GMC G VAN Manual
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GMC G VAN Manual

GMC G VAN Manual

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G V
GMT 600
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 Van (GMT 600) 2002
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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 Van (GMT 600) 2002...
  • Page 2 FRAME Light Duty Crossmember Arrangement, 135” Wheelbase – G (114/214)(05/06) ................ 35 Heavy Duty Crossmember Arrangement, 135” Wheelbase – G (214/314)(05/06) ..............36 Light Duty Crossmember Assembly, 155” Wheelbase – G 217 (05/06) ..................37 G Van (GMT 600) 2002...
  • Page 3 Heavy Duty Cutaway Converter/Muffler Assembly, Engine Options L18, L31 – G 317 (03/32) ..........57 Heavy Duty Cutaway Converter/Muffler Assembly, Engine Options L18, L31 – G 319 (03/32) ..........58 Heavy Duty Cutaway Converter/Muffler Assembly, Engine Option L65 – G (315/318/319)(03/32) .......... 59 G Van (GMT 600) 2002...

  • Page 4: 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 Van (GMT 600) 2002...

  • Page 5: 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 Van (GMT 600) 2002...

  • Page 6: 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 Van (GMT 600) 2002...

  • Page 7: Air Conditioning

    A modification to the A/C system which causes the A/C plumbing lines to increase in length (such as the addition of a rear after-market evaporator and blower assembly) will necessitate the following changes: • Lubrication – PAG refrigerant oil must be added to rear system to provide lubrication for compressor. Refer to the G Van Service Manual for specifications.

  • Page 8: 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 Van (GMT 600) 2002...

  • Page 9: 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 Van (GMT 600) 2002...

  • Page 10: Section 3 - Front Suspension

    GAWR/GVWR. Also, 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 “A” dimensions. See The G Van Service Manual for complete alignment procedure, specifications and measurement of the “A” dimension under “Diagnosis and Front Alignment” section.

  • Page 11: Section 5 - Brakes

    Ensure that the hydraulic brake system is free of air and hydraulic leaks. Bleed brakes if required, following procedures as outlined in the G Van Service Manual. Ensure that the vacuum booster system or hydraulic booster system is functional and free of leaks.

  • Page 12: Section 6 - Engine

    The adjuster will wind in the cable until it can no longer be reconnected if not blocked (pinned). See the Pin UP procedure outlined in Section 5, Enabling the Park Brake Automatic Adjuster, in the G Van Service Manual.
  • Page 13 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 Van (GMT 600) 2002...

  • Page 14: 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 Van (GMT 600) 2002...

  • Page 15: 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 Van (GMT 600) 2002...

  • Page 16: 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 Van (GMT 600) 2002...

  • Page 17: Gaseous Fuel Conversions

    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 Van (GMT 600) 2002...

  • Page 18: 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 Van (GMT 600) 2002...

  • Page 19: 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 Van (GMT 600) 2002...

  • Page 20: 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 Van (GMT 600) 2002...
  • Page 21 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 Van (GMT 600) 2002...

  • Page 22: 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 Van (GMT 600) 2002...

  • Page 23: Section 13 - Cooling

    - radiator heater connection at all times. 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 Van (GMT 600) 2002...

  • Page 24: General Arrangement - G (114/214/217/314/317)(05/06)

    GMT 600 G (114/214/217/314/317)(05/06) General Arrangement TD005165 G Van (GMT 600) 2002...

  • Page 25: 135" Wheelbase, Exterior, 5, 8 Or 12 Passenger - G (114/214/314)(05/06)

    GMT 600 G (114/214/314)(05/06) 135” Wheelbase, Exterior, 5, 8 or 12 Passenger TD005168 G Van (GMT 600) 2002...

  • Page 26: 135" Wheelbase, Interior, 5, 8 Or 12 Passenger - G (114/214/314)(05/06)

    GMT 600 G (114/214/314)(05/06) 135” Wheelbase, Interior, 5, 8 or 12 Passenger TD005170 G Van (GMT 600) 2002...

  • Page 27: 155" Wheelbase, Exterior - G (217/317)(05/06)

    GMT 600 G (217/317)(05/06) 155” Wheelbase, Exterior TD005169 G Van (GMT 600) 2002...

  • Page 28: 155" Wheelbase, Interior, 5, 8 Or 12 Passenger - G (217/317)(05/06)

    GMT 600 G (217/317)(05/06) 155” Wheelbase, Interior, 5, 8 or 12 Passenger TD005171 G Van (GMT 600) 2002...

  • Page 29: 155" Wheelbase, Interior, 15 Passenger - G (217/317)(05/06)

    GMT 600 G (217/317)(05/06) 155” Wheelbase, Interior, 15 Passenger TD005175 G Van (GMT 600) 2002...

  • Page 30: Seat Riser Assembly Mounting - G00000

    GMT 600 G00000 Seat Riser Assembly Mounting TDSeatMount G Van (GMT 600) 2002...

  • Page 31: Side Stringer Locations - G (114/214/217/314/317)(05/06)

    GMT 600 G (114/214/217/314/317)(05/06) Side Stringer Locations TD005796a G Van (GMT 600) 2002...

  • Page 32: Roof Bow Locations - G (114/214/217/314/317)(05/06)

    GMT 600 G (114/214/217/314/317)(05/06) Roof Bow Locations TD005796b G Van (GMT 600) 2002...

  • Page 33: Exterior Glass - G (114/214/217/314/317)(05/06)

    GMT 600 G (114/214/217/314/317)(05/06) Exterior Glass TD005174 G Van (GMT 600) 2002...

  • Page 34: Sign Area - G (114/214/217/314/317)(05/06)

    GMT 600 G (114/214/217/314/317)(05/06) Sign Area TD000000 G Van (GMT 600) 2002...

  • Page 35: Cutaway, Exterior - G (315/318/319)(03/32)

    GMT 600 G (315/318/319)(03/32) Cutaway, Exterior TD005172 G Van (GMT 600) 2002...

  • Page 36: Cutaway, Interior - G (315/318/319)(03/32)

    GMT 600 G (315/318/319)(03/32) Cutaway, Interior TD000000 G Van (GMT 600) 2002...

  • Page 37: G Cutaway, Rear Flange

    GMT 600 G Cutaway, Rear Flange TD000000 G Van (GMT 600) 2002...

  • Page 38: Light Duty Crossmember Arrangement, 135" Wheelbase - G (114/214)(05/06)

    GMT 600 G (114/214)(05/06) Light Duty Crossmember Arrangement, 135” Wheelbase TD005141 G Van (GMT 600) 2002...

  • Page 39: Heavy Duty Crossmember Arrangement, 135" Wheelbase - G (214/314)(05/06)

    GMT 600 G (214/314)(05/06) Heavy Duty Crossmember Arrangement, 135” Wheelbase TD005142 G Van (GMT 600) 2002...

  • Page 40: Light Duty Crossmember Assembly, 155" Wheelbase - G 217 (05/06)

    GMT 600 G 217 (05/06) Light Duty Crossmember Assembly, 155” Wheelbase TD005143 G Van (GMT 600) 2002...
  • Page 41 GMT 600 G (217/317)(05/06) Heavy Duty Crossmember Arrangement, 155” Wheelbase TD005144 G Van (GMT 600) 2002...
  • Page 42 GMT 600 G 315 (03/32) Heavy Duty Cutaway Crossmember Arrangement W/Soft Mt loc & Park Brk routing TD005790 G Van (GMT 600) 2002...
  • Page 43 GMT 600 G 318 (03/32) Heavy Duty Cutaway Crossmember Arrangement W/Soft Mt loc & Park Brk routing TD005791 G Van (GMT 600) 2002...
  • Page 44 GMT 600 G 319 (03/32) Heavy Duty Cutaway Crossmember Arrangement W/Soft Mt loc & Park Brk routing TD005792 G Van (GMT 600) 2002...
  • Page 45 GMT 600 G (114/214/217/314/317)(05/06) Spare Tire Carrier TD005162 G Van (GMT 600) 2002...
  • Page 46 GMT 600 G (114/214/217/314/317)(05/06) Trailer Hitch, 135”/155” Wheelbase TD005163 G Van (GMT 600) 2002...
  • Page 47 GMT 600 G (114/214/217/314/317)(05/06) Front Axle/Tire Data Chart TD005159 G Van (GMT 600) 2002...
  • Page 48 GMT 600 G (114/214/217/314/317)(05/06) Rear Axle/Tire Data Chart TD005160 G Van (GMT 600) 2002...
  • Page 49 GMT 600 G (315/318/319)(03/32) Front Axle/Tire Data Chart TD005164 G Van (GMT 600) 2002...
  • Page 50 GMT 600 G (315/318/319)(03/32) Rear Axle/Tire Data Chart TD005161 G Van (GMT 600) 2002...
  • Page 51 GMT 600 G (114/214/217/314/317)(05/06) General Arrangement, Fuel, 135”/155” Wheelbase TD005157 G Van (GMT 600) 2002...
  • Page 52 GMT 600 G (315/318/319)(03/32) General Arrangement, 35 Gallon and 55 Gallon TD005158 G Van (GMT 600) 2002...
  • Page 53 GMT 600 G (114/214/217/314/317)(05/06) Muffler Arrangement, 135”/155” Wheelbase TD005148 G Van (GMT 600) 2002...
  • Page 54 GMT 600 G (114/214/217/314/317)(05/06) Light Duty Converter Assembly, Engine Options L30, L31, L35 TD005149 G Van (GMT 600) 2002...
  • Page 55 GMT 600 G (217/317)(05/06) Heavy Duty Converter Assembly, Engine Options L31 California, L35 TD005150 G Van (GMT 600) 2002...
  • Page 56 GMT 600 G (217/317)(05/06) Heavy Duty Converter Assembly, Engine Options L31, L18 TD005151 G Van (GMT 600) 2002...
  • Page 57 GMT 600 G (217/317)(05/06) Heavy Duty Converter Assembly, Engine Option L65 TD005152 G Van (GMT 600) 2002...
  • Page 58 GMT 600 G 31503 Heavy Duty Cutaway Converter/Muffler Assembly, Engine Option L35 TD005801d G Van (GMT 600) 2002...
  • Page 59 GMT 600 G 315 (03/32) Heavy Duty Cutaway Converter/Muffler Assembly, Engine Options L18, L31 TD005801a G Van (GMT 600) 2002...
  • Page 60 GMT 600 G 317 (03/32) Heavy Duty Cutaway Converter/Muffler Assembly, Engine Options L18, L31 TD005801b G Van (GMT 600) 2002...
  • Page 61 GMT 600 G 319 (03/32) Heavy Duty Cutaway Converter/Muffler Assembly, Engine Options L18, L31 TD005801c G Van (GMT 600) 2002...
  • Page 62 GMT 600 G (315/318/319)(03/32) Heavy Duty Cutaway Converter/Muffler Assembly, Engine Option L65 TD005801e G Van (GMT 600) 2002...

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