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G/H V
AN
BODY BUILDERS INSTRUCTIONS .......................................................................................................................................................... 1
Section 0 - General Instructions ..................................................................................................................................................... 1
Welding ....................................................................................................................................................................................... 2
Labels ......................................................................................................................................................................................... 2
Section 1 - Body................................................................................................................................................................................ 3
Conversions ................................................................................................................................................................................ 3
Air Conditioning .......................................................................................................................................................................... 4
Rear Air Conditioning .................................................................................................................................................................. 4
Section 2 - Frame ............................................................................................................................................................................. 5
Flanges ....................................................................................................................................................................................... 5
Holes ........................................................................................................................................................................................... 5
Alterations ................................................................................................................................................................................... 6
Shear Plate Attachments ............................................................................................................................................................ 6
Trailer Towing .............................................................................................................................................................................. 6
Section 3 - Front Suspension .......................................................................................................................................................... 7
Section 4 - Rear Suspension ........................................................................................................................................................... 7
Section 5 - Brakes ............................................................................................................................................................................ 8
Section 6 - Engine............................................................................................................................................................................. 9
Section 7 - Transmission ................................................................................................................................................................ 11
Section 8 - Fuel and Exhaust ......................................................................................................................................................... 11
Fuel Systems ............................................................................................................................................................................ 11
Fuel Fill ...................................................................................................................................................................................... 12
Fuel Lines .................................................................................................................................................................................. 12
Fuel Tank ................................................................................................................................................................................... 13
Gaseous Fuel Conversions ....................................................................................................................................................... 14
Exhaust System ........................................................................................................................................................................ 14
Section 9 - Steering ........................................................................................................................................................................ 15
G/H Van (GMT 610) 2005
GMT 610
)
i
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Summary of Contents for GMC GMT 610
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Page 1: Table Of Contents
Section 8 – Fuel and Exhaust ................................. 11 Fuel Systems .................................... 11 Fuel Fill ...................................... 12 Fuel Lines ....................................12 Fuel Tank ....................................13 Gaseous Fuel Conversions ............................... 14 Exhaust System ..................................14 Section 9 – Steering ..................................15 G/H Van (GMT 610) 2005... - Page 2 Seating Positions and H Point Locations 2, 4, 8, 12, 15, 155” WB ....................38 1st Row Driver and Passenger Seat Riser Mounting Locations ....................39 Seating Tie Down Locations, 12 Passenger, 135” WB ......................... 40 G/H Van (GMT 610) 2005...
- Page 3 Spare Tire Carrier, 135” WB – G/H 134/234 (05/06) G 334 (05/06) ....................59 Spare Tire Carrier, 155” WB – G 237/337 (05/06) .......................... 60 AXLE/TIRE DATA Front Axle/Tire Data Chart – Full Body Vans (05/06) ........................61 Front Axle/Tire Data Chart – Cutaway Vans (03) .......................... 62 G/H Van (GMT 610) 2005...
- Page 4 Exhaust System w/Vortec 4800 V8 (LR4) and 6000 V8 (LQ4) – G33503, 139” WB ..............74 Exhaust System w/Vortec 6000 V8 (LQ4) ............................75 Exhaust System w/Vortec 6000 V8 (LQ4) ............................76 G/H Van (GMT 610) 2005 – Revised 08/2005...
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Page 5: Body Builders Instructions
The Sensing and Diagnostic Module (SDM) located under the driver seat and S. I. R. sensor at the lower radiator support cannot, under any circumstance, be moved from their present mounting locations. (Section 0 — continued on next page) G/H Van (GMT 610) 2005... -
Page 6: Welding
NOTE: In order to be in compliance with FMVSS 208, no other label shall be installed on the same side of the sunvisor as the Inflatable Restraint Caution (Air Bag) Label. G/H Van (GMT 610) 2005... -
Page 7: Section 1 - Body
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. (Section 1 — continued on next page) G/H Van (GMT 610) 2005... -
Page 8: Air Conditioning
• Heater/Defroster – No modifications should be made to the heater/defroster system or coolant supply which could affect compliance to FMVSS 103. G/H Van (GMT 610) 2005... -
Page 9: Section 2 - Frame
• The minimum edge distance between any two (2) holes must be larger than twice the diameter of the larger hole. • No holes should exceed 20 mm (0.75 in.) in diameter. • All holes should be drilled in the frame using appropriate drilling practice and safety precautions. (Section 2 — continued on next page) G/H Van (GMT 610) 2005... -
Page 10: Alterations
Note to Body Builder/Final Stage Manufacturer: Failure to keep body and payload CG at least 26 inches forward of centerline of rear axle will result in degradation of trailer towing capacity. Consult the Trailer Towing Guide to determine maximum tongue load for your vehicle. G/H Van (GMT 610) 2005... -
Page 11: Section 3 - Front Suspension
Such crossing could result in rupture, wear-through, or separation due to normal axle motion. NOTE: Notification to the consumer may be required in certain states if tire chains cannot be used. See chassis data information for additional clearances and for assistance in calculating trim heights. G/H Van (GMT 610) 2005... -
Page 12: Section 5 - Brakes
Check power steering fluid level for models equipped with hydraulic booster brake. (Refer to Owner’s Manual). Added floor covering or carpeting must not restrict service or parking brake pedal travel from released position to full pedal travel. (Section 5 — continued on next page) G/H Van (GMT 610) 2005... -
Page 13: Section 6 - Engine
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. (Section 6 — continued on next page) G/H Van (GMT 610) 2005... - Page 14 The diesel engine induction and injector pump system is certified to be in compliance with the Federal Vehicle Emission Standards and/or Noise Standards. Any alterations to the system or components could void compliance and render the vehicle illegal. (Section 6 — continued on next page) G/H Van (GMT 610) 2005...
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Page 15: Section 7 - Transmission
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 and emission standards. (Section 8 — continued on next page) G/H Van (GMT 610) 2005... -
Page 16: Fuel Fill
• 12 in. minimum clearance to exhaust system is required or a metal shield must be provided. • Fuel lines should be clipped (every 600 mm or less) to prevent chafing. Metal clips must have rubber or plastic liners. (Section 8 — continued on next page) G/H Van (GMT 610) 2005 – Revised 08/2005... -
Page 17: Fuel Tank
Similarly, addition of another fuel line for an auxiliary fuel user (such as a generator) will require emission revalidation. 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. (Section 8 — continued on next page) G/H Van (GMT 610) 2005... -
Page 18: Gaseous Fuel Conversions
Tail pipe outlet location must be tested statically and with the vehicle in motion to ensure that exhaust gases do not enter through side or rear windows or underbody seams and holes. Auxiliary power plants should also be tested under the same conditions. Tail pipe exit ahead of rear wheels is not recommended. (Section 8 — continued on next page) G/H Van (GMT 610) 2005... -
Page 19: Section 9 - Steering
The steering column must be locked or pinned to prevent rotation when the steering gear or column-to-gear intermediate shaft is disconnected. Damage to the inflatable restraint control wire can result if this is not done (see Service Manual). G/H Van (GMT 610) 2005... -
Page 20: Section 10 - Tires
To ensure proper operation of the battery cables the following chart on length, gauge and materials must be strictly adhered to. Combined Length of Positive and Negative Cable Gauge Cable in Inches (Copper) (Section 12 — continued on next page) G/H Van (GMT 610) 2005... -
Page 21: Battery Installation
The trays shipped on the rails may be relocated to other areas on the vehicle, keeping in mind the recommendations noted above. For other units, the tray is supplied on the radiator support. (Section 12 — continued on next page) G/H Van (GMT 610) 2005... - Page 22 Any add-on wiring must be properly fused and routed to prevent cut, pinch, chafe problems, and exposure to excessive heat. Care must be exercised that existing (Section 12 — continued on next page) G/H Van (GMT 610) 2005...
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Page 23: Accessory Power Supply Feeds
A junction block has been provided behind the driver’s side ‘B’ pillar. Both switched and unswitched power junction terminals are available (See Owner’s Manual for compatibility). All additional loads should utilize these terminals. NOTE: A ground stud has also been provided above the junction block. G/H Van (GMT 610) 2005... -
Page 24: Section 13 - Cooling
Do not over fill coolant recovery or surge tank containers. Be sure to add coolant to system after adding capacity to system heaters. The use of environmentally friendly long life coolant is required. G/H Van (GMT 610) 2005... -
Page 25: Model Symbol Chart
G/H V GMT 610 MODEL SYMBOL CHART 2003 GMT 610 Body Styles / Models TRUCK (Optional) MODEL/ MODEL/ MODEL/ MODEL/ ENGINEERING GVWR WHEELBASE CAB-TO-AXLE MERCHANDISING MERCHANDISING MERCHANDISING MERCHANDISING MODEL (kg/lbs) (mm/in) (mm/in) DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION G13405 6200 (Q4B) / 135”... - Page 26 G/H V GMT 610 MODEL SYMBOL CHART (Continued) 2003 GMT 610 Body Styles / Models TRUCK (Optional) MODEL/ MODEL/ MODEL/ MODEL/ ENGINEERING GVWR WHEELBASE CAB-TO-AXLE MERCHANDISING MERCHANDISING MERCHANDISING MERCHANDISING MODEL (kg/lbs) (mm/in) (mm/in) DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION G23705 7300 (C6A) / 155”...
- Page 27 G/H V GMT 610 MODEL SYMBOL CHART (Continued) 2003 GMT 610 Body Styles / Models TRUCK (Optional) MODEL/ MODEL/ MODEL/ MODEL/ ENGINEERING GVWR WHEELBASE CAB-TO-AXLE MERCHANDISING MERCHANDISING MERCHANDISING MERCHANDISING MODEL (kg/lbs) (mm/in) (mm/in) DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION G33406 9600 (C6Y) / 135”...
- Page 28 G/H V GMT 610 MODEL SYMBOL CHART (Continued) 2003 GMT 610 Body Styles / Models TRUCK (Optional) MODEL/ MODEL/ MODEL/ MODEL/ ENGINEERING GVWR WHEELBASE CAB-TO-AXLE MERCHANDISING MERCHANDISING MERCHANDISING MERCHANDISING MODEL (kg/lbs) (mm/in) (mm/in) DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION G33903 w/B3D 12000 (C7L) 177”...
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Page 29: General Arrangement, 135" Wb - G/H 134/234/334 And 155" Wb - G/H 237/337
G/H V GMT 610 General Arrangement, 135” WB – G/H 134/234/334 and 155” WB – G/H 237/337 TD005990a G/H Van (GMT 610) 2005... -
Page 30: General Arrangement, 139" Wb - G335 / 159" Wb - G338 / 177" Wb - G339
G/H V GMT 610 General Arrangement, 139” WB – G335 / 159” WB – G338 / 177” WB – G339 TD005886b G/H Van (GMT 610) 2005... -
Page 31: Sign Area, 135" Wb - G/H 134/234/334
G/H V GMT 610 Sign Area, 135” WB – G/H 134/234/334 TD006054a G/H Van (GMT 610) 2005... -
Page 32: Sign Area, 155" Wb - G/H 137/237/337
G/H V GMT 610 Sign Area, 155” WB – G/H 137/237/337 TD006054b G/H Van (GMT 610) 2005... -
Page 33: Window Opening, 135" Wb - G/H 134/234/334
G/H V GMT 610 Window Opening, 135” WB – G/H 134/234/334 TD006054c G/H Van (GMT 610) 2005... -
Page 34: Window Opening, 155" Wb - G/H 137/237/337
G/H V GMT 610 Window Opening, 155” WB – G/H 137/237/337 TD006054d G/H Van (GMT 610) 2005... -
Page 35: Glass Area, 135" Wb - G/H 134/234/334
G/H V GMT 610 Glass Area, 135” WB – G/H 134/234/334 TD006054e G/H Van (GMT 610) 2005... -
Page 36: Glass Area, 155" Wb - G/H 137/237/337
G/H V GMT 610 Glass Area, 155” WB – G/H 137/237/337 TD006054f G/H Van (GMT 610) 2005... -
Page 37: Mirrors - Outside Rearview
G/H V GMT 610 Mirrors — Outside Rearview TD006016a G/H Van (GMT 610) 2005... -
Page 38: G Cutaway, Rear Flange Opening Dimensions
G/H V GMT 610 G Cutaway, Rear Flange Opening Dimensions TD005979a G/H Van (GMT 610) 2005... -
Page 39: Rear Chmsl Location
G/H V GMT 610 Rear CHMSL Location TD006033a G/H Van (GMT 610) 2005... -
Page 40: Seating Positions And H Point Locations 2, 5, 8, 12, 135" Wb
G/H V GMT 610 Seating Positions and H Point Locations 2, 5, 8, 12, 135” WB TD006025a G/H Van (GMT 610) 2005... -
Page 41: Seating Positions And H Point Locations 2, 4, 8, 12, 155" Wb
G/H V GMT 610 Seating Positions and H Point Locations 2, 4, 8, 12, 155” WB TD006025b G/H Van (GMT 610) 2005... -
Page 42: Seating Positions And H Point Locations 2, 4, 8, 12, 15, 155" Wb
G/H V GMT 610 Seating Positions and H Point Locations 2, 4, 8, 12, 15, 155” WB TD006025c G/H Van (GMT 610) 2005... -
Page 43: 1St Row Driver And Passenger Seat Riser Mounting Locations
G/H V GMT 610 1st Row Driver and Passenger Seat Riser Mounting Locations TD005989a G/H Van (GMT 610) 2005... -
Page 44: Seating Tie Down Locations, 12 Passenger, 135" Wb
G/H V GMT 610 Seating Tie Down Locations, 12 Passenger, 135” WB TD006025d G/H Van (GMT 610) 2005... -
Page 45: Seating Tie Down Locations, 12 Passenger, 155" Wb
G/H V GMT 610 Seating Tie Down Locations, 12 Passenger, 155” WB TD006025e G/H Van (GMT 610) 2005... -
Page 46: Seating Tie Down Locations, 15 Passenger, 155" Wb
G/H V GMT 610 Seating Tie Down Locations, 15 Passenger, 155” WB TD006025f G/H Van (GMT 610) 2005... -
Page 47: Roof Bows, 135" And 155" Wb - (05/06)
G/H V GMT 610 Roof Bows, 135” and 155” WB – (05/06) TD006008a G/H Van (GMT 610) 2005... -
Page 48: Side Strainers, Braces And Reinforcements, 135" Wb - G/H134/G234/G334 (05/06)
G/H V GMT 610 Side Strainers, Braces and Reinforcements, 135” WB – G/H134/G234/G334 (05/06) TD006008b G/H Van (GMT 610) 2005... -
Page 49: Side Strainers, Braces And Reinforcements, 135" Wb - G/H134/G234/G334 (05/06)
G/H V GMT 610 Side Strainers, Braces and Reinforcements, 135” WB – G/H134/G234/G334 (05/06) TD006008c G/H Van (GMT 610) 2005... -
Page 50: Side Strainers, Braces And Reinforcements, 155" Wb - G237/G337 (05/06)
G/H V GMT 610 Side Strainers, Braces and Reinforcements, 155” WB – G237/G337 (05/06) TD006008d G/H Van (GMT 610) 2005... -
Page 51: Side Strainers, Braces And Reinforcements, 155" Wb - G237/G337 (05/06)
G/H V GMT 610 Side Strainers, Braces and Reinforcements, 155” WB – G237/G337 (05/06) TD006008e G/H Van (GMT 610) 2005... -
Page 52: Floor Cross Sills Centerline Locations
G/H V GMT 610 Floor Cross Sills Centerline Locations TD006018a G/H Van (GMT 610) 2005... -
Page 53: Floor With Optional E26, 135" Wb - G/H 134/234/334
G/H V GMT 610 Floor with Optional E26, 135” WB – G/H 134/234/334 TD006077a G/H Van (GMT 610) 2005... -
Page 54: Floor Without Optional E26, 135" Wb - G/H 134/234/334
G/H V GMT 610 Floor without Optional E26, 135” WB – G/H 134/234/334 TD006077b G/H Van (GMT 610) 2005... -
Page 55: General Arrangement, Full Body Van - G/H 100/200/300 (05/06)
G/H V GMT 610 General Arrangement, Full Body Van – G/H 100/200/300 (05/06) TD005956a G/H Van (GMT 610) 2005... -
Page 56: General Arrangement, Cutaway - G 335,338,339 (03)
G/H V GMT 610 General Arrangement, Cutaway – G 335,338,339 (03) TD005886a G/H Van (GMT 610) 2005... -
Page 57: Frame And Crossmember Arrangement, 135" Wb - G 134/234 (05/06)
G/H V GMT 610 Frame and Crossmember Arrangement, 135” WB – G 134/234 (05/06) TD005993a G/H Van (GMT 610) 2005... -
Page 58: Frame And Crossmember Arrangement, 135" Wb - H 134/234 (05/06)
G/H V GMT 610 Frame and Crossmember Arrangement, 135” WB – H 134/234 (05/06) TD005993c G/H Van (GMT 610) 2005... -
Page 59: Frame And Crossmember Arrangement, 135" Wb - G 234/334 (05/06)
G/H V GMT 610 Frame and Crossmember Arrangement, 135” WB – G 234/334 (05/06) TD005993b G/H Van (GMT 610) 2005... -
Page 60: Frame And Crossmember Arrangement, 155" Wb - G 237/337 (05/06)
G/H V GMT 610 Frame and Crossmember Arrangement, 155” WB – G 237/337 (05/06) TD005994a G/H Van (GMT 610) 2005... -
Page 61: Frame And Crossmember Arrangement, 139"/159"/177" Wb - G Cutaway (03)
G/H V GMT 610 Frame and Crossmember Arrangement, 139”/159”/177” WB – G Cutaway (03) TD005145a G/H Van (GMT 610) 2005... -
Page 62: Platform Trailer Hitch
G/H V GMT 610 Platform Trailer Hitch TD006052a G/H Van (GMT 610) 2005... -
Page 63: Spare Tire Carrier, 135" Wb - G/H 134/234 (05/06) G 334 (05/06)
G/H V GMT 610 Spare Tire Carrier, 135” WB – G/H 134/234 (05/06) G 334 (05/06) TD006017a G/H Van (GMT 610) 2005... -
Page 64: Spare Tire Carrier, 155" Wb - G 237/337 (05/06)
G/H V GMT 610 Spare Tire Carrier, 155” WB – G 237/337 (05/06) TD006017b G/H Van (GMT 610) 2005... -
Page 65: Front Axle/Tire Data Chart - Full Body Vans (05/06)
G/H V GMT 610 Front Axle/Tire Data Chart – Full Body Vans (05/06) TD005982a G/H Van (GMT 610) 2005... -
Page 66: Front Axle/Tire Data Chart - Cutaway Vans (03)
G/H V GMT 610 Front Axle/Tire Data Chart – Cutaway Vans (03) TD005982b G/H Van (GMT 610) 2005... -
Page 67: Rear Axle/Tire Data Illustration
G/H V GMT 610 Rear Axle/Tire Data Illustration TD005980a G/H Van (GMT 610) 2005... -
Page 68: Rear Axle/Tire Data Chart - Full Body Vans, G/H 100/200/300 (05/06)
G/H V GMT 610 Rear Axle/Tire Data Chart – Full Body Vans, G/H 100/200/300 (05/06) TD005980b G/H Van (GMT 610) 2005... -
Page 69: Rear Axle/Tire Data Chart - Cutaway Vans, G 335/338/339 (03)
G/H V GMT 610 Rear Axle/Tire Data Chart – Cutaway Vans, G 335/338/339 (03) TD005980c G/H Van (GMT 610) 2005... -
Page 70: Fuel Tank And Filler Location - Full Body Vans
G/H V GMT 610 Fuel Tank and Filler Location – Full Body Vans TD005956b G/H Van (GMT 610) 2005... -
Page 71: Fuel Tank And Filler Location With L.h. Swing-Out Doors (Opt. E26) - Full Body Vans
G/H V GMT 610 Fuel Tank and Filler Location with L.H. Swing-Out Doors (opt. E26) – Full Body Vans TD005956c G/H Van (GMT 610) 2005... -
Page 72: Fuel Tank, 35 Gallon Mid-Ship - Cutaway
G/H V GMT 610 Fuel Tank, 35 Gallon Mid-ship – Cutaway TD005887b G/H Van (GMT 610) 2005... -
Page 73: Fuel Tank, 57 Gallon Rear Mounted Behind Rr Axle
G/H V GMT 610 Fuel Tank, 57 Gallon Rear Mounted behind RR Axle TD005887a G/H Van (GMT 610) 2005... -
Page 74: Exhaust System, 135" Wb - W/Vortec 5300 V8 (Lm7)
G/H V GMT 610 Exhaust System, 135” WB – w/Vortec 5300 V8 (LM7) TD006011a G/H Van (GMT 610) 2005... -
Page 75: Exhaust System, 135" Wb - W/Vortec 4800 V8 (Lr4) And 6000 V8 (Lq4)
G/H V GMT 610 Exhaust System, 135” WB – w/Vortec 4800 V8 (LR4) and 6000 V8 (LQ4) TD006011b G/H Van (GMT 610) 2005 – Revised 08/2005... -
Page 76: Exhaust System, 155" Wb - W/Vortec 5300 V8 (Lm7)
G/H V GMT 610 Exhaust System, 155” WB – w/Vortec 5300 V8 (LM7) TD006011d G/H Van (GMT 610) 2005... -
Page 77: Exhaust System, 155" Wb - W/Vortec 4800 V8 (Lr4) And 6000 V8 (Lq4)
G/H V GMT 610 Exhaust System, 155” WB – w/Vortec 4800 V8 (LR4) and 6000 V8 (LQ4) TD006011c G/H Van (GMT 610) 2005 – Revised 08/2005... -
Page 78: Exhaust System W/Vortec 4800 V8 (Lr4) And 6000 V8 (Lq4) - G33503, 139" Wb
G/H V GMT 610 Exhaust System w/Vortec 4800 V8 (LR4) and 6000 V8 (LQ4) – G33503, 139” WB TD005888a G/H Van (GMT 610) 2005 – Revised 08/2005... -
Page 79: Exhaust System W/Vortec 6000 V8 (Lq4)
G/H V GMT 610 Exhaust System w/Vortec 6000 V8 (LQ4) TD005888b G/H Van (GMT 610) 2005 – Revised 08/2005... -
Page 80: Exhaust System W/Vortec 6000 V8 (Lq4)
G/H V GMT 610 Exhaust System w/Vortec 6000 V8 (LQ4) TD005888c G/H Van (GMT 610) 2005 – Revised 08/2005...
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