S/T TRUCK - GM UPFITTER
Contents
1. 122 0 WHEELBAS m 903 0 35 55 512 6 20 18 CENTERL I NG GIN I NTERL IN 481 0 OF VEHICI 18 94 663 20 94 2122 P FRONT AXLE 2 REAR AXLE 2907 6 me 368 3 114 47 14 50 2217 38 me O 3 26 50 gt 10 42 500 500 OUTSIDE OF METAL T NORMAL TOP OF o ERE 9 00 i 163 2 SO we 6 43 2 14 06 34 PICKUP BOX MOUNTING HOLE LOCATIONS MARKED THUS 8 PLACES DIMENSIONS OF MOUNTING HOLES AND FRAME OU ARE SYMMETRICALLY OPPOSITE ABOUT CEN I OF VEHICLE S T Rev 12 98 S T Truck 41 S 10506 Utility 2 Wheel Drive Crossmember Arrangement2. S T 10516 Utility 2 Door 2668 5 652 5 105 06 25 69 O Y i 20 GAL DRAW CAPACITY SA A CENTERLIN O V HICI Lioni T m nV 760 2 o 29 93 545 3 21 47 2553 0 100 51 000 WHEELBAS 3553 f FRONT AXLE Z REAR AXLE 247 0 9 72 OUTSIDE TOP OF 16 88 8 85 11 013 OUTSIDE TOP OF FRAME TO BOTTOM OUTSIDE META OF SHIELD NORMAL TOP OF FRAME 500 mL E LPF LE O Eg IH 204 0 8 03 S T Rev 12 98 S T Truck 55 S 100 03 53 Pickup Gas Engine 2 2L L4 Option LN2 2 8 4 8 835 0 127 9 CATALYTIC 10 96 32 8
3. cai 3122 0 WHEELBAS sam ma 903 0 122 91 35 55 829 0 867 0 32 64 34 13 1609 425 0 515 1 63 36 6 73 i 20 201 a A ui CENTERL I t GIN 11 T gt a CENTERL IN 552 0 481 0 OF VEHICI 21 73 p 18 94 Ey eg pa 1540 0 mo 501 7 60 63 19 75 420 0 16 54 532 0 TD 20 94 2122 GC FRONT AXLE 308 3 EE 14 50 961 113 4 673 0 26 50 4 46 TA 6 C500 Tr 500 TEE OUTSIDE OF D METAL NORMAL Sara OP OF FRAME Li 32507 357 2 163 4 3 14 06 6 43 88 26 PICKUP BOX MOUNT ING HOLE LOCATIONS MARKED THUS 8 PLACES DIMENSIONS OF MOUNT ING HOLES AND FRAME OUTL I RE SYMMETRICALLY OPPOSITE ABOUT CENTERLINE OF VEHICLE S T Rev 12 98 40 S T Truck T 10653 Pickup 4 Wheel Drive Crossmember Arrangement
4. 914 5 36 00 240 5 9 47 CENT 1024 4 NG 40 33 A NI OF V Y 846 0 131 0 wc 33 31 5 16 lt 726 5 28 60 FRONT AXLE Z REAR AXLE 2463 2 um 277 7 96 98 10 93 100 4 v 3 95 OUTSIDE OF METAL 3 82 NORMAL TOP OF FRAME Ne nn 500 be i 7 500 E ELA s F3 fk gt TT 3 500 160 7 6 33 2047 2 337 9 80 60 13 30 i Y INCHES S T Rev 12 98 45 S T Truck S T 100 03 53 Pickup Spare Tire Carrier j NES NEJ Mk GA Se 7 7 NF OUTSIDE OF META P235 5R15 W 7 RIM NORMAL TOP OF FRAME INCHES UNLESS OTHERWISE SPECIF I AL SIDE OF METAL
5. EE S M il TP Sut LE Er A Hr 27 83 E 1 aw N AL AY U CENTERL IN Y OF VEHICI 320 0 6 01 127 5 12 60 5 02 MUFFLER WHEELBAS 3750 10603 FRONT AXLE 10653 946 m AA 1013 1 37 25 49 89 REAR AXLE 257 7 ae 14 08 5 10 129 3 5 09 een 1 LJ 1 n E A 500 3 NS 500 540 0 21 26 64 0 2 52 INCHE MODEL T10603 53 s i W RPO ZR2 HIGH WID Ge De WH 5 USR LET VB s 3L 10603 790 8 31 13 2750 0 108 27 10653 1162 6 45 8 3122 0 122 91 W RPO ZR2 HIGH WIDER S T Rev 12 98 S T Truck 59 S 10506 4 Door Utility Gas 4 3L V6 Option LB4
6. 218 0 107 01 WHEELBAS 2158 0 914 5 84 36 00 La 313 0 12 32 T cor e Bi CENTERLINE ya HD NG GIN 4 36 vi EEE 1024 4 CENTERLIN le 40 33 OF VEHICLE Op U 2 9 12 0 47 892 0 35 12 FRONT AXLE Z REAR AXLE 2547 5 106 4 OUTS ID OF META Gest 242 4 19 NORMAL TOP OF FRAME 8 83 C500 E FT 7 500 166 5 OS 6 56 25 98 S T Rev 12 98 S T Truck T 15506 Utility 4 Wheel Drive Crossmember Arrangement 107 01 WHEELBAS 2158 0 lt 914 5 36 00 Lg Bt 302 0 11 89 Pio d CENT Kaes 110 7 i 4 36 BU
7. 835 2 32 88 2 IT 265 0 10 43 a P ET O A ZZA E ej BD L CENTERLINE lass ye t GIN CENTERL IN OF VEHICLE MUFFLER 2718 0 107 01 WHEELBAS FRONT AXLE P REAR AXLE 945 1 694 9 1077 0 37 25 27 36 42 40 ya 10213 142 5 OUTSIDE OF EE 5 61 META 500 A dr 500 s d 1 DR TT NI 130 9 S215 755 0 29 72 S T Rev 12 98 S T Truck T 10506 4 Door Utility Gas 4 3L V6 Option LB4 CATALYTIC gt 10 0 282 2 NVERTER 265 0 SS EH gt fo gu I SM SAI s 653 4 CENTERL INE 25 72 CENTERL INE m OF VEHICI 2 i MUFFLER 153 0 6 02 lt 2118 4 pr 107 01 WHEELBASE FRONT AXLE Z REAR AXLE 946 1 694 9 1077 0 27525 27 36 42 40 257 4
8. 2995 0 WHEELBAS Jai 1063 0 117 91 41 85 1074 0 1027 42 28 40 43 mg 386 5 m 425 0 m 512 6 6 54 59 16 73 20 18 U za CENTERL I at Vi GIN Al ES BLIN ca 0 552 0 481 0 OF VEHICI 4 111 ela 18 94 CO mE Y 329 0 tl 662 7 52 32 26 09 e 120 0 16 54 532 0 20 94 FRONT AXLE V REAR AXLE 2780 6 e 368 3 109 47 14 50 673 0 2090 9 ca 26 50 82 32 113 2 4 46 SS ag A Fr d i 500 La 6 OUTSIDE OF METAL NORMAL TOP OF 2 ZEE 9 00 163 2 357 2 6 43 3 40 14 06 2014 INCHE 79 31 PICKUP BOX MOUNTING HOLE LOCATIONS MARKED THUS 8 PLACES DIMENSIONS OF MOUNTING HOLES AND FRAME OUTL 1 RE SYMMETRICALLY OPPOSITE ABOUT CENTERL I OF VEHICLE S T Rev 12 98 S T Truck 39 S 10653 Pickup 2 Wheel Drive Crossmember Arrangement
9. 1878 0 73 94 sa 1375 0 54 13 JR une 43 99 gt 15 63 80 40 928 2 i Bet 16 61 i FRONT WHEEI EN e 15 53 i 365 8 14 40 60 40 NEN P 359 0 1077 9 EFFECTIVE LEG ROOM 42 44 1 CLUTCH CTIV i ROO 855 I 33 66 573 0 22 56 God eco 137 9 436 TA ee LERATOR 491 4 19 35 BRAKE 11 02 TRAVEL PASS SIDE ONLY 534 3 CLUTCH 317 8 12 51 BUCKET 21 03 327 8 12 91 60 40 994 0 35 59 60 40 994 2 39 14 BUCKET INCHES S T Rev December 1998 32 S T Truck S T 10003 Pickup Interior Seating H POINTS POINTS H POINTS P q p LE FE ry END l q J J A WA K P4 Y 13 50 1 345 0 13 50 a sl 686 0 27 00 gt 686 0 27 00 27 00 1348 8 m 53 10 UP LEVEL HIP ROOM 60 40 SEATS BUCKET SEAT BENCH SEAT H POINTS X Nn TH gi 404 0 d ji 15 91 500 1 m 130 4 16 94 b m 414 0 16 30 82
10. 32 88 CATALYTIC 210 0 6 27 234 9 218 4 CONV R 9 25 8 60 gt 88 rar g 653 4 25 72 CENTERL I JE p t ENGINE NG ER CENTERL INE 100 9 MUFFLER OF VEHICLE EE 320 0 12 60 53344 100 51 WHEELBASE FRONT AXLE 2 REAR AXLE 946 693 1 913 8 37 25 27 29 35 98 257 4 10 13 OUTSIDE OF 127 0 META 500 500 130 9 5 15 a 584 2 23 00 S T Rev 12 98 S T Truck Electrical diagrams are available from Chevrolet and GMC through service publica tions They have contracted the following companies to handle the ordering and ship ping of the manuals Helm Inc P O Box 07130 Detroit Michigan 48207 1 313 865 5000 for information and inquiries 1 800 782 4356 for credit card orders S T Rev 12 98 63 Routine orders will be shipped within 10 days of receipt Rush orders will be accom modated for an additional charge Order forms are available upon request and orders can be paid by check or money order made payable to the mentioned companies Credit Card orders can be made by phone on the listed toll free phone numbers S T Truck re 8888 S T Rev 12 98
11. REFER TO HITCH DRAWING REFER TO FUEL TANK DRAWING L INCHES S T Rev 12 98 S T Truck PICKUP WEIGHT DISTRIBUTION Regular Cab Extended Cab Pickup Box Short Long gt lt See Note ie A gt lt See Note Body Cargo Weight Distribution i SAL oV Front Rear EE GE CE E 9 S 10003 118 0 1 99 123 0 3 97 108 0 1 99 10003 118 0 1 99 Note Reference Front End Sheet Metal Arrangements S T PICKUP BOX REMOVAL PROGRAM IMPORTANT There is not a 1999 GM approved pickup box removal program for the S 10803 Chevy or GMC pickup S T Rev 12 98 S T Truck S T 10603 Pickup Regular Cab with Short Box General Arrangement 1 199 0 70 8 1 DAYL I GHT OPENING 32 4 3570 6 PET 1 3 140 6 OVERALL 53 4 UG S SN 338 7 13 3 eg B 1 1 Go E OO jra 1688 2
12. JIMENSIONS ARE TO QU S T Rev 12 98 46 S T Truck S T 10506 4Door Utility Spare Tire Carrier SU 15 56 p ua d d AL JE ma AENA xe Ta TANT 1 CY 4 NE ipis Il Il He CENTERLINE OF NYG 7 VEHIC Rl 4 H a Hag ER ef s dft si We at j OUTSIDE OF META NORMAL TOP OF FRAME HOIST SHAFT 500 P205 75R15 W 6 RIM P235 75R15 W77 RIM INCHES UNLESS OTHERWISE SPECIFIED AI IMENSIONS ARE TO OUTSIDE OF METAL S T Rev 12 98 S T Truck S T 105 06 16 Utility Trailer Hitch Mounting MODEI DIM A IM B
13. SLR gt A SECTION ROTATED 90 INCHES Q ALL SEASON TIRE MINIMUM GROUND CLEARANCE TO BE CALCULATED O ON OFF ROAD TIRE BY USING GROSS AXLE WEIGHT AND INFLAT ING IRE PRESSURE TO 35 PS SERIES TIRES SLR GVW RANGE TRACK DIM DIM Bl DIMC DIMD DIM E DIM F DIM G 5 10516 P205 75R15 314 4450 1387 8 6 4 1627 0 1159 8 68 0 180 4 349 5 228 0 206 0 5 10506 P205 75R15 314 4785 1387 8 6 4 1627 0 1159 8 68 0 160 4 349 5 228 0 193 5 T 10516 P205 75R15 314 4850 599 0 150 0 627 0 1171 0 68 0 180 4 349 5 228 0 204 0 P235 75R15 334 4850 399 0 50 0 551 0 1147 0 56 0 205 2 374 5 252 0 224 0 P235 70R15 323 4850 599 0 50 0 651 011147 0 56 0 191 3 360 4 252 0 209 0 51 10 5 361 4850 500 0 50 0 651 011147 0 97 0 214 2 389 8 269 0 209 0 T 10506 P205 75R15 314 5300 599 0 50 0 627 0 11 1 0 68 0 60 4 349 5 228 0 190 0 O P235 75R15 334 5500 599 0 50 0 651 0 147 0 56 0 185 2 374 5 252 0 207 0 O P235 70R15 323 5300 399 0 50 0 651 011147 0 56 0 171 3 36
14. i 33 0 Uer 1890 0 SWB 74 40 11 0 2250 0 LWB 44 0 43 88 58 1 73 u 1 97 SECTION ATA S T Rev 12 98 22 S T Truck S T 100 03 53 Pickup Box Interior 12 0 1 85 27 0 1 06 25 0 e 98 F B 07 0 D Le A 12 09 C 51 0 REAR AXL 12 48 57 5 w st 54 5 t 2 25 2 15 TIE DOWN LOOP ba SECTION a NG i 4 195 95 p FRONT N 4 84 x 1 793 i TOP OF C Li 240 0 FLOOR RIBS 7 10 94 9 45 38 0 55 0 L H PANEL ONLY FUEL FILLER NECK A B E D SECTION I 641 5 1364 5 107 5 505 5 60 5 ST10603 53 25 25 53 72 4 23 19 90 2 38 T 8 798 0 1684 0 264 0 669 0 148 5 6 30 H pi NO A 31 423 66 30 10 399 C26 243 45 77 NOTE R H SYMETRICAL ABOUT 4 lt EW IN CIRCLE 20 0 TYP 4 PLACES 79 S T Rev 12 98 S T Truck S T 100 03 53 Pickup Box Sportside S T Rev 12 98 1295 2 50 99 FLOOR FRONT 1002 4 39 46 FLOOR W HOUSE 12 27 TOP FLOOR 1785 5 FLANGE DE DD
15. 1024 4 C NT Da 4 33 OF VE le p Li Gif PL 2 I p 313 0 MERE ES 892 0 2 er P FRONT AXLE 2 REAR AXLE 2547 5 100 30 IE 106 4 164 0 gt 8 83 4 19 OUTSIDE OF META 45 83 NORMAL TOP OF FRAME 500 500 659 8 25 98 a INCHES S T Rev 12 98 S T Truck 43 S 10516 Utility 2 Wheel Drive Crossmember Arrangement 2553 0 100 51 WHEELBAS 2164 5 85 22 s 96 5 E 240 5 51 12 9 47 CENT N f NT OF V 726 5 28 60 FRONT AXLE Z REAR AXLE 2463 2 lt 277 7 96 98 10 93 204 2 OUTSIDE OF META 8 04 p 97 0 100 4 NORMAL TOP OF FRANE 3 82 3 95 K Sad DW 500 500D 6047 6 33 2047 2 337 9 80 60 13 30 INCHES S T Rev 12 98 S T Truck T 10516 Utility 4 Wheel Drive Crossmember Arrangement
16. W 1728 4 OVERAL 68 04 400 0 15 75 a TOP DLO 2381 6 u 7 95 76 1966 8 77 43 1955 2 w 776 97 72 57 796 6 D I 5 494 0 31 36 22 14 510 7 141 7 20 10 5 57 TN d 246 f j E R 9 69 PEL i TOP OF FLOOR RIBS EN 500 597 8 DATUM 8 50 11 19 1818 0 71 57 a SI ga Ae E SOWA TT 72 72 DIM SHOWN IN MM INCHES INNER PANEL 110 5 4 35 PLATFORM SECTION A A FUEL FILLERNECK 24 S T Truck S T 100 03 53 Pickup Box Sportside Top Rail 24 2 1124 6 98 7 0 95 1204 4 44 27 3 88 TOP 47 41 TOP REAR TOP FLANGE TOP FLANGE FRONT 4 W HOUSE 32 6 1 28 74 59 11 4 44 0 43 1 43 1 97 SECT LON A A S T Rev 12 98 S T Truck S T 100 03 53 Pickup Box Sportside Interior 60 5 1364 3 2 58 04 71 me 473 4 6529 18 63 25 7
17. OF VEHICI 2 o 501 7 19 75 20 0 e 16 54 532 0 GOGH 20 94 Gub FRONT AXLE E 368 3 14 50 673 0 sone at 1844 51 28 50 72 62 r 4 48 u A 4 C500 E 1 i 500 E OF METAL gt SE NE 228 2 FOP 8 98 164 0 6 46 ei 1887 5 INCHES 73 52 PICKUP BOX MOUNTING HOLE LOCATIONS MARKED THUS 8 PLACES DIMENSIONS OF MOUNTING HOLES AND FRAME OUTL I RE SYMMETRICALLY OPPOSITE ABOUT CENTERL 1 OF VEHICLE S T Rev December 1998 36 S T Truck T 10603 Pickup 4 Wheel Drive Crossmember Arrangement 2750 0 WHEELBAS z 903 0 108 27 35 55 829 0 867 0 32 64 34 13 425 0 1 6 73 m a 512 6 CENTERL I 20 18 NG GIN i CENTERL IN I 481 5 OF VEHICI 18 96
18. 10 13 130 9 142 5 OUTSIDE OF 5415 5 61 META e Nat SS Me 1 N i 755 0 29 73 S T Rev 12 98 S T Truck S 10516 2 Door Utility Gas Engine 4 3L V6 Option LB4 835 1 MUFFLER 33 88 _ 210 0 4 218 3 CATALYTIC 8 37 145 O 0 e 653 4 CENTERLINE 5 25 72 NG GIN G CENTERL IN 100 9 OF VEHICI 3 97 2553 0 100 51 WH AS FRONT AXLE Z REAR AXLE 946 I 693 1 amp 4 913 8 37 25 27 29 35 95 257 4 10 13 127 0 OUTSIDE OF 5 00 META e EA ER RS LJ 50 DEN Re st 130 9 5 15 594 2 23 00 S T Rev 12 98 S T Truck T 10516 2 Door Utility Gas Engine 4 3L V6 Option LB4
19. I ISUZU 34 8 ares BRAVADA S T Rev 12 98 S T Truck 19 S T 10003 Pickup Cab Profile 1800 19 184 20 22 r 23 25 27 29 251 17 a 24 26 28 30 16 15 1700 1600 11 1500 1400 1300 TOP OF PICKUP BOX N 1220 00 1200 ER LINE OF VEHICLE 900 300 700 600 500 400 300 200 100 1100 DNIE ABOUT CEN DRIVER SIDE COORDINATES PT WIDTH HEIGHT PT WIDTH HEIGHT PT s WIDTH HEIGHT 1 856 18 1100 00 1 656 52 600 00 22 450 00 1690 00 2 lt 8 25 19 150 00 2 645 93 1616 44 23 400 00 1693 64 3 801 59 1200 00 3 638 72 627 05 24 350 00 1696 69 4 795 63 1250 00 4 627 87 641 88 25 300 00 1699 24 2 81 95 1300 00 5 620 45 1650 00 26 250 00 1701 37 6 767 02 1550 00 6 611 99 657 56 27 200 0011703 11 50 25 1400 00 600 00 1665 28 28 150 00 1704 44 3 731 26 1450 00 3 589 46 1670 01 29 100 00 1705 38 9 709 81 500 00 9 9b4 3 7 675 96 50 20 00 1705 92 10 582 1 1550 00 20 990 00 1670 03 51 00 0011706 05 21 900 00 1685 53 S T Rev December 1998 S T 100 03 53 Pickup Box
20. S T Truck 1440 0 64 0 56 70 2 52 TOF TOP FRONT FRONT FLANGE 1418 0 55 83 TOP W HOUSE 1025 0 40 35 FLOOR W HOUSE 5 2540 2 09 11 81 TOP TOP FLANGE FLOOR REAR INNER PANEL 108 00 4 25 89 00 3 50 FUEL FILLERNECK PLATFORM SECTION A A 1396 0 54 96 TOP REAR 5 0 20 1386 0 54 57 ENDGATE 1725 0 67 91 OVERALL 400 0 15 75 TOP DLO t OF VEH F G A B A 761 5 U 427 0 94 0 30 00 16 81 19 45 485 5 138 0 BEAR 19 11 7 5 43 Y AA y 61 0 2 40 BOTTOM DLO OF VEH J 92 gt 40 0 TOP OF 1 57 FLOOR RIBS TOP FLANGE En DATUM 30 0 LINE 1 18 D sel 323 0 12 72 H es E VIEW IN CIR A i J m CIRCLE DIM SHOWN IN MM INCHES A B C D E F E H J ST10603 53 1941 1838 581 196 920 2379 1965 1820 1850 76 42 72 36 22 87 7 72 36 22 93 66 77 36 71 65 72 83 0 2346 2243 741 441 1165 2784 2370 2225 2255 92 36 88 31 29 17 17 36 45 87 109 60 93 31 87 60 88 78 S T Rev 12 98 S T Truck 01 1440 0 56 70 N 427 0 16 81
21. m 2 2 66 5 Wr 1785 3 OVERALL 70 3 s 2012 1 480 5 79 2 18 9 1210 6 or ES 423 0 Pea 399 8 16 7 e 1642 7 15 7 L OUTSIDE TOP OF RAIL 64 7 a 2729 0 107 4 840 5 33 1 3949 3 155 5 4208 6 165 7 S T Rev 12 98 S T Truck S T 10603 Pickup Regular Cab with Short Box Hi Wider General Arrangement 1799 0 70 8 E ff y he a 7 dr 1 3 3570 6 OVERALL 1356 3 4 H 140 6 53 4 338 7 lt a 678 4 26 7 iasa Mez J zi UN 1 UI e A 120 1 U bo 44 1 U na DI ya 500 i 1688 2 M CO ST 66 5 2 2 U OVERALL GI 1785 3 N 70 3 V 2012 1 79 2 1000 CHMSL 1765 4 480 5 81 9 ma 70 3 18 9 3 2 OVERALL HI WIDER 1 a bu i 1214 1 R
22. 1 SL tm 502 0 19 76 420 0 16 54 532 0 8 20 94 5755 FRONT AXLE V REAR AXLE 2535 6 368 3 14 50 873 0 T 26 50 6 94 113 2 4 46 zx I 600 R jag i i 500 147 7 i u OUTSIDE OF META 5 81 NORMAL TOP OF FRAME 86 4 het 357 2 63 2 a 1769 6 93 40 14 06 6 43 69 67 INCHE PICKUP BOX MOUNTING HOLE LOCATIONS MARKED THUS 8 PLACES DIMENSIONS OF MOUNT ING HOLES AND FRAME OUTL RE SYMMETRICALLY OPPOSITE ABOUT CENTERLINE OF VEHICLE S T Rev 12 98 S T Truck 37 S 10803 Pickup 2 Wheel Drive Crossmember Arrangement 2995 0 WHEELBAS D 1063 0 117 1 j 4 41 85 1074 0 1027 0 42 28 40 43 8425 0 4 513 1 6 73 20 20 P 1 CENTERL I NG GI
23. 280 0 403 0 15 0 15 9 3611 3 142 2 NORMAL OUTSIDE TOP OF RAIL S T Rev 12 98 30 S T Truck S T 10 6 8 03 Pickup Regular Cab Interior Z 1375 0 54 13 P 1092 0 42 99 PREZ 928 2 gt ANGLE 36 54 C FRONT WH n 394 5 15 53 a 418 0 18 45 BENCH 417 6 16 44 BUCK ni 1077 9 25 445 EFFECTIV G ROOM CLUTCH CTIVE ROOM 855 OINT 33 66 1 0 4 09 573 0 22 56 295 0 11 61 50G Go 137 9 3 2 SILL 5 43 MAX CLUTCH 436 3 RAVEL 17 18 ACCELERATO 491 4 19 35 BRAKE ONLY 234 3 CLUTCH 21 03 994 0 35 59 BENCH 994 2 39 14 BUCKET 999 4 39 35 60 40 TED S T Rev 12 98 S T Truck 31 S T 10653 Pickup Extended Cab Interior
24. CLUTCH 79 REARWARD TRAVEL 16 54 ACCELERATOR eae 7 09 FORWARD TRAVEL 492 8 gt 19 40 BRAKE 534 4 21 04 CLUTCH 995 0 A 39 17 SEATS OF FRT AXLE 1453 7 57 22 SHOULDER Rap i oe _ 1302 1 1322 52 05 HIP 51 26 H P ev D i FRONT VIEW REAR VIEW OF FRONT SEAT H M MS A OF REAR SEAT H POINT Lu P H POINT AT 1 Es 343 0 343 0 13 50 13 50 686 0 97 00 686 0 BOT bigi S T Rev 12 98 S T Truck 35 S 10603 Pickup 2 Wheel Drive Crossmember Arrangement 2750 0 WHEELBAS 903 0 108 27 A A 35 55 829 0 567 0 32 64 34 13 6425 0 pa m 512 7 6 73 20 19 IL 4 CENTERL I GIN M RLIN we
25. EA ES TOP OF RAIL L rte 4 TN 7 a 500 l 423 0 el 414 5 16 15 16 32 d lu 1642 7 tl 840 7 64 67 33 10 2988 5 117 66 Lu 1354 2 171 43 1613 181 64 S T Rev December 1998 1000 S T Truck S T 10653 Pickup Extended Cab with Short Box General Arrangement DAYL I GHT 1000 OPENING 1356 3 53 4 e 2171 Q 85 5 32 4 678 1 Sei 26 7 3570 6 OVERALL 140 6 m Y U I 44 1 E 500 L T Y 1 1688 2 54 5 3 A d po 66 5 2 1 U MAX OVERALL NN 1483 0 OPT E24 1785 3 N S 58 4 70 3 _ d 480 5 ND 79 2 RMS 82 0 SK x 1 1424 2 NN 1206 4 1213 7 ROOF 56 1 a 47 5 47 8 423 0 _ a i 417 8 T 16 7 84 7 16 4 33 1 NORMAL 3119 0 OUTSIDE TOP OF 122 8 RAIL La 321 3 170 1
26. released attachment points used by the pick up box along with fasteners of the same diameter These are minimum requirements additional fasteners are permissible 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 and camber should be set with reference to the dimensions See Truck Service Manual for complete alignment procedure specifications and measurement of the 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 3 Axle at design position Allowance for the tire chain clearance shown on maxi mum 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 Pip
27. s AV 10516 212 5 18 371 367 2 14 46 i 10506 47 5 11 871 202 2 7 96 La 161 5 6 36 Se 45 0 A E E 20 MA NZ i gt lt e e N Al 5 16 40 5 Ad 5 53 0 03 7 13 00 2S HOLE Lag e I A ele TRAILER HITCH amp BUMPER BRACKET a A ER HITCH BRACKE 5545 A P N tt 1 39 a a Y 1 i d e Al gt TE L CAD 2 92 S T Rev 12 98 48 S T Truck TRACK gt ES MAX TIRE WIDTH SN T w 8 _ MINIMUM GROUND CLEARANCE TO BE CALCULATED ALL SEASON T RE GROUND CLEARANCE BY USING GROSS AXLE WEIGHT AND INFLATING SERIES TIRES SLR GVW RANGE TRACK NA e ee P205 75R15 317 0 4200 383 6 0 233 5 224 S 10603 383 6 0 0 233 5 224 P205 75R15 317 0 4600 396 4 6 4 233 5 224 P215 65R15 306 0 4600 396 4 6 4 222 5 232 383 6 0 0 233 5 224 S 10803 205 75R15 317 0 4200 4900 396 4 6 4 233 5 224 P215 65R15 306 0 4600 396 4 6 4 222 5 232 383 6 0 0 233
28. 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 compo nents and 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 OCCU pant area If it is necessary to change the exhaust outlet location the exhaust dis charge 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 Ibs GVWR come under Federal noise regulation of the Environmental Protection Agency ve hicles lt 10 000 Ibs GVWR are regulated by various state and local regulations of the see those regulations for rules test procedure an
29. 0 97 9 317 0 REAR AXLE 3 85 12 48 25 0 Less 2 08 2 25 m i 1 D FRONT NN i 1 TOP OF 292 1 C FLOOR RIBS 246 2 I L H PANEL ONLY L H INNER PANEL PICKUP BOX FUEL FILLER NECK NOTE R H SYMETRICAL ABOUT 160 0 6 30 VIEW IN CIRCLE TYP 4 PLACES S T Rev 12 98 1 78 JI Gand E _ 55 7 1905 2 19 SECTION B B Ke 45 6 12 1 79 27 0 1 06 25 3 MN 99 308 0 12 12 i a TIE DOWN LOOP SECTION C C S T Truck S 7 10506 4 Door Utility Exterior with End Gate General Arrangement s CZL FRT AXLE 3 DAYLIGHT OPENING NS 48 80 AE JI m Iz W 23 40 a D J d 140 57 a r 30 21 1 OVERALL K q Y CAL YEN fi Z m 1 131 LA SN e GC GES E 500 M i 2 15 OUTSIDE RAIL Bm 80 41 ERAD u 46 59 1 1 mn 61 08 55 1 5 403 0
30. 0 4 252 0 199 0 S T Rev 12 98 52 S T Truck st AA m 1041 0 40 98 226 8 90 nl UT O s GAL ALL 69 6 DRAW 2 74 CAPACITY 1 e f s RLIN i OF VEHICI cd Hp 4 E 132 9 5 23 788 I 724 5 31 03 28 52 407 1 16 03 OUTSIDE TOP OF FRAME TO BOTTOM FRONT AXLE Z REAR AXLE OF SHIELD 14 91 371 4 17 8 OUTSIDE TOP OF 14 62 4 21 FRAME TO BOTTOM OF TANK OUTSIDE META NORMAL TOP OF FRAME 1 500 T a 500 R 7 NORMAL TOP OF FRAME 264 4 10 41 ODEI JIM AA WB INCHES ST 10603 1583 5 2750 ST 10803 1828 5 2995 UNLESS OTHERWISE SPECIF IED AI ST 10653 1955 5 3122 TMENSIONS ARE TO OUTSIDE OF METAL S T Rev 12 98 S T Truck X S
31. 0 5 330 5 232 0 172 0 5 10653 P205 75R15 319 0 4600 387 8 6 4 1605 8 1169 8 72 4 54 5 344 5 224 0 184 0 P205 75R15 515 0 4900 387 8 6 4 1605 8 1169 8 72 4 54 5 344 5 224 0 180 0 T 10603 P205 75R15 319 0 4650 399 0 50 0 1617 0 1181 0 78 0 54 5 344 5 224 0 191 0 O P205 75R15 321 0 4650 399 0 50 0 1607 0 1191 0 83 0 54 5 344 5 224 0 186 0 P235 75R15 337 0 5150 399 0 50 0 1639 0 1159 0 67 0 78 5 368 5 247 0 202 0 31 X 10 5 361 0 4650 500 0 50 0 1769 0 1231 0 103 0 199 8 389 8 269 0 230 0 10803 P205 75R15 319 0 4650 399 0 50 0 1617 0 1181 0 78 0 54 5 344 5 224 0 191 0 O P205 75R15 321 0 4650 399 0 50 0 1607 0 1191 0 83 0 54 5 344 5 224 0 186 0 P235 75R15 337 0 5150 309 0 50 0 1639 0 1159 0 67 0 78 5 368 5 247 0 202 0 10653 P205 75R15 319 0 4650 399 0 50 0 1617 0 1181 0 78 0 54 5 344 5 224 0 191 0 P205 75R15 321 0 4650 399 0 50 0 1607 0 1191 0 83 0 54 5 344 5 224 0 186 0 P235 75R15 337 0 5150 399 0 50 0 1639 0 1159 0 67 0 78 5 368 5 247 0 202 0 31 X 10 5 261 0 4650 500 0 50 0 1769 0 1231 0 67 0 78 5 368 5 269 0 230 0 S T Rev 12 98 S T Truck S T 105 06 16 Utility Rear Axle Tire Data Chart 6 1025 0 40 35 OUTSIDE FRAME
32. 1453 6 50 232 7 252 S T Rev 12 98 50 S T Truck S T 10003 Pickup Rear Axle Tire Data Chart C 1025 0 NT tae i JI EN vw A SECTION A A ROTATED 90 INCHES A ALL SEASON TIRE I MINIMUM GROUND CLEARANCE TO BE CALCULATED O ON OFF ROAD TIRE BY USING GROSS AXLE WEIGHT AND INFLATING TIRE PRESSURE TO 35 PSI SERIES TIRES SLR GVW RANGE TRACK a DIM A DIM 8 DIM c DIM D DIM E DIM F DIM G S 10603 P205 75R15 319 0 4200 387 8 6 4 1605 8 1169 8 72 4 54 5 344 5 224 0 184 0 P205 75R15 319 0 4600 387 8 6 4 1605 8 1169 8 72 4 54 5 344 5 224 0 184 0 P215 65R15 307 0 4600 387 8 6 4 16153 8 1161 8 68 4 40 5 330 5 232 0 172 0 5 10803 P205 75R15 319 0 4200 387 8 6 4 1605 8 1169 8 72 4 54 5 344 5 224 0 184 0 P215 65R15 307 0 4600 387 8 6 4 1613 8 1161 8 68 4 40 5 330 5 232 0 172 0 P205 75R15 315 0 4900 387 8 6 4 1605 8 1169 8 72 4 54 5 344 5 224 0 180 0 P215 65R15 307 0 4900 287 8 6 4 1613 8 1161 8 68 4 4
33. 5 224 S 10653 205 75R15 317 0 4600 4900 396 4 6 4 233 5 224 P215 65R15 306 0 4900 396 4 6 4 222 5 232 P205 75R15 316 0 4450 396 4 6 4 215 0 224 S 10516 P205 75R15 316 0 4785 396 4 6 4 215 0 SCH S 10506 S T Rev 12 98 S T Truck T 10000 Front Axle Tire Data Chart MAX TIRE WIDTH SLR REF JH Y ALL SEASON TIRE GROUND CLEARANCE BY USING GROSS AXLE HE GHT AND RECOMMENDED t ON OFF ROAD TIRE TIRE PRESSURE SERIES TIRES SLR GVW RANGE TRACK nue dii urla ws P205 75R15 317 0 4650 1453 6 50 2173 224 1P205 75R15 317 0 4650 1453 6 50 2173 224 P235 75R15 337 0 5150 1453 6 50 269 8 247 31 X 10 5 357 0 4650 1553 6 50 289 7 269 Q P205 75R15 317 0 4650 1453 6 50 2173 224 O P205 75R15 317 0 4650 1453 6 50 217 3 224 P235 75R15 337 0 5150 1453 6 50 269 8 247 men P205 75R15 317 0 4650 1453 6 50 217 3 224 O P205 75R15 317 0 4650 1453 6 50 217 3 224 P235 75R15 337 0 5150 1453 6 50 269 8 247 31 X 10 5 357 0 4900 1553 6 50 289 7 269 EA P205 75R15 316 0 4850 1453 6 50 209 6 228 P235 70R15 326 0 4850 1453 6 50 220 3 252 31 X 10 5 357 0 4850 1553 6 50 240 2 269 O P235 75R15 337 0 4850 1453 6 50 231 2 252 P205 75R15 316 0 5300 1453 6 50 211 2 228 P235 70R15 326 0 5300 1453 6 50 221 3 252 O P235 75R15 337 0 5300
34. 7 9 72 L A 4 7 SEA D SET 669 0 e 26 34 225 3 37 f RLIN OF VEHICI 88 107 0 lt 295 4 4 24 11 63 MUFFLER gt WHEELBAS FRONT AXLE Z REAR AXLE 557 9 AA ma 1047 2 21 97 41 23 12 45 OUTSIDE OF META 500 500 482 6 INCHE 9 00 MODE DIM AA WHEELBAS jy gt aur he Sans 45 071 12780 0 108 27 i SIOBOS 1369 9 54 72 2995 0 117 91 5106523 1516 9 59 72 3122 0 122 91 S T Rev 12 98 S T Truck S 100 03 53 Pickup Gas Engine 4 3L V6 Option LB4 ZR2 m 835 0 32 87 245 2 9 65 A km V 1 El Ta OH i 669 0 A 26 34 4 i Y RLIN 225 8 104 1 OF VEHICI 8 89 4 10 MUFFLER 23 0 17 01 WHEELBAS f FRONT AXLE 2 REAR AXLE 599 0 AA if BB 35 39 315 9 12 44 OUTSI
35. 8 0 32 60 REAR VIEW SHOWING BACK JUMP SEATS FOR EXTENDED CAB SIDE NOT INCLUDED WITH E24 S T Rev 12 98 S T Truck S T 10516 2 Door Utility Interior Seating 855 4 776 5 33 68 523 1 30 57 20 60 0 0 5 08 MAX CLUTCH 15 35 19 19 ACCELERATOR 18 403 BRAKE 21 04 CLUTCH 995 0 39 17 as PA FRONT VIEW Art H OF FRONT SEAT A H POINTS FE E 1 FRONT VIEW OF FRONT SEAT S T Rev December 1998 295 0 334 0 11 613 13 15 REARWARD TRAVEL FORWARD TRAVEL 1452 9 57 20 SHOULDER REAR VIEW OF REAR SEAT POINTS 258 0 10 16 516 0 20 31 1009 8 39 786 HP REAR VIEW OF REAR SEAT S T Truck 34 S T 10506 4 Door Utility Interior Seating 88 07 4 1792 9 70 59 1560 0 81 42 667 6 mia 26 28 ka ne K ww NES 1 9 855 4 z 4 35 06 33 68 1 776 5 r 1630 57 853 8 33 61 295 0 334 0 151 6 Fann 11 61 13 15 5 97 MAX
36. DE OF META 104 7 4 12 4 CE 500 500 vel NG f e A gt 584 2 INCH MODE DIM AA IM BB WHEELBAS a s 5106031 805 0 31 69 1046 0 41 18 2750 0 108 27 510803 1052 35 141 43111043 65 41 0912995 0 117 91 5106531 1170 35 46 43 1043 65 41 091 3122 0 122 91 S T Rev 12 98 S T Truck T 100 03 53 Pickup Gas Engine 4 3L V6 Option LB4 ZR2 210 7 CATALYT I id 282 2 30 9 8 80 J T 28 77 gt SET 20 27 m RLIN OF VEHIC WHEELBAS P FRONT AXLE REAR AXLE 946 AA 108578 37 054 40 771 318 9 112 58 OUTSIDE OF META 505 we 500 i 128 6 i5 EN SM INCHES MODEI DIM AA WHEELBAS A CN T10803 768 4 30 28 2780 0 108 27 T10803 1013 4 136 901 2995 0 1117 91 T10653 1140 4 44 901 3122 0 122 91 S T Rev 12 98 S T Truck T 106 03 53 Hi Wider Pickup Gas Engine 4 3L V6 Option LB4 amp ZR2
37. N N CENTERL IN 552 0 481 0 OF VEHICI 21 73 5 Li 18 94 _ 662 5 26 08 pal 420 0 e 16 54 532 0 20 94 FRONT AXLE 2 REAR AXLE 2780 6 368 3 109 47 14 50 673 0 gt 2089 4 3 A 26 50 82 26 s ZG 50 S ZO zm 264 6 113 4 a 4 46 34 6 10 42 0 97 pa 1 1 e 7 mE T y 500 P E 500 E ASS FI S i gt OUTSIDE OF METAL S NORMAL TOP OF ii FRAME D 163 4 2017 Log Bel 3057 2 6 43 14 06 83 17 PICKUP BOX MOUNTING HOLE LOCATIONS MARKED THUS 8 PLACES DIMENSIONS OF MOUNT ING HOLES AND FRAME OUTL I ARE SYMMETRICALLY OPPOSITE ABOUT CENTERL I OF VEHICLE S T Rev December 1998 38 S T Truck T 10803 Pickup 4 Wheel Drive Crossmember Arrangement
38. O O 15 87 E a gt 500 I j Y Y 642 7 m L PA em DI ea NORMAL OUTSIDE NOCE GE EROS TOP OF RAIL H 3 00 07 01 776 3 148 67 S T Rev 12 98 S T Truck S T 10506 4 Door Utility Exterior with Lift Gate General Arrangement 4163 2 E he m 3720 5 based A a i z 1656 1 Sy 65 2 W I 1619 3 GAT 153 8 1553 1 I GLASS Za 61 1 3 1 500 S T Rev 12 98 S T Truck S T 10516 2 Door Utility Exterior General Arrangement OPTION PIG SPARE TIRE CARRIER DAYLIGHT OPENING 1785 3 70 29 1721 7 87 78 MAX OVERALL 2012 1 79 22 3523 4 138 72 S l I 403 0 15 87 1544 I 80 79 1426 4 KA 56 16 gt O wa 64 68 E 2553 0 33 51 100 51 3611 3 142 18 3909 3 153 91 S T Rev 12 98 S T Truck S T 10516 Utility 2 Door Exterior Hi Wider General Arrangement DAYLIGHT OPENING 1815 7 71 5 x MAX OVERALL LE LX NN VW 150 2 3523 4 138 7 ZD 33 3 gt MER SN ES gt
39. OOF 1426 4 a 47 7 47 8 Y B 56 2 PI IM a rai IN _ ve LI 500 LH ES ele AE 399 8 33 2 16 5 15 7 840 5 a 1642 7 33 1 84 7 2729 0 E 107 4 a 3949 3 Le 155 5 4208 6 165 7 S T Rev December 1998 14 S T Truck S T 10603 Pickup Regular Cab with Short Box Isuzu General Arrangement 1000 1799 0 DAYLIGHT 70 8 OPENING E 3570 6 OVERALL UG 140 6 1688 2 66 5 MAX OVERALL 1214 1 ROOF NORMAL OUTSIDE TOP OF RAIL S T Rev 12 98 S T Truck S T 10803 Pickup Regular Cab with Long Box General Arrangement 1000 J DD DAYL I GHT OPENING 4 1358 3 53 40 H 678 1 gt 338 7 26 70 13 33 3570 6 140 58 OVERALL 1 CEJ 4 Co Ela JC OC SU OC UD CE 70 29 W NG Y 1 00 AS T NU E KN NAN Les 1684 8 m 66 33 OVERALL 480 5 Les 32 4 18 92 70 83 1 28 CHMSL 2012 tel e 79 22 PA 7 3 22 1 SN 1 S 1210 6 1417 3 18 92 47 66 1211 2 17 69 C NORMAL OUTSIDE
40. S T Truck BODY BUILDERS INSTRUCTIONS 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 The Body Builders Manual 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 ap plicable Federal Motor Vehicle Safety Standard or Emission Regulation Intermedi ate and final stage manufacturers should be familiar with all Federal Motor Vehicle Safety Standards and Emission Regulations and aware of their specific responsibili ties as manufacturers For further assistance contact Upfitter Integration at 1 800 875 4742 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 environ men
41. T 10506 Utility 4 Door a l1464 8 1165 1 BAD 45 87 246 4 9 70 9 D op ESL s 2 33 UT TT CENTERL IN OF VEHICI GR I y OE JE om D 2 lo Ul 85 7 413 37 780 1 545 3 29 92 21 47 1009 3718 429 5 o 16 91 EE Z REAR AXLE OUTSIDE TOP OF 2718 0 TY FHAME IO BOTTOM OF SHIELD 1097 01 nm 402 0 er EE EE OUTSIDE TOP OF FRAME TO BOTTOM OUTSIDE METAI DE TA NORMAL TOP 1 A Kee ST 500 NXT A 5 J 1 NORMAL TOP O AME 430 3 Li 16 94 2 S T Rev 12 98 S T Truck
42. ank pump for PFI and SCPI systems Coupled hose or nylon quick connects must be used Clamped hose is not acceptable for PFI and SCPI systems 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 Califor nia vehicle emission standards Alterations to fuel tank and metering unit lines can ister 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 incorporate water drain provisions in the fuel system These valves are only to be opened when siphoning water and contaminants from the fuel system Fuel Tank For vehicles with full frames the tank must have a minimum clearance of 2 in top front rear and sides to body and other supports Tank may be pressurized 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 detrimen tal and affect tank dura
43. ansmission use a hydraulic clutch actuator Check fluid level as outlined in the vehicle owners manual It is mandatory that no change be made to the clutch master cylinder location clutch master or slave cylinder push rod length or pedal postion 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 FMVSS 301 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 System includes e Fueltank metering unit lines including purge control solenoids and canister or canisters For these reasons NO ALTERATION OF THE FUEL SYSTEM IS RECOMMENDED Fuel Lines Fuel line routing precautions e 12in minimum clearance to exhaust system is required or a metal shield must be provided S T Rev 12 98 S T Truck 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 t
44. bility The use of auxiliary fuel tanks is not recommended f an auxiliary fuel tank is add ed the alterer must take responsibility for compliance with affected motor vehicle safety standards Also if an auxiliary fuel tank is added to a gasoline powered ve hicle the fuel must be drawn through pipe at the top of the tank balance line be tween tanks is not permitted Gasoline fueled vehicles are now equipped with a fuel pump return line an auxiliary tank is added the tank selector valve must include 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 dis connected before starting any work on the fuel system S T Rev 12 98 9 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 truck etc and the system should be vented to the outside of the vehicle In addition vehicles converted to gas eous 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
45. d noise levels permitted Tail pipe outlet location must be tested statically and with the vehicle in motion to en sure that exhaust gases do not penetrate side or rear windows or under body seams and holes Auxiliary power plants should also be tested under the same conditions Tail pipe exit ahead of rear wheels is not recommended Check for leaks in exhaust systems and repair as required Any exhaust joint which has been disassembled must have the exhaust gasket re placed and the fasteners torqued to specifications Re check exhaust system for leaks 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 6 the rated temperature limits of the components Due to variants in underbody configu rations 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 shielding 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 wellthis area is ventilated in your individual designs Her
46. e again temperature checks of interior areas surrounding the engine should be made to determine if your insula tion is adequate This is the same engineering practice we have followed on our com plete vehicles incorporating these exhaust systems Exhaust system materials are selected and tested to withstand the operating environ ment of the vehicle Do not modify the exhaust system in any way The tail pipes are made of 409 aluminized stainless steel Heat shields are mounted to the underbody and or exhaust system components cat alytic converter muffler and tailpipe Shields for the propshaft hanger bearings are also provided in some vehicles 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 not to be altered Section 10 Tires Check wheel lug nuts for proper torgue specifications are provided in the Owner s Manual Substitution of tires of greater capacity than those offered as original eguipment by vehicle manufacturer is not approved for use on original eguipment wheels Any usage of higher capacity tires must be accompanied by higher capacity wheels How ever 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 co
47. ealer Those installing aftermarket systems should provide information as to where and how to obtain service Section 1 Body Body structures interior and accessory arrangements must be designed into the ve hicle 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 section of the Incomplete Vehicle Document Body insulation provided by General Motors should not be removed This includes any thermal or underbody heat shields This insulation is provided to protect the ve hicle 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 Underbody exhaust muffler and tailpipe shields and insulators Rear load floor interior insulation Front floor interior insulation Dash mat insulation Engine cowl insulation interior and exterior Engine cover insulation If body builder installs seating other than that supplied with vehicle it is the body build er 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 poin
48. ed in series between the S terminal of the generator and the B terminal of the battery Modifications add on wiring must be carefully reviewed to ensure compatibility with the base vehicle wiring by reviewing 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 revi sions For this reason any person modifying existing vehicle wiring must assume re sponsibility 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 S T Rev 12 98 S T Truck least as large as the the wire to which it is attaching in order for fuse protection to be maintained 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 com ponents 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 com
49. elerator cable is properly routed Specifications are as follows e Route cable to maximize all bend radii In no case should bend radii be less than 3 in 76 mm e Minimum distance from exhaust manifold to be 6 0 in 150 mm unless a heat shield is provided e Do notuse accelerator cable or clips to route wires harnesses or other cables Cable sheath must be clipped so as not to pinch inner cable Cable must not be loose in clip allowing sheath to move when accelerator pedal is applied and released e Cable must not be subjected to kinking or routing across any sharp edges e Cable routing must be perpendicular to the surface of the front of dash at the dash fitting No objects or routings should force cable to have a bend at the dash fitting Flexible components hoses wires conduits etc must not be routed within 2 0 in 50 mm of moving parts or accelerator linkage unless routing is positively controlled 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 ha
50. es 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 See chassis data information for additional clearances and for assistance in calculat ing trim heights Section 5 Brakes See Truck Service Manual for brake specifications S T Rev 12 98 3 Due to the critical nature of brake systems anyone making modifications or alter ations must assume complete responsibility for system reliability performance and certification to FMVSS 105 or FMVSS 121 Itis mandatory that no change be made to the brake main cylinder location brake ped al 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 truck chassis service manual Ensure that vacuum booster system or hydroboost system is functional and free of leaks Check master cylinder fluid level and fill as necessary Refer to Owner s Manual Check power steering fluid level for models equipped with hydroboost brake Refer to Owner s Manual Added floor covering or carpeting must not restrict service or parking brake pedal trav el from released position to full pedal travel No body part or chassis mounted component may be located within 2 0 in of b
51. he radiator must be installed When shut off valve is required in heating system it must be teed into the system in such a manner as to maintain continuous flow be tween engine heater connection radiator heater connection at all times 6 Use GM 6277M Long Life Coolant only Do not install any internal flow restrictors e Heater hose 3 way or 4 way valves must be used to provide constant water flow through the intake manifold pad area e Ifin line shut off valve is used in combination with 3 way valves shut off valve must not be closed until 3 way valve at engine is in the proper position Red White Valve Corp Carson CA 213 549 1010 gt Ranco Controls Div Delaware OH 614 876 8022 4 Way Ranco Controls Div Delaware OH Be sure to add coolant to system after adding capacity to system heaters 8 S T Truck S T 10003 Pickup General Arrangement REFER TO FRAME DRAWING I I oe REFER TO EXHAUST DRAWING REFER TO FUEL TANK DRAWING EFER TO 000 BODY DRAWING FRONT AXLE 7 REAR AXLE OUTSID NORMAL OF FRA FT A INCHES UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE TO OUTSIDE OF METAL S T Rev 12 98 S T Truck S T 70576 2 Door Utility General Arra
52. les should exceed 20 0 75 in in diameter e All holes should be drilled in the frame using appropriate drilling practice and safety precautions Welding CAUTION Fuel tank and fuel lines must be drained and all vapors purged to ensure non combustible mixture before any welding brazing or soldering S T Truck When welding low carbon steel side rails crossmembers and brackets 32 000 or 36 000 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 onthe 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 atthe 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 careful ly inspect wiring and electrical components for shorts or other damage which could draw excessive currents and possibly cause an electrical system short when the bat tery is reconnected Apply protective coating 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 for warranty on i
53. mponents S T Truck Increasing tire and wheel capacity does not necessarily increase vehicle GVW rat ings It is recommended that tire chain clearance guideline J683 from the Society of Auto motive Engineers be adhered to in designing rear wheelhouse clearance Check tires and inflate to recommended tire pressure according to the tire pressure information provided in Owner s Manual and tire inflation label provided with vehicle Any substitution of tires may affect Speedometer Odometer accuracy Section 12 Electrical Battery and Battery Cables The vehicle battery should be located and positioned to make use of the existing bat tery cables Ifthe battery requires relocation and longer cables are required a propor tionately larger gauge wire must be used If in relocating the battery the negative ground cable is attached to frame rail a cable of similar gauge be provided between the frame rail and the engine This is required due to the heavy electrical loads im posed by the starting circuit To ensure proper operation of the battery cables the fol lowing chart on length gauge and materials must be strictly adhered to Combined length of positive and negative Cable in Inches Copper Cable Gauge 4 66 2 107 0 170 If the battery is remotely mounted other than in the engine compartment the sense circuit in the generator regulator shall be used The sense circuit consists of a 7 76 OHM 1 4 watt resistor connect
54. ngement REFER TO FRAM RAW ING g REFER TO EXHAUST DRAWING r N REFER TO HITCH DRAWING TO FUEL TANK DRAWING REFER TO BODY DRAWING Q553 Ea o gt MEER Es We 17 EN EST a 500 M y FRONT AXLE INCHES S T Rev 12 98 10 S T Truck S T 10506 4 Door Utility General Arrangement REFER TU EXHAUST DRAWING REFER TO FRAME DRAWING R DRAWING
55. ponents 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 wiring 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 8 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 sol der with an electrical grade rosin core solder Wrap splice area with tape 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 6 For further information refer to the instruction manual in the wiring repair kit refer enced elsewhere in this section Accessory Power Supply Feed For power requirements to service additional devices to be added by body builder up fitter the power supply source must be at the j
56. ra 1580 6 180 3 OF FRT AXLE S T Rev 12 98 17 S T Truck S T 10003 Pickup Front End Sheet Metal Arrangement Chevrolet GMC GRILLE gt 51 0 GRILLE m 57 2 0 2 6 lt 401 9 TYP WHL OPNG 15 8 E i 500 500 425 9 lt 16 8 CHEVY BASE A TRD AM 123 2 CHEVY UPLEVEL AIRDAM a 107 1 4 2 4 9 895 7 279 6 35 3 34 6 000 Qooo gt sui RO GRILLE 7 h 91 6 O 346 GA BAR 500 v i H 500 432 4 ES ne gt ATRDAM e 108 2 17 0 ATRDAM gt 97 68 17 4 4 3 3 8 898 1 GMC BASE 594 9 GMC UPLEVEL 35 4 35 2 00 gt TOO S T Rev December 1998 S T Truck S T 10000 Pickup Front End Sheet Metal Arrangements Isuzu Bravada 0 A E O W RACKE I m 15 6 LIG PLATE Ka 206 6 AIRDAM m 8 1 419 4 430 7 ea a AIRDAM m 17 0 3 2 a 842 B53 7 ER 33 6 a O 3 5 36 0 OE S
57. rake hose routing in all wheel and axle positions All exhaust system components must also have 8 minimum of 2 0 in clearance to brake hoses in closest positions Be sure to account for brake hose travel with suspension Body builder is to verify that the brake warning switch is operative The brake warning switch on models equipped with vacuum hydraulic brakes is located adjacent to the master cylinder vacuum unit This includes both the brake system differential pres sure and parking brake actuator switch Section 6 Engine For additional information refer to Body Section 1 Air conditioning and auxiliary belt driven equipment installation recommendations No alterations or additions to the accessory drive belt system will be warranted on ser pentine belt systems The serpentine belt type of drive is designed as a total system incorporating a single poly V belt and an automatic tensioner In this type of system degrees of pulley wrap belttension and pulley alignment are very critical factors Modification is not recom mended In some single belt serpentine systems belt tension is determined by the automatic tensioner and its position relative to the belt No adjustment is required 4 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 Caution must be exercised so that the acc
58. s been designed to provide mini mum driver movement and should not be altered in any way Gasoline engine 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 throttle body and port fuel injection PFI or sequential central port injector SCPI and associated tubes hoses and pipes air cleaner outside air hose mass air flow sensor fuel pump and inlet manifold fuel vapor canister e Exhaust system e Ignition system distributor and initial spark timing setting spark plugs spark plug wires e Crankcase ventilation system S T Truck Section 7 Transmission Light duty models equipped with manual transmission have a clutch operated start safety switch Starter should operate whenever the ignition is turned to start and the clutch is fully depressed Readjust if necessary as outlined in the Truck Service Manu al Models equipped with automatic transmissions have a steering column mounted or a transmission mounted neutral park start safety mechanical lockout feature which interfaces with the steering column ignition switch Starter should operate only when gear shift lever is in neutral or park position Readjust the shift linkage or neutral start backup switch if necessary as outlined in the Truck Service Manual Models equipped with manual tr
59. t 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 Powertrain Con trol Module PCM Vehicle Control Module VCM or any electronic unit associated with an inflatable restraint system See Owner s Manual If arc welding is employed on the chassis precautions must be taken to protect all vehicle components especially brake fuel lines and fuel tank assembly electrical wir ing and ECM PCM TCM or VCM 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 S T Rev 12 98 When welding components to the frame assembly remove the wax coating in the area of the weld in order to obtain secure welds After completion of the weld a compatible corrosion protection should be applied to the affected weld areas 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
60. tems such as drive shafts universal joints center bearings and rear transmission tailshaft transfer case and transmission case fractures output shaft bushings bearings brakes fuel sys tems and any other related component failures Additionally the customer must be alerted in the modifier s owners manual that parts for the reworked area are not avail able through the General Motors service parts system 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 16 mm in diameter are consistently 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 larg er 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 is allowed S T Rev 12 98 S T Truck Rear bodies or platforms added to the vehicle must utilize the
61. ts and seat travel of the original equip ment seats only 2 Air Conditioning For additional information refer to Engine Section 6 NOTE Air conditioning systems using R 134A refrigerant are equipped with metric fittings to prevent interchange with R 12 refrigerant components Do not interchange R 134A components refrigerant oil or service equipment with R 12 components refrigerant oil or service equipment Section 2 Frame Hole drilling welding modifications or alterations to the frame assembly are the re sponsibility 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 Material between edge of hole and inside of upper or lower flange must not be less than 37 mm 1 50 in for low carbon steel 36 000 PSI yield e The minimum edge distance between any two 2 holes must be larger than twice the diameter of the larger hole e No ho
62. unction block on the front of dash above battery using the small on the left hand side of junction block NOTE ground stud has also been provided above the junction block S T Rev 12 98 7 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 influ ence fan blade stress 2 Grille opening size configuration and the external baffles provided should not be al tered in any manner Any reduction in cooling ability may adversely affect engine transmission performance 3 Fan clutches not conforming to the original equipment specifications may not oper ate correctly and may stay on continuously never come on or cycle on and off ex cessively This will result in a reduction of fuel economy engine overheat at times and annoying cycling respectively 4 Continuous coolant flow is necessary from heater connection on engine to heater connection on radiator to control transmission oil temperatures during closed ther mostat warm up operation Do not alter this flow as it may result in premature en gine or transmission failure 5 If a heater unit is not installed in the vehicle or a heater shut off valve is required a line connecting the heater connection on the engine to the heater connection on t
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