General Instructions C Series
Contents
1. em Dury GeneraL Instructions GheveoLer amp GMC C amp T Series Isuzu F Series i BODY BUILDER INFORMATION issiccccissteisispanpannsccwenducuettemansnessncuaxanesiemanenonsseneucuaniessioniwanmianai gudkstue nenaneuatamanastisneuauanandvastuckansbienananedsxanensnesteness 1 Section A PP 1 Te NET E 2 Seatin EE 3 Rear Heater eege eebe E E o mA e 3 Rear Air Conditioning A e o 3 Section E 4 EE EE A e La TE 4 WEldiNg EE 4 A PP o FU EEE ERE o E OO a en eee eee eee 5 EK gbeet gege y 5 PA O A 5 Section 3 Front SUSPENSION iia caeduadeuirideineninteiiewienecencceadadsinusiceceececes 6 SECUONA gt Rear SUS EN 6 nn nn PP 6 Air Brake Systems iss ecco er ei cece ces ce nc sec esc ie sense E 7 Section 6 e Uu CN 7 Section 2 TAMSIN SSI OU EEN 11 Section 8 Fuel and EXNaUSt EN 11 Fuel Systems EE 11 Temporary Tank E 11 A 6 EO O A 12 FS TE EE 12 ET EE 13 2007 Diesel Emissions Compliant Exhaust Systems da 14 en EE TT A A 16 2009 MD General Instructions C amp T F Rev 04 09 Menu Duty Genera Instructions CheveoLEr amp GMC C amp T Series Isuzu F Series Eli BODY BUILDER INFORMATION continued Section O UE 16 Section 12 Electrical Battery and Battery Cables wicvvsisiscsscccnassnisiwnsnsuenccsncnsncsescanenanexenesencsesteanauebenoudhansecanetanncanceenenskeseonsenencehave 17 Gasoline Endesa isa 17 Diesel ENGINES EN 17 B ttery Installation E 17 Fusible LINK Repair Procedur2. 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 of the vehicle by developing abrasion and wear points from moving parts or degradation from extreme environment or thermal exposure or may increase interior noise Check headlamp aim and all vehicle illumination systems for proper operation when the vehicle has been completed Re aim headlamps when necessary Check for proper operation of windshield washer wipers and defroster system Extreme care must be taken when working on vehicles equipped with Brake Control Module BCM Engine Control Module ECM Transmission Control Module TCM Gee Owner s Manual If arc welding is performed on the chassis precautions must be taken to protect all vehicle components especially brake fuel lines and fuel tank assembly electrical wiring and BCM ECM TCM To avoid electronic component damage disconnect battery batteries disconnect the negative cable first followed by the positive To reconnect cables connect the positive first then the negative All labels on the vehicle any message applied to the vehicle or vehicle component that informs instructs or warns must appear on the completed vehicle so the user can read them easily and without obstruction Service and service replacement parts for your add on systems may not be available from a GM d
3. Rev 04 09 Neu Dury General Instructions ChevroLet amp GMC LA T Series Isuzu F Series Section 9 Steering Check power steering fluid level and system operations Refer to Owner s Manual Steering wheel and horn pad must not be altered or replaced The steering column mast jacket must not be altered Section 10 Tires Check wheel lug nuts for proper torque specifications are provided in the Owner s Manual Substitution of tires of greater capacity than those offered as original equipment by vehicle manufacturer is not approved for use on original equipment wheels Any usage of higher capacity tires must be accompanied by higher capacity wheels with the same type mounting and fasteners However the wheel offset and distance from centerline of rim to wheel mounting face must be the same as the replaced original equipment wheel to ensure proper wheel bearing loading and clearance of tires to body and chassis components Increasing tire and wheel capacity does not necessarily increase vehicle GVW ratings It is recommended that tire chain clearance guideline J683 from the Society of Automotive Engineers be adhered to in designing rear wheelhouse clearance Check tires and inflate to recommended tire pressure according to the tire inflation label provided with the vehicle as referenced in the owner s manual Any substitution of tires may affect Soeedometer Odometer accuracy 2009 MD General Instructions C amp T F
4. Vibration frequencies of 10 Hz or below with accompanying high displacements may cause electrolyte acid expulsion from the battery and should be avoided 12 Accessibility The hold down should be convenient for tools and hands so that personal injury does not occur There should be clearance at the insulated and grounded terminals so that wrenches can be used so that accidental grounds or shorts will not occur Terminal polarity markings warning labels and test hydrometer should be visible The battery ground connection must be readily accessible for disconnection as required for vehicle electrical service requirements 13 Tilt Angles For normal vehicle operation at GVW the battery should not be tilted 0 For installation or removal it should not be necessary to tip or tilt the battery in excess of 40 This is to prevent acid spillage For short duration vehicle shipment do not tilt the battery more than 19 from the horizontal 14 Temperature The temperature of the electrolyte should not 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 15 Battery Trays Battery trays are supplied with the chassis In the case of motor homes and diesel school busses the trays are secured to the frame rail for shipping only For other units the tray is supplied on the radiator support The trays shippe
5. V8 LF8 07 Diesel Emission Compliant During normal vehicle operation and during the exhaust particulate filter regeneration process gas temperature inside the filter can reach levels approximately as high as 650 degrees C which is considerably higher than previous diesel exhaust systems Therefore materials and components installed near the exhaust system and exhaust gas stream should be shielded or de signed to now withstand higher temperatures On all LMM systems an exhaust cooling device has been designed for the end of the tailpipe to significantly reduce the exhaust gas exit temperature This device is required and is designed to draw in ambient air to cool the exhaust stream The exhaust and ambient air streams into the cooler assembly should remain unob structed and free from foreign material Section 8 continued on next page 2009 MD General Instructions C amp T F Rev 04 09 Neu Dury General Instructions GhevroLET amp GMC C amp T Series Isuzu F Series When possible the tailpipe outlet location should not be modified because doing so could adversely affect noise If it is neces sary to modify the tailpipe the following restrictions apply and noise performance becomes the responsibility of the modifier The tailpipe should be 1 6 mm 06 minimum wall thickness 3 5 diameter and the proper material is 409 aluminized stainless steel Any extension to the system must minimize surface temperatures and the transfer of h
6. components body and occupants from excessive heat and or provide noise attenuation Any replacement material internal to the occupant compartment must be certified for MVSS standard on flammability Areas of specific concern but not limited to are e Underbody exhaust muffler and tailpipe shields and insulators e Rear load floor interior insulation e Front floor interior insulation e Dash mat insulation e Engine cowl insulation interior and exterior e Engine cover insulation Accessory items such as refrigerator hot water heater furnace etc which operate on liquid propane gas should be located and protected to prevent exposure to any flame Section 1 continued on next page 2009 MD General Instructions C amp T F Rev 04 09 PAGE co Meoium Dury GeneraL Instructions GhevroLET amp GMC C amp T Series Isuzu F SERIES Section 1 continued from previous page Seating If a bodybuilder installs seating other than that supplied with the vehicle it is the bodybuilder s responsibility to ensure that the seating and restraint systems comply with FMVSS requirements The restraint systems supplied with the vehicle were designed to accommodate the seating reference points and seat travel of the original equipment seats only Rear Heater The heater system is designed to support a rear heater core heat rejection of 543 Btu min 82 580 Btu hr If additional heat is required a Fuel Operated
7. the battery Section 13 Cooling To provide satisfactory engine cooling the following conditions must be met 1 Do not locate any large objects in front of the radiator core or grille such as batteries spare tires lights sirens etc They restrict air flow into the radiator core and influence fan blade stress 2 Grille opening size configuration and the external baffles provided should not be altered in any manner Any reduction in cooling ability may adversely affect engine transmission performance 3 Fan clutches not conforming to the original equipment specifications will not operate correctly and will stay on continuously never come on or cycle on and off excessively This will result in a reduction of fuel economy engine overheat at times and annoying cycling respectively 4 Heavy duty cooling equipment is required when air conditioning auxiliary belt driven equipment snow plows winches etc are installed 5 Grille open area must not be less than 85 of radiator core frontal area The remaining 15 less blockage must be evenly distributed 6 Continuous coolant flow is necessary from heater connection on engine to heater connection on radiator to control transmission oil temperatures during closed thermostat warm up operation Do not alter this flow as it may result in premature transmission failure When adding additional heaters the system must be properly refilled to avoid air pockets Use Dexcool coolan
8. the cable diameter Insulation failure can occur if this happens 3 The cable must be supported by clips spaced at a distance of not more than 450 mm where possible In this clipping they shall not have a free movement that will allow rubbing on any vehicle component either fixed or moveable Section 12 continued on next page 2009 MD General Instructions C amp T F Rev 04 09 18 PAGE Neu Dury General Instructions GhevroLeT amp GMC C amp T Series Isuzu F Series Section 12 continued from previous page 4 All clips used must be of the rubber lined type not rubber dipped 5 Do not splice the battery cables Cable modifications can result in vehicle starting problems and loss of other key systems 6 The cables must be clipped to the battery tray such that the cable pull loads are not transferred into the battery posts due to slide tray movement Failure to do so can result in loose terminals poor starting and battery failure Battery acid leakage could result around posts not properly relieved of strain 7 The cable attachments at the battery 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 horizontally from the terminals to prevent a lever action that may loosen connections Terminal corrosion inhibitors and other coatings should not be applied to the s
9. vehicle In addition vehicles converted to gaseous fuels should not be stored in enclosed places such as garages Further General Motors cautions purchasers that the design location and installation of any type of fuel storage system involves significant technical and engineering considerations and that these statements on gaseous fuel conversions should not be interpreted to be an approval by General Motors of any modification to the original equipment fuel system Conversions to gaseous fuel should be made in conformance with applicable Federal and State regulations Removal of emission control components or the addition of gaseous fuel systems which could damage or reduce the longevity of those components could also cause the mechanical and emission performance warranty to be voided Exhaust System Particular care should be taken to prevent the possibility of exhaust fumes and carbon monoxide exposure to vehicle occupants in units completed by body builders Holes and openings through the floor and all other parts of the body must be permanently and adequately sealed by the body builder to avoid exhaust intrusion into any occupant area If it is necessary to change the exhaust outlet location the exhaust discharge must be unobstructed and directed away from occupant areas Alteration of the exhaust outlet or its position may increase exhaust noise and render the vehicle illegal in those areas with pass by noise regulations All vehicles gt 10 000
10. 009 MD General Instructions C amp T F Rev 04 09 Meoium Dury General Instructions GhevroLer amp GMC C amp T Series Isuzu F SERIES Section 2 continued from previous page When welding side rails crossmembers and brackets 50 000 or 80 000 PSI yield strength emphasis is placed upon weld application techniques to avoid stress risers that may adversely affect frame operating stresses When welding is performed anywhere on the vehicle precautionary measures should be taken to prevent damage to electrical system wiring or components Prior to any welding parts or components which could be damaged by excessive temperatures must be removed or adequately shielded the battery cables should be disconnected at the battery Also prior to welding the area to be welded and surrounding area must be cleaned of all frame protective coating After welding when parts are cool carefully inspect wiring and electrical components for shorts or other damage which could draw excessive currents and possibly cause an electrical system short when the battery is reconnected Apply protective coating equal to the original finish to areas where coating was removed Alterations If the wheelbase is modified the alterer must take responsibility for compliance with affected motor vehicle safety standards and also for warranty on items such as driveshafts universal joints center bearings and rear transmission tailshaft transfer case and transmission case f
11. 9 Neu Dury GeneraL Instructions CheveoLeT amp GMC C amp T Series Isuzu F Series Section 1 continued from previous page Section 2 Frame Hole drilling welding modifications or alterations to the frame assembly are the responsibility of persons performing these operations These same individuals assume complete responsibility for frame assembly reliability performance after alterations and compliance to applicable FMVSS requirements The following procedures and specific precautionary instructions are recommended for proper installation of special bodies and or equipment on GM frames Failure to follow these recommendations could result in serious damage to the basic vehicle Flanges Do not drill holes in frame flanges Holes Holes to mount brackets supports and out riggers must be drilled in the vertical side rail web with the following restrictions e The minimum edge distance between any two 2 holes must be larger than twice the diameter of the larger hole e No holes should exceed 20 mm 0 75 in in diameter e All holes should be drilled in the frame using appropriate drilling practice and safety precautions no more than four 4 holes in a row vertically Welding CAUTION Fuel tank and fuel lines must be drained and all vapors purged to ensure noncombustible mixture before any welding brazing or soldering No welding is permitted on Family 3 heat treated frames Section 2 continued on next page 2
12. F Rev 04 09 PAGE O Nenn Dury Genera Instructions GHevoLer amp GMC C amp T Series Isuzu F Series Section 3 Front Suspension See chassis data information for clearances and assistance in calculating trim heights Since there is a large variation in completed vehicle front weight due to differences in body weight and equipment the front suspension alignment must be checked and reset if necessary after the vehicle is completed Caster should be set with reference to the A dimensions Camber is designed into the axle and cannot be adjusted See Truck Service Manual for complete alignment procedure for specifications and measurement of the A dimension under Diagnosis and Front Alignment section Section 4 Rear Suspension Clearance to body should be provided 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 metal to metal stop and 8 Axle at design position Allowance for the tire chain clearance shown on a maximum grown tire must allow for 1 66 in clearance to the sides of the tire and 2 5 in to the top of the tire Be sure sufficient clearance is provided for suspension axle and tire and wheel in full vertical travel up and down NOTE Notification to the consumer may be required in certain states if tire chains cannot be used Pipe
13. Heater should be considered A fuel operated heater can provide an additional 17 500 Btu hr to the system coolant The total of the rear auxiliary heater system supports 50 080 Btu Hr with a base engine plus an additional fuel operated heater Front Heater Core 37 020 Btu hr Rear Heater Core 32 580 Btu hr Fuel Operated Heater 17 500 Btu hr directly to the coolant Diesel engines may set the Check Engine light if too large a rear heater core is installed The coolant temperature needs to be able to maintain a minimum of 70 degrees C 158 degrees F for regeneration of the particulate filter to occur It is important that any upfit add on heating or cooling lines or hoses be correctly routed and properly supported to eliminate any interference or stress loads on OEM accessories and drive systems Rear Air Conditioning A C system is designed to support a rear Evaporator Core heat rejection of 450 Btu min 27 000 Btu hr The system will not be properly balanced if a larger rear evaporator core is used without other system modifications This condition may lead to poor performance and or potential component failure Front Evaporator Core 28 200 Btu hr Rear Evaporator Core 27 000 Btu hr It is important that any upfit add on heating or cooling lines or hoses be correctly routed and properly supported to eliminate any interference or stress loads on OEM accessories and drive systems 2009 MD General Instructions C amp T F Rev 04 0
14. IES Section 8 continued from previous page Tank may be pressurized temporarily to 1 25 psi maximum to check for final line leakage or for forcing fuel through the system Pressures greater than this amount may be detrimental and affect tank durability The use of auxiliary fuel tanks is not recommended If an auxiliary fuel tank is added the alterer must take responsibility for compliance with affected Federal Motor Carrier Safety Regulations and other motor vehicle safety standards Also if an auxiliary fuel tank is added to a gasoline powered vehicle the fuel must be drawn through a pipe at the top of the tank balance line between tanks is not permitted All vehicles are now equipped with a fuel return line If an auxiliary tank is added the tank selector valve must include a return port which returns fuel to the tank from which the fuel is being drawn In gasoline engines the fuel pump is located in the fuel tank The battery must be disconnected before starting any work on the fuel system In the use of dual fuel systems the vehicle operator should strictly adhere to the manufacturer s procedures for switching from gasoline to gaseous fuel operation Improper switching procedures may result in overheating and damage to the exhaust system and the vehicle The gaseous fuel tank should not be mounted in an enclosed area of the vehicle such as the passenger compartment trunk etc and the system should be vented to the outside of the
15. NO ALTERATION OF THE FUEL SYSTEM IS RECOMMENDED Temporary Tank The temporary fuel container and sender unit must be replaced with a permanent fuel tank assembly prior to placing the vehicle into use The replacement tank supplier and or body builder is responsible for certifying evaporative emissions NOTE If a temporary tank fuel sender unit is used with a permanent fuel tank the Body Builder must assure that there is not degradation of the fuel system integrity and performance Section 8 continued on next page 2009 MD General Instructions C amp T F Rev 04 09 12 PAGE Meoium Dury Genera Instructions GhevroLET amp GMC C amp T Series Isuzu F SERIES Section 8 continued from previous page Fuel Lines Fuel line routing precautions e When using non metallic fuel lines operating environment should not exceed 194 F continuous and 239 F instantaneous e 12 in minimum clearance to exhaust system is required or a metal shield must be provided e Fuel lines should be clipped to chassis to prevent chafing Metal clips must have rubber or plastic liners e Use corrosion resistant steel tubing with short sections of approved hose to connect components Hose to tube connections should be clamped for diesel systems Steel tube ends should be beaded for hose retention Fuel supply is pressurized by an in tank pump for gasoline systems Coupled hose connects must be used Clamped hose is not acceptable for gas f
16. Rev 04 09 em Dury Genera Instructions GhevroLer amp GMC C amp T Series Isuzu F Series 21 17 Section 12 Electrical Battery and Battery Cables The vehicle battery should be located and positioned to make use of the existing battery cables If the battery requires relocation and longer cables are required a proportionately larger gauge wire must be used If in relocating the battery the negative ground cable is attached to the frame rail a cable of similar gauge must be provided between the frame rail and the engine This is required due to the heavy electrical loads imposed by the starting circuit To ensure proper operation of the battery cables the following chart on length gauge and materials must be strictly adhered to Gasoline Engines Combined Length of Positive and Negative Cable oe Cable in Inches Copper Diesel Engines Any increase in battery cable lengths from the General Motors design should change to 000 cable gauge Battery Installation The battery and cable installation provided by the body upfitter must comply with the following guidelines Non compliance may result in a failure of the vehicle electrical component system the shutdown of the engine loss of backup brake system and the possibility of fire 1 The cables must not contact any sharp edge s in either the normal stored or slid maintenance position school bus application 2 Thecables must not be bent in a radius of smaller than 10 times
17. belt driven equipment installation recommendations No alterations or additions to the accessory drive belt system will be warranted on either multiple belt systems or serpentinebelt systems 2009 MD General Instructions C amp T F Rev 04 09 Section 6 continued on next page Neu Dury GeneraL Instructions GhevroLer amp GMC C amp T Series Isuzu F SERIES Section 6 continued from previous page Multiple belt systems may incorporate several conventional V belts or a combination of conventional V and poly V belts If modification to this type of system is made the following should be considered 2009 MD General Instructions C amp T F Rev 04 09 When additional alternators A C compressors and or other aftermarket accessory components are added to the OEM accessory drive system on the engine the Upfitter must be aware that these increased system loads may impact the components of the accessory drive system including the bearing life and durability of the OEM accessories drive belts water pump idler pulleys and belt tensioners The General Motors New Vehicle Limited warranty does not cover any damage or failure resulting from modification or alteration to the vehicle s original equipment as manufactured or assembled by GM Any issues resulting from body or equipment additions and any alterations to any of the parts components systems or assemblies installed by GM must be addressed by the special body company or equi
18. d on the rails may be relocated to other areas on the vehicle keeping in mind the recommendations noted above 16 Battery Storage Today s vehicles have several electronic devices which result in very small but continuous current drains on their batteries commonly referred to as parasitic loads Vehicles that are not used for an extended period of time may develop extremely discharged and or permanently damaged batteries resulting from these parasitic loads Discharged batteries can freeze at temperatures as high as 20 F causing permanent damage To alleviate this condition check to make sure the green dot is visible recharge as necessary then disconnect the negative battery cable on vehicles which are not going to be in service within a 30 day period If this is not possible batteries should be recharged periodically every 30 60 days until the green dot is visible Section 12 continued on next page 2009 MD General Instructions C amp T F Rev 04 09 20 PAGE Meoium Dury Genera Instructions ChevroLET amp GMC C amp T Series Isuzu F Series Section 12 continued from previous page NOTE The ignition switch must be off when connecting or disconnecting battery cables or hangers jumper cables Failure to do so may overstress or damage the ECM PCM or other electronic components Modifications add on wiring must be carefully reviewed to ensure compatibility with the base vehicle wiring by rev
19. device has been installed to the tailpipe to significantly reduce the exhaust gas exit tem perature This device consists of a nozzle which exits into a cooler pipe and is designed to draw in ambient air to cool the exhaust stream The exhaust stream into the cooler pipe should remain unobstructed and free from foreign material When possible the tailpipe outlet location should not be modified If it is necessary to modify the tailpipe the following restrictions apply The LF8 7 8L Isuzu exhaust tail pipe should use 409 aluminized stainless steel 1 6 mm 06 minimum wall thickness 3 5 diameter The LF6 7 2L Catepillar exhaust should use 409 aluminized stainless steel 1 6 mm 06 minimum wall thickness 4 00 diameter Any extension to the system must be insulated to minimize surface temperatures and prevent the transfer of heat to the vehicle and surrounding environment air gap tubing _ wrap with a protective cover or shielding are recommended If equipped with an exhaust cooling device the nozzle must be reattached to the end of the tailpipe extension and the cooler pipe must be installed in the same relative position to the nozzle as the factory installation Finally a tailpipe extension shall not be more than 10 linear feet containing less than 270 degrees of combined bends Please consult the exhaust system schematics for each vehicle model and option combination for further clarification 2009 MD General Instructions C amp T F
20. e ai 20 Accessory Power Supply Feed E 21 Section E e E 21 Po a See Family 2 Section A See Family 3 Section 2009 MD General Instructions C amp T F Rev 04 09 PAGE aah Nenn Dury Generar Instructions CHevroLeT amp GMC C amp T Series Isuzu F Series BODY BUILDER INFORMATION The Incomplete Vehicle Document IVD is supplied with each incomplete vehicle and provides information that should be used by intermediate and final stage manufacturers in determining conformity to applicable Federal Motor Vehicle Safety Standards FMVSS The IVD also includes information which must be followed in order to ensure that Environmental Protection Agency EPA and California emissions certification requirements and NHTSA Fuel Regulations are met This Body Builders Book contains information that may be used in addition to the IVD for any manufacturer making alterations to an complete incomplete vehicle No alteration should be made to the incomplete vehicle which either directly or indirectly results in any component assembly or system being in nonconformance with any applicable Federal Motor Vehicle Safety Standard or Emission Regulation Intermediate and final stage manufacturers should be familiar with all Federal Motor Vehicle Safety Standards and Emission Regulations and aware of their specific responsibilities as manufacturers For further assistance contact Upfitter Integration at 1 800 875 4742 or go to our Web site at
21. ealed electrical contact areas Terminal torque of the sealed terminal shall be 10 20 Nem for side terminal batteries and 14 20 Nem for top post batteries 8 Mounting Base Tray The tray should be of substantial material minimum 1 75 mm thick or sufficiently reinforced to resist flexing and cracking The tray must provide firm continuous support of the battery and not amplify vibration levels There must be no protrusions or projections in the tray or mountings that would damage the battery Cantilevered mountings are not recommended and the tray should be mounted flat so as not to aggravate electrolyte spillage or lead fatigue A rounded lip of adequate height to ensure stiffness and retention should be provided around the perimeter of the tray With the battery mounted in avehicle a static force of 22 kg applied to a 6 54 sq cm area at any corner should not move the battery any more than 25 mm 9 Freedom Battery The hold down must be able to withstand a 22 G 3 millisecond shock loading and prevent the battery movement relative to the mounting base or hold down Torque at the battery hold down shall be 15 20 Nem 133 177 Ibs in at the base clamp or 2 3 4 5 Nem 20 40 Ibs in at the top bar A bottom hold down centrally located at the sides of the battery is recommended 10 Linehaul Battery A tight secure hold down is essential Hold down brackets must retain the battery at a 22 G 3 millisecond shock loading A top hold down sho
22. ealer Those installing aftermarket systems should provide information as to where and how to obtain service and replacement parts Section O continued on next page 2009 MD General Instructions C amp T F Rev 04 09 PAGE Neu Dury General Instructions GhevroLer amp GMC C amp T Seres Isuzu F Series Section O continued from previous page When installing a Power Take Off PTO with hydraulic lines the following care should be exercised e Route and secure all hydraulic lines so that they are not in close proximity to any parts of the exhaust system Keep all fittings and connections away from the exhaust system Make sure connections and fittings cannot leak on the exhaust system e Exhaust system heat can damage and degrade hydraulic lines and components Oils and hydraulic fluid coming in contact with a hot exhaust system could result in a fire Section 1 Body Body structures interior and accessory arrangements must be designed into the vehicle to provide for proper load distribution on both axles and not to exceed any gross axle weight ratings Lateral load equalization must also be maintained The resultant Center of Gravity of the unladen vehicle must be within the limits tabulated in the FMVSS 105 and FMVSS 121 section of the IVD Body insulation provided by General Motors should not be removed This includes any thermal or underbody heat shields This insulation is provided to protect hoses seals
23. eat to the vehicle and surrounding environment The exhaust cooling device must be reattached to the end of the tailpipe with the outlet positioned appropriately for the body installed by the body builder Finally an extension of the tailpipe shall not result in a total tailpipe length GM pipe length length added by body builder longer than 25 linear feet containing less than 320 degrees of combined bends Please consult the exhaust system schematics for each vehicle model and option combination for further clarification TOPKICK KODIAK C6500 7500 8500 amp ISUZU H Series LF8 7 8L 16 07 Diesel Emission Compliant LF6 7 2L 16 07 Diesel Emission Compliant SOP 08 Chevrolet GMC T6500 7500 8500 amp ISUZU F Series LF8 7 8L 16 07 Diesel Emission Compliant LF6 7 2L 16 07 Diesel Emission Compliant SOP 08 During normal vehicle operation and during the exhaust particulate filter regeneration process gas temperature inside the filter can reach levels approximately as high as 650 degrees C which is considerably higher than previous diesel exhaust systems Air gap tubing and shielding has been installed where possible to minimize the surface temperatures of the exhaust system however these temperatures are considerably higher than previous diesel exhaust systems Materials and components in stalled near the exhaust system and exhaust gas stream should be shielded or designed to withstand these temperatures On some systems an exhaust cooling
24. h the steering column ignition switch Starter should operate only when gearshift lever is in neutral or park position Readjust theshift linkage if necessary as outlined in the Truck Service Manual Power Take Off PTO systems refer to Section O General Instructions e In instances where it is necessary to drain and refill or add fluid to the transmission such as when installing PTO DO NOT substitute any other lubricant Installation of other lubricants may result in internal transmission damage Refer to owner s service manuals for specific information e Models equipped with Eaton manual transmission have synthetic lube installed as the factory fill When the transmission is drained for PTO installation it must be refilled with synthetic lube GM P N 12345724 or Eaton approved 50 weight synthetic gear lube Section 8 Fuel and Exhaust Fuel Systems Due to the critical nature of sealing the fuel system anyone making modifications or alterations to the existing system must assume complete responsibility for the system reliability performance and compliance to Government Regulations The fuel evaporative emission control equipment is certified to be in compliance with the Federal and California Vehicle Emission Standards Any alterations to systems or components and their location could void compliance The system includes e Fuel tank metering unit lines including purge control solenoids and canister or canisters For these reasons
25. iewing system schematics wire routing paths harness connections etc Due to the wide range of modifications that may be required for vocational needs it is not feasible for the O E M to take into account all potential revisions For this reason any person modifying existing vehicle wiring must assume responsibility that the revisions have not degraded the electrical system performance Any add on wiring must be properly fused and routed to prevent cut pinch and chafe problems as well as avoid exposure to excessive heat Care must be exercised that existing vehicle interfaces do not have their current load capabilities exceeded and that the respective control devices are not overloaded Added wire size should be at least as large as the the wire to which it is attaching in order for fuse protection to be maintained A Packard electric wiring repair kit is available through Kent Moore GM P N 12085264 Kent Moore P N J38125 4 This kit contains instructions tools and components for making repairs to wiring harness components This kit would also greatly assist in accomplishing necessary add on wiring such as body marker lamps so that system reliability durability is maintained Electrical wiring components can be obtained through your authorized GM dealer Many Packard Electric components are also available through Pioneer Standard Company 1 800 PACKARD Pioneer may also be able to assist in making necessary wiring additions by providing custom wi
26. ing to ensure safe operation of his 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 this area is ventilated in your individual designs Here again temperature checks of interior areas surrounding the engine should be made to determine if your insulation is adequate This is the same engineering practice we have followed on our complete vehicles incorporating these exhaust systems Exhaust system materials are selected and tested to withstand the operating environment of the vehicle Do not modify the exhaust system in any way The tailpipes are made of 409 stainless steel or aluminized steel Heat shields are mounted to the underbody and or exhaust system components catalytic converter and muffler Shields for the propshaft hanger bearings are also provided in some vehicles 2007 Diesel Emissions Compliant Exhaust Systems Beginning in 2007 vehicles with diesel engines have been equipped with exhaust particulate filters These exhaust systems have been specifically designed in conjunction with the engine hardware and software to meet the emissions certification requirements established by the U S Environmental Protection Agency For this reason modifications to any part of the exhaust system be tween the engine and exhaust particulate filter outlet are not permitted TOPKICK KODIAK C4500 5500 LMM 6 6L
27. ity is enough to cool the interior space of the completed vehicle Section 6 continued on next page PAGE o Neu Dury GeneraL Instructions GhevroLeT amp GMC C amp T Series Isuzu F SERIES Section 6 continued from previous page e Addition or relocation of items in front of or behind the arc of the fan blade travel or changes to fan fore and aft location relative to accessory drive will alter fan stresses and could contribute to fan blade failure Moving the fan and or clutch forward is also likely to overload the water pump bearing e The addition of air conditioning could affect conformance to FMVSS 301 Fuel System Integrity The added equipment in the event of an accident could be displaced into and possibly rupture fuel system lines hoses filters and equipment Care must be taken not to affect such conformance e The curb weight of the vehicle will be affected by the weight of the added system In multiple belt systems belt tension must be measured using either a mechanical gage such as Borroughs or Kent Moore or an electronic gage G S E or Beta Tech Each gage model is calibrated for a specific type and size of belt E G 3 8 in V 4 rib poly V 6 rib poly V 1 2 in V etc Therefore it is necessary to follow the gage manufacturer s usage instructions to get correct readings Refer to the appropriate shop manual for tension settings Original equipment poly V serpentine belt drive system
28. k power steering fluid level for models equipped with Hydroboost or Hydromax brake Refer to Owner s Manual Added floor covering or carpeting must not restrict service or brake pedal travel from released position to full pedal travel No body part or chassis mounted component may be located within 2 0 in of brake hose routing in all wheel and axle positions All exhaust system components must also have a minimum of 2 0 in clearance to brake hoses in closest positions Be sure to account for brake hose travel with suspension All ABS sensor wiring routing must not be altered or secured in locations other than as installed Body builder is to verify that the brake warning switch is operative Air Brake Systems When any air operated equipment is added to the vehicle it is mandatory that a pressure protection valve be installed between such equipment and the main air supply to prevent loss of air to the brakes No body parts or chassis mounted component may be located within 2 0 in of brake hose routing in all wheel and axle positions be sure that brake hose travel is accounted for All ABS sensor wiring routing must not be altered or secured in locations other than as installed Chassis heat shields added by the original manufacturer should not be removed Any air brake lines added or revised that are near the exhaust must be shielded Section 6 Engine For additional information refer to Section 1 Body Air conditioning and auxiliary
29. lbs GVWR come under Federal noise regulations of the Environmental Protection Agency see those regulations for rules test procedure and noise levels permitted Tailpipe outlet location must be tested statically and with the vehicle in motion to ensure that exhaust gases do not penetrate side or rear windows or underbody seams and holes Auxiliary power plants should also be tested under the same conditions Tailpipe extension must extend 2 0 to 2 5 in outboard of body side panels Tailpipe exit anead of rear wheels is not recommended Section 8 continued on next page 2009 MD General Instructions C amp T F Rev 04 09 14 PAGE Neu Dury GeneraL Instructions GhevroLer amp GMC C amp T Series Isuzu F Series Section 8 continued from previous page Check for leaks in exhaust systems and repair as required Exhaust temperatures can exceed 1600 F under extreme operating conditions with pipe surface temperatures slightly less than this Extreme care must be used when placing body components in the proximity of the exhaust system so as not to exceed the rated temperature limits of the components Due to variants in underbody configurations of the vehicles we are not in a position to make recommendations on how to insulate or design components in the proximity of the exhaust system Each manufacturer must make temperature checks of critical areas of his vehicle and adjust his design accordingly or provide shield
30. ny alterations to the system or components could void compliance and render the vehicle illegal System includes e Fuel system Injection pump injector lines and injectors fuel return hoses and pipes air cleaner outside air hose fuel pump fuel filter fuel heater assembly and intake manifold e Exhaust system e Crankcase pressure regulation system e Charge air cooler system e External engine components such as air cleaner crankcase pressure regulator valve alternator injection pipes fuel return hoses from injectors exhaust manifolds oil fill pipe etc must be provided with sufficient clearance for engine roll and torque e When a vehicle is equipped with a direct injection DI engine it has an engine control module ECM This ECM must be maintained at a temperature below 85 C or 185 F at all times This is most essential if the vehicle is put through a paint baking process The ECM will become inoperative if its temperature exceeds 185 F Therefore it is recommended that temporary insulation be placed around the ECM during the time the vehicle is in a paint oven or undergoing another high temperature process 2009 MD General Instructions C amp T F Rev 04 09 11 PAGE Neu Dury GeneraL Instructions upper amp GMC C amp T Series Isuzu F Series Section 7 Transmission Models equipped with automatic transmissions have neutral park start safety mechanical lockout feature which interfaces wit
31. pment installer The addition of a pulley sheave forward of the production sheaves may subject the crankshaft and water pump bearings to loads beyond the desired limits Generally an added load is preferable in the first belt track closest to the engine to minimize the overhang moment effect on bearings Heavy or improperly balanced pulleys may contribute to bearing failure because of load induced by their mass and or unbalance It is extremely important especially on the water pump to have well balanced and concentric pulley sheaves in order to avoid premature bearing failure Pulley unbalance must not exceed 0 25 oz in and lateral and radial runout must not exceed 0 010 in in T I R The fan fan clutch and fan drive ratio fan pulley diameter crankshaft pulley diameter that come with the vehicles are matched to the equipment and conditions encountered in normal operation Substitution of the fan and or fan clutch and fan drive ratio will affect cooling performance A substitute fan will be subjected to excessive stresses and might break Substitution is therefore not allowed The incorporation of an aftermarket air conditioning system could have the following consequences Vehicle engine coolant overheating in certain geographical areas that normally experience high ambient temperatures Restrictions to engine cooling fan airflow resulting in higher fan blade stress Inadequate air conditioning performance unless system capac
32. ractures output shaft bushings bearings brakes brake lines fuel systems and any other related component failures and that the Anti lock Brake System ABS Module may require reprogramming Additionally the customer must be alerted in the modifier s owner s manual that parts for the reworked area are not available through the General Motors service parts system NOTE After any alterations make sure to check for leaks Shear Plate Attachments Attachments of shear plates should be accomplished by using existing manufacturing holes already available in the frame side rails Manufacturing holes normally 19 mm in diameter are placed along the frame side member in the center of the web on each frame When additional holes are required for shear plate attachment they should be no larger than 20 mm 0 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 and no closer than 89 mm 3 5 in from any suspension attachments For frame holes drilled rearward of the rear axle hole centers are to be no closer than 51 mm 2 0 in from the top or bottom flange and no closer than 89 mm 3 5 in from suspension attachments No additional holes or notching of either top or bottom frame flanges are allowed In addition the frame integrity should be maintained 2009 MD General Instructions C amp T
33. ring stubs or jumpers to your specifications Fusible Link Repair Procedure 1 Cut damaged fusible link from wiring harness assembly splice 2 Strip insulation from harness wire as required to splice on new 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 the wording to identify it as fusible link Fusible link cable is not the same as normal vehicle wiring 4 Terminate fusible link harness wire with a suitable compression splice clip and solder with an electrical grade rosin core solder Wrap splice area with heat shrink tubing to provide electrical insulation as well as mechanical strain relief at the splice 5 Strip terminate solder and insulate remaining end of fusible link with appropriate termination to be compatible with the rest of the electrical system Section 12 continued on next page 2009 MD General Instructions C amp T F Rev 04 09 21 PAGE Neu Dury General Instructions upper amp GMC C amp T Series Isuzu F SERIES Section 12 continued from previous page 6 For further information refer to the instruction manual in the wiring repair kit referenced elsewhere in this section NOTE A ground stud has also been provided above the junction block Accessory Power Supply Feed Power for two way radios should be obtained directly from
34. s wiring conduits and any other related components must not be placed where they cross the path of motion of the rear axle driveshaft axle brake pipes hoses spring or tires Such crossing could result in rupture wear through or separation due to normal axle motion NOTE Any alteration to wheelbase or tire rolling radius may require re programming of the ABS module See chassis data information for additional clearances and for assistance in calculating trim heights Section 5 Brakes See Truck Service Manual for brake specifications Due to the critical nature of brake systems anyone making modifications or alterations must assume complete responsibility for system reliability performance and certification to FMVSS 105 or FMVSS 121 Section 5 continued on next page 2009 MD General Instructions C amp T F Rev 04 09 PAGE Neu Dury General Instructions GhevroLer GMC C amp T Seres Isuzu F SERIES Section 5 continued from previous page It is mandatory that no change be made to the brake main cylinder location brake pedal push rod length or pedal position Ensure that hydraulic brake system is free of air and hydraulic leaks Bleed brakes if required following procedures as outlined in the Truck Chassis Service Manual Ensure that the vacuum booster system or Hydroboost Hydromax system is functional and free of leaks Check master cylinder fluid level and fill as necessary Refer to Owner s Manual Chec
35. s that use a spring loaded automatic tensioner do not require belt tension adjustment If the belt is replaced use only the belt specified by GM for the replacement Even though an aftermarket belt is the same length and it has the same number of poly V ribs the belt cord material and construction may be different and this can result in improper belt performance Due to the critical nature of the accelerator system anyone making modifications or alterations assumes complete responsibility for system reliability performance and compliance to FMVSS 124 e Caution must be taken so that the accelerator pedal remains properly located Guidelines for accelerator pedal locations are as follows Ensure that the accelerator can freely operate from idle to wide open throttle position and return Make sure that the pedal will not hang up on any nearby items such as carpets floor screws wiring harnesses etc Engine cover should have at least one inch 25 mm clearance to side of accelerator pedal with the carpet mat installed Accelerator to brake pedal relationship has been designed to provide minimum driver movement and should not be altered in any way Gasoline engine air induction exhaust and cooling fan system is certified and in compliance with the Federal Vehicle Noise Requirements Section 6 continued on next page 2009 MD General Instructions C amp T F Rev 04 09 Neu Dury General Instructions meer GMC LA T Series Isuz
36. t only When adding additional A C equipment the final refrigerant charge must be determined by the Body Builder Use R134A refrigerant only Add on units and lines should comply to ARI standards 2009 MD General Instructions C amp T F Rev 04 09
37. u F Series Section 6 continued from previous page Gasoline engine air induction and or ignition system is certified in compliance with the Federal Vehicle Emission Standards Any alterations to the systems or components could void compliance and render the vehicle illegal System includes e Fuel system central port injector CPI and associated tubes hoses and pipes air cleaner outside air hose and spacer heat stove and heat stove pipe fuel pump and inlet manifold fuel vapor canister e Cooling system fan fan clutch drive and driven pulleys e Exhaust system muffler cat convertor piping sizing e Air Induction system air cleaner duct work e Ignition system distributor and initial spark timing setting spark plugs spark plug wires e Crankcase ventilation system e When a vehicle is equipped with an electronic fuel injection EFI engine it has an engine control module PCM This PCM must be maintained at a temperature below 185 F at all times This is most essential if the vehicle is put through a paint baking process The PCM will become inoperative if its temperature exceeds 85 C or 185 F Therefore it is recommended that temporary insulation be placed around the PCM during the time the vehicle is in a paint oven or undergoing another high temperature process Diesel engine induction and injector pump system is certified to be in compliance with the Federal Vehicle Emission Standards and or Noise Standards A
38. uel systems e Non metallic fuel lines cannot be altered e When using non metallic fuel line components all the components must be conductive to maintain ground All engines require a fuel return system which returns excess fuel from the injection pump and injector nozzles back to fuel tanks Care should be taken that these lines are not blocked nor their hoses pinched The engine may run poorly or stall if these lines are restricted or blocked All gasoline engine vehicles are equipped with fuel evaporative emission control equipment which is certified to be in compliance with the Federal or applicable California vehicle emission standards Alterations to fuel tank and metering unit lines canister or canisters canister filters canister purge control valves relay switches tank auxiliary vent valve engine speed controller or other devices systems are therefore not allowable since vehicle adherence to C A R B and Federal regulations may be affected Diesel powered vehicles may incorporate water drain provisions in the fuel system These valves are only to be opened when eliminating water and contaminants from the fuel system Fuel Tank The tank must have a minimum clearance of 2 inches from top front rear and sides to body and other supports Section 8 continued on next page 2009 MD General Instructions C amp T F Rev 04 09 13 PAGE Neu Dury GeneraL Instructions GhevroLeT GMC C amp T Series Isuzu F SER
39. uld be spaced a minimum of 15 mm from terminal posts to avoid possible ground paths If a top hold down is used a non corrosive non conductive coating is desirable Location The battery should be located in a well ventilated area where a temperature build up does not occur The location should also provide protection to the battery to prevent damage from foreign objects The ends of the battery in the area of the vent ports should be free of obstructions so that the gasses generated during charging can be freely dissipated into the atmosphere Section 12 continued on next page 2009 MD General Instructions C amp T F Rev 04 09 19 PAGE Neu Dury General Instructions GhevroLer amp GMC C amp T Series Isuzu F Series Section 12 continued from previous page 11 Vibration Freedom Batteries The mounting should not subject the battery to vibration levels in excess of a PSD of more than 0 8 G RMS for the frequency range 8 to 200 Hz in any axis when exposed to the Manufacturer s Driving Schedule The mounted battery assembly shall not have resonant frequency lower that 50 Hz Vibration Linehaul Battery s should not be subjected to peak vibration levels in excess of 3 Gs in any axis when exposed to the manufacturer s driving schedule Vibration frequencies of 20 to 40 Hz will cause resonance of battery parts and should be avoided particularly at levels above 1 G acceleration in horizontal directions
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