCRIPTION DESCRIPTION DESCRIPTION G23705 7300 C6A 155 Cargo Van 8600 C6P 20 Series G23705 w YF7 8600 C6P 155 Cargo Van G23706 8600 C6P 155 Passenger Van G33405 9600 C6Y 135 Cargo Van G33405 w YF7 9...

Страница 27: ...SCRIPTION G33406 9600 C6Y 135 Passenger Van G33706 9600 C6Y 155 Passenger Van 9600 C6Y G33503 10000 C7A 139 TBD Commercial Cutaway 11000 C7E 12000 C7L 30 Series G33503 w B3D 9600 C6Y Commercial Cutawa...

Страница 28: ...NG MERCHANDISING kg lbs mm in mm in DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION G33903 w B3D 12000 C7L 177 TBD Commercial Cutaway G33503 w YF1 9600 C6Y Motor Home Cutaway 11500 C7G 139 TBD 30 Seri...

Страница 29: ...G H Van GMT 610 2005 G H VAN GMT 610 25 PAGE General Arrangement 135 WB G H 134 234 334 and 155 WB G H 237 337 TD005990a...

Страница 30: ...G H Van GMT 610 2005 G H VAN GMT 610 26 PAGE TD005886b General Arrangement 139 WB G335 159 WB G338 177 WB G339...

Страница 31: ...G H Van GMT 610 2005 G H VAN GMT 610 27 PAGE TD006054a Sign Area 135 WB G H 134 234 334...

Страница 32: ...G H Van GMT 610 2005 G H VAN GMT 610 28 PAGE TD006054b Sign Area 155 WB G H 137 237 337...

Страница 33: ...G H Van GMT 610 2005 G H VAN GMT 610 29 PAGE TD006054c Window Opening 135 WB G H 134 234 334...

Страница 34: ...G H Van GMT 610 2005 G H VAN GMT 610 30 PAGE TD006054d Window Opening 155 WB G H 137 237 337...

Страница 35: ...G H Van GMT 610 2005 G H VAN GMT 610 31 PAGE TD006054e Glass Area 135 WB G H 134 234 334...

Страница 36: ...G H Van GMT 610 2005 G H VAN GMT 610 32 PAGE TD006054f Glass Area 155 WB G H 137 237 337...

Страница 37: ...G H Van GMT 610 2005 G H VAN GMT 610 33 PAGE TD006016a Mirrors Outside Rearview...

Страница 38: ...G H Van GMT 610 2005 G H VAN GMT 610 34 PAGE TD005979a G Cutaway Rear Flange Opening Dimensions...

Страница 39: ...G H Van GMT 610 2005 G H VAN GMT 610 35 PAGE TD006033a Rear CHMSL Location...

Страница 40: ...G H Van GMT 610 2005 G H VAN GMT 610 36 PAGE TD006025a Seating Positions and H Point Locations 2 5 8 12 135 WB...

Страница 41: ...G H Van GMT 610 2005 G H VAN GMT 610 37 PAGE TD006025b Seating Positions and H Point Locations 2 4 8 12 155 WB...

Страница 42: ...G H Van GMT 610 2005 G H VAN GMT 610 38 PAGE TD006025c Seating Positions and H Point Locations 2 4 8 12 15 155 WB...

Страница 43: ...G H Van GMT 610 2005 G H VAN GMT 610 39 PAGE TD005989a 1st Row Driver and Passenger Seat Riser Mounting Locations...

Страница 44: ...G H Van GMT 610 2005 G H VAN GMT 610 40 PAGE TD006025d Seating Tie Down Locations 12 Passenger 135 WB...

Страница 45: ...G H Van GMT 610 2005 G H VAN GMT 610 41 PAGE TD006025e Seating Tie Down Locations 12 Passenger 155 WB...

Страница 46: ...G H Van GMT 610 2005 G H VAN GMT 610 42 PAGE TD006025f Seating Tie Down Locations 15 Passenger 155 WB...

Страница 47: ...G H Van GMT 610 2005 G H VAN GMT 610 43 PAGE TD006008a Roof Bows 135 and 155 WB 05 06...

Страница 48: ...G H Van GMT 610 2005 G H VAN GMT 610 44 PAGE TD006008b Side Strainers Braces and Reinforcements 135 WB G H134 G234 G334 05 06...

Страница 49: ...G H Van GMT 610 2005 G H VAN GMT 610 45 PAGE TD006008c Side Strainers Braces and Reinforcements 135 WB G H134 G234 G334 05 06...

Страница 50: ...G H Van GMT 610 2005 G H VAN GMT 610 46 PAGE TD006008d Side Strainers Braces and Reinforcements 155 WB G237 G337 05 06...

Страница 51: ...G H Van GMT 610 2005 G H VAN GMT 610 47 PAGE TD006008e Side Strainers Braces and Reinforcements 155 WB G237 G337 05 06...

Страница 52: ...G H Van GMT 610 2005 G H VAN GMT 610 48 PAGE TD006018a Floor Cross Sills Centerline Locations...

Страница 53: ...G H Van GMT 610 2005 G H VAN GMT 610 49 PAGE TD006077a Floor with Optional E26 135 WB G H 134 234 334...

Страница 54: ...G H Van GMT 610 2005 G H VAN GMT 610 50 PAGE TD006077b Floor without Optional E26 135 WB G H 134 234 334...

Страница 55: ...G H Van GMT 610 2005 G H VAN GMT 610 51 PAGE TD005956a General Arrangement Full Body Van G H 100 200 300 05 06...

Страница 56: ...G H Van GMT 610 2005 G H VAN GMT 610 52 PAGE TD005886a General Arrangement Cutaway G 335 338 339 03...

Страница 57: ...G H Van GMT 610 2005 G H VAN GMT 610 53 PAGE TD005993a Frame and Crossmember Arrangement 135 WB G 134 234 05 06...

Страница 58: ...G H Van GMT 610 2005 G H VAN GMT 610 54 PAGE TD005993c Frame and Crossmember Arrangement 135 WB H 134 234 05 06...

Страница 59: ...G H Van GMT 610 2005 G H VAN GMT 610 55 PAGE TD005993b Frame and Crossmember Arrangement 135 WB G 234 334 05 06...

Страница 60: ...G H Van GMT 610 2005 G H VAN GMT 610 56 PAGE TD005994a Frame and Crossmember Arrangement 155 WB G 237 337 05 06...

Страница 61: ...G H Van GMT 610 2005 G H VAN GMT 610 57 PAGE TD005145a Frame and Crossmember Arrangement 139 159 177 WB G Cutaway 03...

Страница 62: ...G H Van GMT 610 2005 G H VAN GMT 610 58 PAGE TD006052a Platform Trailer Hitch...

Страница 63: ...G H Van GMT 610 2005 G H VAN GMT 610 59 PAGE TD006017a Spare Tire Carrier 135 WB G H 134 234 05 06 G 334 05 06...

Страница 64: ...G H Van GMT 610 2005 G H VAN GMT 610 60 PAGE Spare Tire Carrier 155 WB G 237 337 05 06 TD006017b...

Страница 65: ...G H Van GMT 610 2005 G H VAN GMT 610 61 PAGE Front Axle Tire Data Chart Full Body Vans 05 06 TD005982a...

Страница 66: ...G H Van GMT 610 2005 G H VAN GMT 610 62 PAGE Front Axle Tire Data Chart Cutaway Vans 03 TD005982b...

Страница 67: ...G H Van GMT 610 2005 G H VAN GMT 610 63 PAGE Rear Axle Tire Data Illustration TD005980a...

Страница 68: ...G H Van GMT 610 2005 G H VAN GMT 610 64 PAGE Rear Axle Tire Data Chart Full Body Vans G H 100 200 300 05 06 TD005980b...

Страница 69: ...G H Van GMT 610 2005 G H VAN GMT 610 65 PAGE Rear Axle Tire Data Chart Cutaway Vans G 335 338 339 03 TD005980c...

Страница 70: ...G H Van GMT 610 2005 G H VAN GMT 610 66 PAGE Fuel Tank and Filler Location Full Body Vans TD005956b...

Страница 71: ...G H Van GMT 610 2005 G H VAN GMT 610 67 PAGE Fuel Tank and Filler Location with L H Swing Out Doors opt E26 Full Body Vans TD005956c...

Страница 72: ...G H Van GMT 610 2005 G H VAN GMT 610 68 PAGE Fuel Tank 35 Gallon Mid ship Cutaway TD005887b...

Страница 73: ...G H Van GMT 610 2005 G H VAN GMT 610 69 PAGE Fuel Tank 57 Gallon Rear Mounted behind RR Axle TD005887a...

Страница 74: ...G H Van GMT 610 2005 G H VAN GMT 610 70 PAGE Exhaust System 135 WB w Vortec 5300 V8 LM7 TD006011a...

Страница 75: ...G H Van GMT 610 2005 Revised 08 2005 G H VAN GMT 610 71 PAGE Exhaust System 135 WB w Vortec 4800 V8 LR4 and 6000 V8 LQ4 TD006011b...

Страница 76: ...G H Van GMT 610 2005 G H VAN GMT 610 72 PAGE Exhaust System 155 WB w Vortec 5300 V8 LM7 TD006011d...

Страница 77: ...G H Van GMT 610 2005 Revised 08 2005 G H VAN GMT 610 73 PAGE Exhaust System 155 WB w Vortec 4800 V8 LR4 and 6000 V8 LQ4 TD006011c...

Страница 78: ...G H Van GMT 610 2005 Revised 08 2005 G H VAN GMT 610 74 PAGE Exhaust System w Vortec 4800 V8 LR4 and 6000 V8 LQ4 G33503 139 WB TD005888a...

Страница 79: ...G H Van GMT 610 2005 Revised 08 2005 G H VAN GMT 610 75 PAGE Exhaust System w Vortec 6000 V8 LQ4 TD005888b...

Страница 80: ...G H Van GMT 610 2005 Revised 08 2005 G H VAN GMT 610 76 PAGE Exhaust System w Vortec 6000 V8 LQ4 TD005888c...

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