Chevrolet - Cargo Van - Owners Manual - 2015 - 2016

2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Revision 1.0 Release date January 25, 2016 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 2 Contents GENERAL INFORMATION ............................................................................................................................................................. 7 FOREWORD ............................................................................................................................................................................. 7 IMPORTANT SAFETY NOTICE ................................................................................................................................................... 7 DISCLAIMER ............................................................................................................................................................................. 7 IMPORTANT REGULATORY INFORMATION ............................................................................................................................. 7 SAFETY INFORMATION ................................................................................................................................................................ 9 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PRECAUTIONS ..................................................................................................... 9 Precaution for Supplemental Restraint System (SRS) “Airbag” and “Belt Pre-Tensioner”.................................................. 9 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENT LOCATIONS ........................................................................................ 10 OCCUPANT CLASSIFICATION SYSTEM ........................................................................................................................................ 12 FRONT AIR BAG DEPLOYMENT ZONES ...................................................................................................................................... 13 FRONT AIR BAG MODULE LOCATIONS .................................................................................................................................. 13 Front Air Bag Modules — Overhead View............................................................................................................................. 14 Front Air Bag Modules — Driver Side .................................................................................................................................... 15 Front Air Bag Modules — Passenger Side ............................................................................................................................. 16 Driver Air Bag Deployment Width ......................................................................................................................................... 17 Front Passenger Air Bag Deployment Width ......................................................................................................................... 18 Headlining Cut — Front Side Curtain Air Bags Clearance for Bulkhead Installation.............................................................. 19 AIR BAG DEPLOYMENT KEEP-OUT ZONES ............................................................................................................................. 20 Front Air Bag Keep-Out Zones — Overhead View ............................................................................................................. 20 Front Air Bag Keep-Out Zone — Driver Side View ............................................................................................................. 21 Front Air Bag Keep-Out Zone — Passenger Side View ...................................................................................................... 22 INFLATED AIR BAG ZONE DIMENSIONS ................................................................................................................................. 23 Driver and Passenger Air Bag Inflation Zones — Forward View ........................................................................................ 23 Front Air Bag Inflation Zones — Overhead View ............................................................................................................... 24 Front Air Bag Inflation Zones — Driver Side View ............................................................................................................. 25 Front Air Bag Inflation Zones — Passenger Side View....................................................................................................... 26 Side Curtain Air Bag Inflation Zones — Overhead View .................................................................................................... 27 Side Air Bag Inflation Zones — Overhead View ................................................................................................................. 28 ALTERED VEHICLES .................................................................................................................................................................... 29 SAFETY INFORMATION .......................................................................................................................................................... 29 Safety / Emissions - Certification Labels for Altered Vehicles ........................................................................................... 29 BRAKE COMPLIANCE GUIDELINES ............................................................................................................................................. 31 Brake Compliance Guidelines (FMVSS and CMVSS 135) ....................................................................................................... 31 CENTER OF GRAVITY (CG) .......................................................................................................................................................... 32 Vehicle Center of Gravity Measurement Process.................................................................................................................. 32 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 3 Introduction....................................................................................................................................................................... 32 Vehicle Center of Gravity Measurement Process .................................................................................................................. 33 List of Terms ...................................................................................................................................................................... 33 Recommended ...................................................................................................................................................................... 34 Measurement Methods.................................................................................................................................................... 34 Analysis Method .................................................................................................................................................................... 35 Results ............................................................................................................................................................................... 35 Vehicle Center of Gravity Envelope — Unloaded Vehicle Weight (UVW) ......................................................................... 35 Maximum Unloaded Vehicle Weight (UVW) Resource Chart — 2015 - 2016 Model Year ............................................... 36 F/CMVSS 126 Electronic Stability Control Systems and F/CMVSS 135 Light Vehicle Brake Systems .................................... 37 FMVSS AND CMVSS REGULATION LIST ...................................................................................................................................... 38 Standards............................................................................................................................................................................... 38 PRECAUTIONS ............................................................................................................................................................................ 39 Precautions for Electrical CAN (Controller Area Network) System ....................................................................................... 39 MODEL INFORMATION .............................................................................................................................................................. 40 LABEL INFORMATION ............................................................................................................................................................ 40 BODY DIMENSIONS ................................................................................................................................................................... 41 PASSENGER COMPARTMENT ................................................................................................................................................ 41 Seat Mounting Holes ......................................................................................................................................................... 41 RH Front Seat Front Mounting Hole Location ........................................................................................................................... 43 LH Front Seat Front Mounting Hole Location ............................................................................................................................ 44 Seat Position Diagrams .............................................................................................................................................................. 45 SgRP Front Seat Dimension ............................................................................................................................................... 45 Body Dimensions ....................................................................................................................................................................... 46 CARGO AREA ......................................................................................................................................................................... 46 Interior Dimensions ............................................................................................................................................................... 46 Overall ............................................................................................................................................................................... 46 Wheel Well Clearance ........................................................................................................................................................... 47 Cut-away side view - RH .................................................................................................................................................... 47 Wheel Well Clearance ........................................................................................................................................................... 48 Cut-away side view - LH..................................................................................................................................................... 48 Cutaway Wheel Well and Rear Views ................................................................................................................................... 49 Cutaway Overhead View ....................................................................................................................................................... 50 D-Ring Tie-Downs (If Equipped) ............................................................................................................................................ 51 SIGN AREA ................................................................................................................................................................................. 52 RH Exterior Dimensions ......................................................................................................................................................... 52 LH Exterior Dimensions.......................................................................................................................................................... 53 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 4 RH Slide Door Exterior Dimensions ....................................................................................................................................... 54 LH Slide Door Exterior Dimensions ........................................................................................................................................ 55 Hood Surface Exterior Dimensions ........................................................................................................................................ 56 Hood Surface Exterior Dimensions (continued) .................................................................................................................... 57 Back Door Sign Area .............................................................................................................................................................. 58 Back Door Window Opening Sign Area ................................................................................................................................. 59 EXTERIOR ................................................................................................................................................................................... 60 Front Door Opening Measurements ..................................................................................................................................... 60 RH Slide Door Opening Measurements — Without Slide Door Installed ............................................................................. 61 LH Slide Door Opening Measurements — Without Slide Door Installed .............................................................................. 62 RH Slide Door Opening Measurements — With Slide Door Installed ................................................................................... 63 LH Slide Door Opening Measurements — With Slide Door Installed ....................................................................................... 64 Back Door Opening Measurements .......................................................................................................................................... 65 Doors and Mirrors Dimensions .............................................................................................................................................. 66 Overhead View .................................................................................................................................................................. 66 Exterior Overall Dimensions .................................................................................................................................................. 67 UNIBODY AND FRAME ........................................................................................................................................................... 68 Cross-member and Body Mount Dimensions ................................................................................................................... 68 Cross-member and Body Mount Dimensions (continued) ................................................................................................ 69 ELECTRICAL ................................................................................................................................................................................ 70 FUEL SYSTEMS........................................................................................................................................................................... 71 FUEL SYSTEM PRECAUTIONS .................................................................................................................................................. 71 Fuel Pressure Release Procedure .......................................................................................................................................... 72 FILLER NECK AREAS ................................................................................................................................................................... 73 Chassis ................................................................................................................................................................................... 73 Fuel Filler Pipe and EVAP Canister Location .......................................................................................................................... 74 TANK LOCATION ........................................................................................................................................................................ 75 Tank Mounting ...................................................................................................................................................................... 75 Drilling Precaution Area ........................................................................................................................................................ 76 Fuel Tank — Floor Area ..................................................................................................................................................... 76 Drilling Precaution Area (continued) ..................................................................................................................................... 77 Drilling Precaution Area Filler Neck ....................................................................................................................................... 78 B-Pillar Area ....................................................................................................................................................................... 78 TRAILER TOW............................................................................................................................................................................. 79 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 5 COOLING.................................................................................................................................................................................... 80 Engine Cooling System .......................................................................................................................................................... 80 HVAC.......................................................................................................................................................................................... 81 Changes to the HVAC System ................................................................................................................................................ 81 HVAC System Component Locations ..................................................................................................................................... 81 Manual Air Conditioning System ....................................................................................................................................... 81 EXHAUST .................................................................................................................................................................................... 82 Exhaust System...................................................................................................................................................................... 82 Exhaust Measurements ......................................................................................................................................................... 83 Exhaust System - Precautions................................................................................................................................................ 84 WHEEL AND TIRE ....................................................................................................................................................................... 85 General .................................................................................................................................................................................. 85 STEERING AND SUSPENSION ..................................................................................................................................................... 86 Vehicle Handling Information ................................................................................................................................................ 86 DRIVELINE .................................................................................................................................................................................. 87 TRANSMISSION .......................................................................................................................................................................... 87 UNIBODY AND FRAME ............................................................................................................................................................... 87 Jacking and Lifting Points .......................................................................................................................................................... 87 HIGH STRENGTH STEEL LOCATIONS .......................................................................................................................................... 88 Precaution in Repairing High Strength Steel (HSS) ................................................................................................................ 88 High Strength Steel Locations ................................................................................................................................................... 89 WELDING ................................................................................................................................................................................... 92 VEHICLE INTERIOR ..................................................................................................................................................................... 95 Modifications in the Vehicle Interior ..................................................................................................................................... 95 General .............................................................................................................................................................................. 95 Modifications in the Roof of the Cabin............................................................................................................................. 95 PAINT GENERAL INFORMATION ................................................................................................................................................ 95 ADHESIVE INFORMATION .......................................................................................................................................................... 96 MSDS Information ............................................................................................................................................................. 96 REPLACING BOLTS ..................................................................................................................................................................... 97 Tightening Torque Table........................................................................................................................................................ 97 ADD ON EQUIPMENT ................................................................................................................................................................ 98 ANTI-CORROSION PROTECTION ............................................................................................................................................. 98 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 6 SHELVING AND BULKHEAD INSTALLATION .............................................................................................................................. 98 Bulkhead ............................................................................................................................................................................ 98 H Body Side and D-pillar Inner .......................................................................................................................................... 99 RH Body Side and D-pillar Inner .......................................................................................................................................... 100 LH Body Side and D-pillar Inner ....................................................................................................................................... 101 Floor ................................................................................................................................................................................ 102 Interior Roof Bow Mounting Points ................................................................................................................................ 103 ROOF RACKS ............................................................................................................................................................................ 104 RECOMMENDED FLUIDS AND LUBRICANTS ............................................................................................................................ 106 SPECIFICATIONS:.................................................................................................................................................................. 106 Precaution for Fuel (Unleaded Regular Gasoline Recommended) ...................................................................................... 107 Engine Coolant Recommendation ....................................................................................................................................... 107 SUSPENSION ............................................................................................................................................................................ 108 General Specification (Front) .............................................................................................................................................. 108 Front Wheel Alignment (Unladen*1) .................................................................................................................................. 108 Wheel Turning Angle ........................................................................................................................................................... 109 General Specification (Rear) ................................................................................................................................................ 110 Rear Wheel Alignment (Unladen*)...................................................................................................................................... 110 Wheels and Tires ..................................................................................................................................................................... 111 Bulbs ........................................................................................................................................................................................ 111 Exterior Bulbs ...................................................................................................................................................................... 111 Interior lamp/Illumination ................................................................................................................................................... 111 Battery ................................................................................................................................................................................. 111 Acronyms ................................................................................................................................................................................. 112 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 7 GENERAL INFORMATION FOREWORD This manual contains body builder’s information for the 2015 and 2016 Chevrolet City Express Cargo Vehicle. In order to assure your safety and the efficient functioning of the vehicle, this guide should be read thoroughly. All information in this guide is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice. IMPORTANT SAFETY NOTICE The proper performance of procedures is essential for both the safety of the technician and the efficient functioning of the vehicle. The methods in this Body Builder’s Guide are described in such a manner that they may be performed safely and accurately. Methods vary with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using procedures, tools or parts which are not specifically recommended by General Motors and/or the OEM must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the method selected. DISCLAIMER All information, specifications and illustrations in this manual are those in effect at the time of printing. General Motors and/or the OEM reserves the right to change specifications or design without notice and without obligation. The body builder, conversion company, aftermarket equipment manufacturer, second stage manufacturer, upfitter, dealer and the vehicle purchaser are responsible to abide by the regulations issued by the National Highway Traffic Safety Administration (NHTSA), the Occupational Safety and Health Act (OSHA), state, local, or provincial government laws. These regulations and laws may require the installation of additional equipment for the intended vehicle uses. IMPORTANT REGULATORY INFORMATION Emission standards and motor vehicle safety standards for new vehicles and equipment have been established by the United States and Canadian Governments under the provisions of the Clean Air Act, the Noise Control Act, and the National Traffic and Motor Vehicle Safety Act in the U.S., and the Canadian Motor Vehicle Safety Act in Canada. These Acts govern General Motors and the Original Equipment Manufacturer of the Chevrolet City Express Cargo vehicles. They also govern dealers, body builders, and all others who manufacture and market new motor vehicles and equipment. Part 568 of the Title 49 Code of Federal Regulations (CFR) describes requirements for intermediate manufacturers, final-stage manufacturers, and manufacturers who assume legal responsibility for a vehicle. This Body Builder’s Guide (Guide) partially fulfills both General Motors and the OEM’s obligations as the original equipment manufacturer. Additionally, this guide identifies regulatory requirements to assist intermediate and final stage manufacturers to determine their obligations to conform to these standards. Compliance labels affixed to Chevrolet City Express Cargo vehicles provide the status of initial compliance at the date of manufacture by the Original Equipment Manufacturer (OEM). Subsequent modifications made to this vehicle may affect the final certification of the engine, vehicle or equipment. Any and all body builders, conversion companies, or dealers have the responsibility to certify the altered vehicle and equipment complies or continues to comply with all 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 8 IMPORTANT REGULATORY INFORMATION (continued) applicable motor vehicle safety standards and emissions regulations. The vehicle modifier is responsible for making sure the modifications or installed equipment does not affect the safety of the vehicle, which may result in a collision, serious personal injury or death. General Motors and/or the OEM does not assume the responsibility as the final stage manufacturer for modified or altered vehicles. General Motors and/or the OEM is not responsible for the final certification, product liability claims, or warranty claims, resulting from any component, assembly, or system being altered by the body builder, Conversion Company, dealer or vehicle purchaser. General Motors and/or the OEM is not responsible for modifications which cause the vehicle to become noncompliant with any of the motor vehicle safety standards, emissions regulations, or modifications that cause the vehicle to be or become defective or unsafe. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 9 SAFETY INFORMATION SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PRECAUTIONS Precaution for Supplemental Restraint System (SRS) “Airbag” and “Belt Pre-Tensioner” WARNING: To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized General Motors dealer. Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. • Do not use electrical test equipment on any circuit related to the SRS. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Precautions When Using power tools (air or electric) and hammers. WARNING: When working near the Air bag Diagnosis Sensor Unit or other Air bag System sensors with the ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury. When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the battery, and wait at least 3 minutes before performing any service. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENT LOCATIONS Pa g e | 10 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 11 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENT LOCATIONS (continued) 1. Driver air bag module 2. Passenger air bag OFF indicator 3. Front passenger air bag module 4. Spiral cable 5. Air bag diagnosis sensor unit 6. Instrument Cluster (SRS warning light) (view with center console removed) 7. Crash zone sensor 8. Front LH seat belt pre-tensioner (RH similar) (view with front grille removed) (view with lower center pillar cover removed) 9. Front side air bag satellite sensor LH (RH similar) 10. Front LH side air bag module (RH similar) 11. Front door satellite sensor LH (RH similar) 12. (A) Occupant classification control unit (B) Occupant classification system sensor (view with front door finisher LH removed) 13. LH side front curtain air bag module (RH similar) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 12 OCCUPANT CLASSIFICATION SYSTEM WARNING: After removal and installation of the front passenger seat, a zero point reset function must be performed by a Chevrolet dealer using a special tool. If zero point reset is not performed, the occupant classification system may not operate normally which may increase the risk of serious us injury or death in a collision. WARNING: Do not disturb or modify the front passenger seat wiring. Failure to follow this instruction may cause incorrect operation of the occupant classification system and front passenger air bag or system failure and may increase the risk of serious injury or death in a collision. The front passenger seat is equipped with seat weight sensors as part of the supplemental restraints occupant classification system. The occupant classification sensors (weight sensors) are on the seat cushion frame under the front passenger seat and are designed to detect an occupant and objects on the seat. The front passenger air bag status lamp is illuminated when the system is disabled. For occupant classification system and front passenger air bag operation, refer to the Owner’s Manual. For repair of the front passenger seat, occupant classification system, air bags or if an air bag warning lamp is illuminated, refer to a Chevrolet dealer. For seat mounting and fastener torque specifications, refer to Seat Mounting Holes 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 13 FRONT AIR BAG DEPLOYMENT ZONES FRONT AIR BAG MODULE LOCATIONS WARNING: Modifications must not interfere with air bag modules or deployment zones. Damage to air bag modules may cause serious personal injury or death. Objects placed within air bag deployment zones may cause serious personal injury or death. NOTE: Do not add accessory items that, when installed, will interfere with the installed position of the air bag or the zones of the deploying air bags. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 14 Front Air Bag Modules — Overhead View = Air Bag Module Locations (No modifications in these areas.) 6 1 4 1 2 5 2 5 3 3 1. 2. 3. 4. 5. 6. Driver air bag module Side curtain air bag module, driver Side air bag module, driver Side air bag module, passenger Side curtain air bag module, passenger Front passenger air bag module 4 6 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 15 Front Air Bag Modules — Driver Side = Air Bag Module Locations (No modifications in these areas.) 1 2 3 Front of vehicle 1. Side curtain air bag module (located behind LH side of headlining and across windshield header) 2. Side air bag module (located at outboard side of driver seatback) 3. Driver air bag module (located in steering wheel) Front Air Bag Modules — Passenger Side = Air Bag Module Locations (No modifications in these areas.) 1 3 2 = Front of Vehicle 1. Side curtain air bag module (located behind RH side of headlining and across windshield header) Revision: 1.0 2. Front passenger air bag module (located in RH side of instrument panel) 3. Side air bag module (located at outboard side of passenger seatback) 11/12/2015 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Driver Air Bag Deployment Width A. Center of the driver air bag module housing B. 267.5 mm (10.53 in) C. Maximum lateral projection of the deployed driver air bag 535 mm (21.06 in) D. 267.5 mm (10.53 in) Pa g e | 17 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Front Passenger Air Bag Deployment Width A. Maximum lateral projection of the deployed front passenger air bag 475 mm (18.7 in) B. Center of front passenger air bag module housing C. 237.5 mm (9.35 in) D. Reference point: glove box striker inboard fastener E. 199 mm (7.83 in) F. 38.5 mm (1.52 in) Pa g e | 18 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Headlining Cut — Front Side Curtain Air Bags Clearance for Bulkhead Installation 1. Headlining 2. Driver side curtain air bag module 3. Portion of headlining to be cut off and discarded 4. Passenger side curtain air bag module A. 50 mm (1.97 in) B. 50 mm (1.97 in) C. Headlining cut line (50 mm [1.97 in] behind rear edge of side curtain air bag module’s rolled material) Pa g e | 19 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL AIR BAG DEPLOYMENT KEEP-OUT ZONES Front Air Bag Keep-Out Zones — Overhead View = Center of seat Reference point(s): 1. Instrument panel edge 2. Door glass trim edge 3. Seat center lines 4. Door glass trim edge Pa g e | 20 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Front Air Bag Keep-Out Zone — Driver Side View A. 635 mm (25 in) D. 405 mm (15.94 in) B. 510 mm (20.08 in) E. 915 mm (36.02 in) C. 685 mm (26.97 in) F. 355 mm (13.98 in) Pa g e | 21 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Front Air Bag Keep-Out Zone — Passenger Side View Reference point(s): 1. Zone follows windshield surface 2. Zone follows instrument panel surface contour A. 635 mm (25.00 in) B. 405 mm (15.94 in) C. 685 mm (26.97 in) D. 510 mm (20.08 in) Pa g e | 22 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL INFLATED AIR BAG ZONE DIMENSIONS Driver and Passenger Air Bag Inflation Zones — Forward View Reference point(s): 1. Door glass trim edge 2. Maximum inflated driver air bag 3. Vehicle center line 4. Maximum inflated front passenger air bag 5. Door glass trim edge A. 150 mm (5.91 in) E. 690 mm (27.17 in) between door glass trim edge and air bag B. 535 mm (21.06 in) F. 150 mm (5.91 in) C. 535 mm (21.06 in) G. 120 mm (4.72 in) D. 475 mm (18.70 in) H. 125 mm (4.92 in) between door glass trim edge and air bag. Pa g e | 23 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Front Air Bag Inflation Zones — Overhead View 1. Maximum inflated driver air bag 2. Maximum inflated front passenger air bag 3. Reference point: instrument panel seam A. 110 mm (4.33 in) B. 340 mm (13.39 in) between instrument panel and air bag. C. 645 mm (25.39 in) D. 40 mm (1.57 in) Pa g e | 24 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Front Air Bag Inflation Zones — Driver Side View 1. Maximum inflated side curtain air bag 3. Maximum inflated driver air bag. 2. Maximum inflated side air bag A. 760 mm (29.92 in) C. 350 mm (13.78 in) E. 200 mm (7.87 in) B. 750 mm (29.53 in) D. 550 mm (21.65 in) F. 110 mm (4.33 in) between instrument panel and air bag Pa g e | 25 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Front Air Bag Inflation Zones — Passenger Side View 1. Maximum inflated side curtain air bag 3. Maximum inflated front passenger air bag 2. Front edge of front passenger air bag module 4. Maximum inflated side air bag A. 760 mm (29.92 in) C. 645 mm (25.39 in) E. 350 mm (13.78 in) B. 750 mm (29.53 in) D. 550 mm (21.65 in) Pa g e | 26 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Side Curtain Air Bag Inflation Zones — Overhead View A. 210 mm (8.27 in) B. 60 mm (2.36 in) between door glass trim edge and air bag C. 60 mm (2.36 in) between door glass trim edge and air bag D. 210 mm (8.27 in) Pa g e | 27 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Side Air Bag Inflation Zones — Overhead View A. 200 mm (7.87 in) B. 115 mm (4.53 in) between door glass trim edge and air bag C. 115 mm (4.53 in) between door glass trim edge and air bag D. 200 mm (7.87 in) Pa g e | 28 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 29 ALTERED VEHICLES SAFETY INFORMATION Safety / Emissions - Certification Labels for Altered Vehicles USA: A person or company who alters a previously certified vehicle before the first purchase by the final customer in such a manner that its stated weight ratings are revised, is required by Federal Regulation (49 CFR Part 567.7) to affix an Altered Vehicle Certification Label in addition to the FMVSS and CMVSS Certification Label. The label must be affixed to the vehicle in the manner and form described in 49 CFR Part 567.4:       The label shall, unless riveted, be permanently affixed in such a manner that it cannot be removed without destroying or defacing it. The label shall be affixed to either the hinge pillar, B-pillar, or the door edge that meets the door-latch post next to the driver’s seating position or, if none of these locations is practicable, to the left side of the instrument panel (other permissible locations are also specified in 49 CFR Part 567.4). The lettering on the label shall be of a color that contrasts with the background of the label. The label shall contain the required statements in the English language and lettered in block capitals and numerals not less than three thirty-seconds of an inch high. The lettering shall be permanent. If typed or written, a protective clear cover may be necessary to prevent information from being wiped off. Label must not cover or obscure the FMVSS or CMVSS Certification Label. Canada: “Modifiers” of motor vehicles are required to affix a permanent label on vehicles that they manufacture bearing a statement of compliance as provided by Section 9 of the Canadian Motor Vehicle Safety Regulations. The vehicle modifier should affix a corporate label containing information shown on this page.       Insert the name of the company that altered the vehicle. Insert the month and year during which the alteration of the vehicle was completed. Insert a drawing of the National Safety Mark which includes their unique manufacturer number. Insert revised GVWR or PNBV capacities in kilograms of the vehicle as altered, where they differ from those shown on the original certification label. Insert the GAWR/PNBEs of the vehicle as altered, where they differ from those shown on the original certification label. Also, include the tire size, rim size and tire inflation pressure. Insert the vehicle type stated on the safety standard certification label provided by the OEM. The type of vehicle, in both official languages, or the word "TYPE" along with one of the following abbreviations, namely: o "AT/PA" to refer to an auto transporter, o "ATV/VTT" to refer to an all-terrain vehicle, o "B/A" to refer to a bus, o "BT/RA" to refer to a bus trailer, o "CD/CCC" to refer to a C-dolly, o "CMC/MCC" to refer to a competition motorcycle, o "LDD/CRC" to refer to a load divider dolly, o "MH/AC" to refer to a motor home, o "MC" to refer to a motorcycle, o "MPV/VTUM" to refer to a multi-purpose passenger vehicle, o "RUM/MUR" to refer to a restricted-use motorcycle, o "SB/AS" to refer to a school bus, o "TRA/REM" to refer to a trailer, o "TCD/CDC" to refer to a trailer converter dolly, o "TRU/CAM" to refer to a truck, o "TT/CT" to refer to a truck tractor. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 30 Safety / Emissions - Certification Labels for Altered Vehicles (continued) The label must meet the following requirements as described in Section 9:  Shall be permanently attached.  Shall be affixed adjacent to the original compliance label required by Section 6.  The lettering of the label shall be clear, indelible, indented, or embossed, or of a color that contrasts with the background color of the label, and in block capitals and numerals not less than 2.0 mm (0.1 in) high.  The label shall be permanently affixed to the same surface as that to which the FMVSS or CMVSS label is affixed. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 31 BRAKE COMPLIANCE GUIDELINES Brake Compliance Guidelines (FMVSS and CMVSS 135) The calculations and abbreviated definitions necessary for the Center of Gravity (CG) measurements are included in this manual. Any changes to the vehicle must still comply with FMVSS and CMVSS 135 allowing for the following provisions:      No alterations, modifications or replacements are made to the following systems: o parking brake o anti-lock brakes o engine vacuum o steering o wheels or tires o brakes o indicator lamps and wiring o brake system reservoir labeling o suspension ride height or spring rate The vehicle is re-balanced by the addition of an equivalent weight if components are permanently removed. The applicable GAWRs and GVWR weights are not exceeded. The applicable center of gravity limitations are met using the calculation methods in Center of Gravity (CG) section. The vertical distance from the ground to the completed vehicle center of gravity should not exceed 915 mm (36 in) at the Gross Vehicle Weight Rating (GVWR). 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL CENTER OF GRAVITY (CG) Vehicle Center of Gravity Measurement Process Introduction Pa g e | 32 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 33 Vehicle Center of Gravity Measurement Process List of Terms Term Definition CG h Horizontal distance from the center line of the front wheels to the center of gravity of the completed vehicle [mm (in)]. CG hl Horizontal distance from the center line of the front wheels to the center of gravity of the cargo [mm (in)]. If CG hl is not known, it may be estimated as the distance from the center line of the front wheels to the horizontal midpoint of the cargo area. CG hb Horizontal distance from the center line of the front wheels to the center of gravity of SUB and/or permanently attached equipment [mm (in)]. CG hp Horizontal distance from the center line of the front wheels to the center of gravity of the passenger load [mm (in)]. CG v Vertical distance from the ground to the center of gravity of the completed vehicle [mm (in)]. CG vb Vertical distance from the ground to the center of gravity of the SUB and/or permanently attached equipment [mm (in)]. CG vc Vertical distance from the ground to the center of gravity of the chassis (including cab); use 644 mm (25.3 in) in formulas (1) and (2). CG vl Vertical distance from the ground to the center of gravity of the cargo [mm (in)]. CG vp Vertical distance from the ground to the center of gravity of the passenger load [mm (in)]. GVW Actual Gross Vehicle Weight (pounds). GVW = W b + W c + W l + P GVWR Gross Vehicle Weight Rating of the vehicle [kg (lbs)]. hf Vertical distance between the front wheel center to ground line. hR Vertical distance between the rear wheel center to ground line. P Two passenger load 136 kg (300 lbs). Pf Passenger front load distribution [kg (lbs)]. P f = P – P r Pr SUB P x CG hp Passenger rearBody load distribution kgof (lbs). P rstructure = A Second Unit (SUB) consists the body and/or all the cargo carrying, work performing and/or load bearing components and/or equipment installed by a subsequent stage manufacturer. WB Wb Weight of the SUB and/or permanently attached added equipment [kg (lbs)]. WB Vehicle wheelbase [mm (in)]. Wc Weight of the vehicle (chassis and cab with fuel tank full), including options weight [kg (lbs)]. WF W FO Weight at the front wheels of the vehicle (chassis and cab with fuel tank full), including options weight at raised [kg (lbs)]. Weightposition at the front wheels of the vehicle (chassis and cab with fuel tank full), including options weight at Wl horizontal position Weight of the cargo[kg [kg(lbs)]. (lbs)]. Wp Weight of one passenger 68 kg (150 lbs) WR W rb Weight at the rear wheels of the vehicle (chassis and cab with fuel tank full), including options weight at raised position [kg (lbs)]. Weight at the rear wheels of the SUB and/or permanently attached added equipment [kg (lbs)]. W rl Weight at the cargo on the rear wheels [kg (lbs)]. W RO Weight at the rear wheels of the vehicle (chassis and cab with fuel tank full), including options weight at horizontal position [kg (lbs)]. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 34 Recommended Procedure Setup The following vehicle conditions should be verified prior to the measurement: • Vehicle Mass: Unloaded Vehicle Condition — Full fluids, spare tire, jack and tire tool. • Vehicle Posture: Unloaded Vehicle Condition — Adjust fender opening height to the design value. • Tire: Production parts shall be used. Tire pressure should be set to the specified pressure on the Tire Placard (located near the front LH door striker) once the vehicle has cooled. • Steering Wheel: Set to center of stroke with wheels pointing forward. • Seats: Adjust to reference position: • Longitudinal slide: Center of slide • Seat Lifter: Lowermost • Back angle: Set to normal driving condition or as close to 21° as possible. • Window Glass: Fully closed. • Other Parts: Production parts shall be used. • Road Surface to be used: Flat load cell. • Measurement Needed: Wheelbase, height of wheel centers from ground, lift heights, axle loads. • Shift Position: Neutral for both AT and MT vehicles. For safety, apply the parking brake. Measurement Methods 1. 2. 3. 4. 5. 6. 7. 8. 9. The vehicle should be at its unloaded vehicle condition, with full fluids and equipped with spare tire, jack and tools. Measure the wheelbase of the vehicle (WB) on the left-hand and right-hand sides of the vehicle and use the average value for the calculations. Measure the height of the 4 wheel centers from the ground to get h f and h r. Replace the shock absorbers with turnbuckles or solid link to avoid suspension travel. Increase the tire air pressure to the maximum recommended level specified in tire placard or Owner’s Manual. Once the vehicle is on the scale, set the parking brake to prevent vehicle from rolling. Measure the rear wheel load (W RO) in horizontal position. Raise the front of the vehicle with a hoist. Lift height should be at 0.5 m (1.6 ft) to start, with additional lift heights used to improve accuracy. (i.e., 0.5 m (1.6 ft) + a, 0.5 m (1.6 ft) + B). Measure the rear wheel load (W R) with raised vehicle. Change the lift height and measure the load on the rear wheel to find the relationship between lift and load. Measure two times for each lift height. Follow the same procedure from (7) to (9) by raising the rear wheels. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 35 Analysis Method 1. 2. 3. Plot the relation between the lift height (E) and the load on rear wheels (W RO) for raising the front wheels and the relation between the lift (E) and the load on the front wheels (W FO) for raising the rear wheels. Draw a regression line for both cases with front or rear wheels raised. Obtain the shifted load (∆ W RO and ∆ W FO) for the lift (E) according to the graph. ∆ W RO and ∆ W FO with E = 0.5 m (1.6 ft.) shall be representative value. Calculate the CG height by using the following equations: Results The center of gravity height (GC V) obtained is theoretically the same for both cases with the front or rear wheels raised. The accuracy of the results should be verified by performing several tests and averaging the results. Vehicle Center of Gravity Envelope — Unloaded Vehicle Weight (UVW) The diagrams below show the vehicle center of gravity envelope. [The center of gravity (CG) envelopes are not restrictive as long as the accessory reserve capacity (ARC) weight is lower than the envelope restriction weight] The CG zone shall not be exceeded by any upfitter package. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 36 Maximum Unloaded Vehicle Weight (UVW) Resource Chart — 2015 - 2016 Model Year Model Wheelba Max Payload ARC Max Cargo se GVWR Kg (lbs) Weight Kg (lbs) mm (in) Kg (lbs) *1 Kg (lbs) *3 *2 S 2,925 2,155 (115.2) (4,751) 353 (778) 181.4 (400) SV 2,925 2,155 (115.2) (4,751) 336 (742) 181.4 (400) S 2,925 2,155 (115.2) (4,751) 370 (816) 136 (300) 2,925 2,155 (115.2) (4,751) 353 (779) 136 (300) SV Refer to “Max C” Refer to “Max C” Max GAWR Kg (lbs) Base Curb Weight Kg (lbs) Front Rear — Front Rear Total 1,040 (2,293) 1,150 (2,535) USA 900.6 (1,985) 577.1 (1,272) 1,477.7 (3,258) 1,040 (2,293) 1,150 (2,535) USA 901.4 (1,987) 577.5 (1,273) 1,478.9 (3,260) 1,040 (2,293) 1,150 (2,535) USA 900.6 (1,985) 577.1 (1,272) 1,477.7 (3,258) 1,040 (2,293) 1,150 (2,535) USA 901.4 (1,987) 577.5 (1,273) 1,478.9 (3,260) *1: Load rating representing maximum allowable weight of people, cargo and body equipment and is reduced by optional equipment weight. [e.g. If CG for SV grade is on X = 1,303 mm; then Payload is 742 lbs. considering; 2 Passenger weight 300 lbs. + ARC 400 lbs. + Cargo 42 lbs. (If the CG is located closer to X = 1,397 mm; the Payload will increase due to mass distribution between front & rear axles).] *2: ARC aftermarket equipment Accessory Reserve Capacity for models with standard equipment. *3: When an ARC is installed, the Max Cargo capacity must be considered by the calculation for Max C. The CG hb can be approximated using the following formula: CG hb - The Max C can be approximated using the following formula: Max C = W rb x WB √ √b (FR GAWR – WFO – Pf) x WB After calculating Max C, GVW can be confirmed using the following formula: If GVW is greater than GVWR, then Max C must be reduced. WB – CG hb GVW = W c + W b + Max C + P 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 37 F/CMVSS 126 Electronic Stability Control Systems and F/CMVSS 135 Light Vehicle Brake Systems For Body Builder’s use and applicable to F/CMVSS 126 (1) and 135 (2), the vertical vehicle center of gravity location can be approximated by following the formula below: 1.) 2.) For GVC, please use the constant number described on "List of Terms" The Vertical Center of Gravity of completed vehicle at Unloaded Vehicle Weight + 136 Kg (300 lbs) Passenger Load CGv (Equation 1 and 2 above) must not exceed 846 mm (33 in), when measured from the ground at the Unloaded Vehicle Weight (UVW). 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL FMVSS AND CMVSS REGULATION LIST Standards For FMVSS standards, refer to the following website: www.nhtsa.gov/staticfiles/rulemaking/pdf/FMVSS-QuickRefGuide-HS811439.pdf For CMVSS standards, refer to the following website: www.tc.gc.ca/eng/acts-regulations/regulations-crc-c1038.htm Pa g e | 38 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 39 PRECAUTIONS Precautions for Electrical CAN (Controller Area Network) System • Do not modify the CAN system. • For additional information and identification of CAN system, refer to the Service Manual or contact GM Upfitter integration (www.gmupfitter.com/contacts/contact_us). 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 40 MODEL INFORMATION LABEL INFORMATION Identification Number 1 10 9 2 3 8 6 7 4 5 1. SRS air bag warning label 2. Air conditioning specification label 3. Transmission fluid specification label 4. Brake fluid warning label 5. Emission control information label 6. Tire and loading information label 7. Vehicle Identification Number 8. FMVSS/CMVSS Certification Label 9. Vehicle Identification Number (VIN) plate (Chassis number) (located near RH side of passenger seat) 10. SRS air bag warning label 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 41 BODY DIMENSIONS PASSENGER COMPARTMENT Seat Mounting Holes Front Seat Mounting Hole Dimensions Warning To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, the front passenger seat cannot be permanently removed. C D A A Front of Vehicle A. 380 mm (15.0 in) D. 550 mm (21.7 in) B. 375 mm (14.8 in) C. 560 mm (22.0 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 42 WARNING After removal and installation of the front passenger seat, a zero point reset function must be performed by a General Motors dealer using a special tool. If zero point reset is not performed, the occupant classification system may not operate normally which may increase the risk of serious injury or death in a collision. WARNING Do not disturb or modify the front passenger seat wiring. Failure to follow this instruction may cause incorrect operation of the occupant classification system and front passenger air bag or system failure and may increase the risk of serious injury or death in a collision. NOTE: For complete removal and installation procedure of the front seats, refer to the vehicle service manual. Basic seat installation uses the following sequence: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Before removing or installing the front seats, turn ignition switch OFF, disconnect both battery terminals and wait at least 3 minutes. Place the seat in the vehicle on the mounting stud with the locator pin correctly seated. Make sure there are no foreign objects under the seat, seat belts, pinched wires or carpeting between the seat mounting feet and floor. Fully connect the seat electrical connectors and make sure the inboard and outboard seat tracks are positioned evenly and locked in place. Install the front outboard seat bolt and hand tighten only. Install the front inboard seat bolt and tighten to 40 Nm (30 ft-lb). Tighten the front outboard seat bolt to 40 Nm (30 ft-lb). Move the seat forward and install the rear inboard seat bolt. Make sure both seat tracks are locked in place and tighten to 40 Nm (30 ft-lb). Install the rear outboard seat nut. Tighten to 40 Nm (30 ft-lb) and install the cap. Connect the battery. For front passenger seat, the zero point reset function must be performed by a Chevrolet dealer. Install all the seat fastener caps. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL RH Front Seat Front Mounting Hole Location 1. Inboard center of hole 2. Outboard center of hole X: 874.1 mm (34.4 in) X: 874.1 mm (34.4 in) Y: 188.6 mm (7.4 in) Y: 568 mm (22.4 in) Z: 265.6 mm (10.5 in) Z: 265.6 mm (10.5 in) Pa g e | 43 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL LH Front Seat Front Mounting Hole Location 1. Inboard center of hole 2. Outboard center of hole X: 874.1 mm (34.4 in) X: 874.1 mm (34.4 in) Y: -188.6 mm (-7.4 in) Y: -568 mm (-22.4 in) Z: 265.6 mm (10.5 in) Z: 265.6 mm (10.5 in) Pa g e | 44 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Seat Position Diagrams SgRP Front Seat Dimension NOTE: Seat is in full down and back position. A. 1,086.5 mm (42.77 in) D. 365 mm (14.37 in) B. 625.9 mm (24.64 in) C. 240 mm (9.44 in) Pa g e | 45 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 46 Body Dimensions CARGO AREA Interior Dimensions Overall H A A D C A. Length behind seat back in upright position: E. Maximum width at floor: • Rear-most: 2,022 mm (79.6 in) • Between slide doors: 1,480 mm (58.3 in) • Center: 2,144 mm (84.4 in) • Behind wheel wells: 1,390.8 mm (54.8 in) • Front-most: 2,262 mm (89.1 in) B. Maximum length at floor behind seat base: 2,103.5 mm (82.8 in) C. Maximum cargo height: 1,330 mm (52.4 in) D. Height at rear wheel center: 1,317 mm (51.9 in) F. Width at floor between wheel wells: 1,219.4 mm (48 in) G. Maximum height at rear cargo entrance with striker: 1,198 mm (47.2 in) H. Maximum width at center of window opening area: 1,500 mm (59.1 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Wheel Well Clearance Cut-away side view - RH NOTE: View from inside of vehicle. A. Seat position: • Rear-most: 856 mm (33.7 in) • Center: 952 mm (37.5 in) • Front-most: 1,096 mm (43.15 in) B. 296 mm (11.65 in) Pa g e | 47 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Wheel Well Clearance Cut-away side view - LH NOTE: View from inside of vehicle. A. Seat position: • Rear-most: 856 mm (33.7 in) • Center: 952 mm (37.5 in) • Front-most: 1,096 mm (43.15 in) B. 296 mm (11.65 in) Pa g e | 48 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 49 Cutaway Wheel Well and Rear Views A C D Rear H Left Hand Right Hand Front of Vehicle A. 261.8 mm (10.3 in) B. 1,175 mm (46.3 in) C. 1,250 mm (49.2 in) D. 1,260 mm (49.6 in) E. 725 mm (28.5 in) F. 271 mm (10.6 in) G. 785 mm (30.9 in) H. 288 mm (11.3 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 50 Cutaway Overhead View A C A Front of Vehicle A. 570 mm (22.4 in) B. 1,323 mm (52.1 in) C. 1,432 mm (56.4 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 51 D-Ring Tie-Downs (If Equipped) Front of Vehicle WARNING Do not exceed the maximum total D-ring tie down loading of 5,000N (1,124 lbs). * D-ring tie down location. A. 1,005 mm (39.6 in) B. 845 mm (33.3 in) D. 817 mm (32.2 in) E. 1,138 mm (44.8 in) C. 1,275 mm (50.2 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 52 SIGN AREA RH Exterior Dimensions A. 918 mm (36.1 in) B. 825 mm (32.5 in) C. 408 mm (16.1 in) D. 713 mm (28.1 in) E. Inset depth: 18 mm (0.7 in) F. 781 mm (30.7 in) G. 450 mm (17.7 in) H. 300 mm (11.8 in) J. 81 mm (3.2 in) K. 723 mm (28.5 in) L. 114 mm (4.5 in) M 1,115 mm (43.9 in) N. 693 mm (27.3 in) P. 180 mm (7.1 in) Q. 210 mm (8.3 in) R. 440 mm (17.3 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 53 LH Exterior Dimensions A. 674 mm (26.5 in) B. 836 mm (32.9 in) C. 987 mm (38.9 in) D. 1,059 mm (41.7 in) E. 1,429 mm (56.3 in) F. 1,587 mm (62.5 in) G. 210 mm (8.3 in) H. 322 mm (12.7 in) J. 383 mm (15.1 in) K. 760 mm (29.9 in) L. 1,330 mm (52.4 in) M. 2,670 mm (105.1 in) N. 250 mm (9.8 in) P. 785 mm (30.9 in) Q. 258 mm (10.2 in) R. Inset depth: 18 mm (0.7) S. 783 mm (30.8 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 54 RH Slide Door Exterior Dimensions Without Glass A. 1,450 mm (57.1 in) D. 1,002 mm (39.4 in) B. 941 mm (37.0 in) E. 165 mm (6.5 in) C. 858 mm (33.8 in) F. 200 mm (7.9 in) G. Inset depth: 27 mm (1.1 in) H. Inset depth: 27 mm (1.1 in) J. 450 mm (17.7 in) K. 870 mm (34.3 in) L. Inset depth: 14 mm (0.6 in) M. 75 mm (3.0 in) With Glass A. 1,450 mm (57.1 in) B. 941 mm (37.0 in) C. 858 mm (33.8 in) D. 1,002 mm (39.4 in) E. 165 mm (6.5 in) F. 200 mm (7.9 in) G. Inset depth: 27 mm (1.1 in) H. Inset depth: 27 mm (1.1 in) J. 452 mm (17.8 in) K. 874 mm (34.4 in) L. Inset depth: 14 mm (0.6 in) M. 86 mm (3.4 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 55 LH Slide Door Exterior Dimensions A. 1,450 mm (57.1 in) B. 941 mm (37.0 in) C. 858 mm (33.8 in) D. 1,002 mm (39.4 in) E. 165 mm (6.5 in) F. 200 mm (7.9 in) G. Inset depth: 27 mm (1.1 in) H. Inset depth: 27 mm (1.1 in) J. 450 mm (17.7 in) K. 870 mm (34.3 in) L. Inset depth: 14 mm (0.6 in) M. 75 mm (3.0 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 56 Hood Surface Exterior Dimensions A. 275 mm (10.8 in) B. 745 mm (29.3 in) D. 568 mm (22.4 in) E. 80 mm (3.1 in) C. 120 mm (4.7 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Hood Surface Exterior Dimensions (continued) A. Flat surface area: 1.026 m2 (1,590 in2) B. 1,479 mm (58.2 in) D. 55 mm (2.2 in) E. 140 mm (5.5 in) C. 310 mm (12.2 in) Pa g e | 57 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 58 Back Door Sign Area A. 50 mm (2.0 in) B. 61 mm (2.4 in) C. 580 mm (22.8 in) D. 796 mm (31.3 in) E. 128 mm (5.0 in) F. 75 mm (3.0 in) G. 36 mm (1.4 in) H. 54 mm (2.1 in) J. 70 mm (2.8 in) K. 628 mm (24.7 in) L. 30 mm (1.2 in) M. 255 mm (10.0 in) N. 643 mm (25.3 in) P. 77 mm (3.0 in) Q. 130 mm (5.1 in) R. 38 mm (1.5 in) S. 213 mm (8.4 in) T. 875 mm (34.4 in) U. 445 mm (17.5 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 59 Back Door Window Opening Sign Area 1. Door gap seam A. 128 mm (5.0 in) B. 426 mm (16.8 in) C. 455 mm (17.9 in) D. 488 mm (19.2 in) E. 438 mm (17.2 in) F. 750 mm (29.5 in) G. 782 mm (30.8) H. Inset depth: 11 mm (0.4 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 60 EXTERIOR Front Door Opening Measurements Front of Vehicle Without Door Seal and Interior Trim A. 1,191 mm (46.9 in) B. 870 mm (34.3 in) D. 715 mm (28.1 in) E. 88 mm (3.5 in) C. 1,278 mm (50.3 in) With Door Seal and Interior Trim A. 1,188 mm (46.8 in) B. 863 mm (34.0 in) D. 706 mm (27.8 in) E. 78 mm (3.1 in) C. 1,264 mm (49.8 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 61 RH Slide Door Opening Measurements — Without Slide Door Installed Front of Vehicle Without Door Seal and Interior Trim A. 818 mm (32.2 in) B. 735 mm (28.9 in) D. 1,181 mm (46.5 in) E. 27 mm (1.06 in) C. 1,181 mm (46.5 in) F. 1,181 mm (46.5 in) With Door Seal and Interior Trim 1. Headlining A. 812 mm (32.0 in) 1,168 mm (46.0 in) G. 22 mm (0.9 in) B. 728 mm (28.7 in) E. 35 mm (1.37 in) H. 190 mm (7.5 in) C. 1,168 mm (46.0 in) D. F. 1,168 mm (46.0 in) J. 617 mm (24.3 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 62 LH Slide Door Opening Measurements — Without Slide Door Installed Front of Vehicle Without Door Seal and Interior Trim A. 818 mm (32.2 in) B. 735 mm (28.9 in) C. 1,181 mm (46.5 in) D. 1,181 mm (46.5 in) E. 27 mm (1.06 in) With Door Seal and Interior Trim 1. Headlining A. 812 mm (32.0 in) F. 1,181 mm (46.5 in) mm (28.7 in) C. 1,168 mm (46.0 in) D. 1,168 mm (46.0 in) E. 35 mm (1.37 in) F. 1,168 mm (46.0 in) H. 190 mm (7.5 in) J. 617 mm (24.3 in) G. 22 mm (0.9 in) B. 728 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 63 RH Slide Door Opening Measurements — With Slide Door Installed Front of Vehicle Without Door Seal and Interior Trim A. 623 mm (24.5 in) B. 1,181 mm (46.5 in) C. 622 mm (24.5 in) D. 624 mm (24.6 in) E. 27 mm (1.06 in) With Door Seal and Interior Trim 1. Headlining A. 620 mm (24.4 in) B. 1,168 mm (46.0 in) C. 620 mm (24.4 in) D. 622 mm (24.5 in) E. 35 mm (1.37 in) F. 22 mm (0.9 in) G. 196 mm (7.7 in) H. 613 mm (24.1 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 64 LH Slide Door Opening Measurements — With Slide Door Installed Front of Vehicle Without Door Seal and Interior Trim A. 623 mm (24.5 in) B. 1,181 mm (46.5 in) C. 622 mm (24.5 in) D. 624 mm (24.6 in) E. 27 mm (1.06 in) With Door Seal and Interior Trim 1. Headlining A. 620 mm (24.4 in) B. 1,168 mm (46.0 in) C. 620 mm (24.4 in) D. 622 mm (24.5 in) E. 35 mm (1.37 in) F. 22 mm (0.9 in) G. 196 mm (7.7 in) H. 613 mm (24.1 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 65 Back Door Opening Measurements A. 1,175 mm (46.3 in) B. 1,238 mm (48.75 in) D. 1,250 mm (49.2 in) E. 193 mm (7.6 in) C. 1,260 mm (49.6 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 66 Doors and Mirrors Dimensions Overhead View A. 3,523 mm (138.7 in) B. With Mirrors Unfolded: 2,010 mm (79.1 in) D. 671 mm (26.4 in) E. 1,019 mm (40.1 in) F. 1,537 mm (60.5 in) C. With Mirrors Folded: 1,856 mm (73.1 in) G. 2,919 mm (114.9 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 67 Exterior Overall Dimensions A. 4,732.5 mm (186.3 in) B. 2,925 mm (115.2 in) C. 968.2 mm (38.1 in) D. 839.3 mm (33 in) E. 535.7 mm (21 in) F. 1,226.7 mm (48.3 in) G. 1,871.7 mm (73.7 in) H. 1,729.5 mm (68.1 in) Between front fender outboard edges: J. 1,525 mm (60 in) K. 1,520 mm (59.8 in) L. 996.6 mm (39.2 in) M. 1,710 mm (67.32 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 68 UNIBODY AND FRAME Cross-member and Body Mount Dimensions Front of Vehicle A. 4,311.65 mm (169.75 in) B. 520 mm (20.5 in) C. 508.05 mm (20 in) D. 376.94 mm (14.84 in) E. 68.14 mm (2.68 in) F. 343.87 mm (13.5 in) G. 472.97 mm (18.6 in) H. 844.21 mm (33.23 in) J. 329.36 mm (12.9 in) K. 909.28 mm (35.8 in) L. 383.22 mm (15.08 in) M. 220.22 mm (8.67 in) N. 272.91 mm (10.75 in) P. 326.32 mm (12.85 in) Q. 339.07 mm (13.35 in) R. 442.02 mm (17.4 in) S. 220.01 mm (8.66 in) T. 305.8 mm (12 in) U. 268.69 mm (10.6 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 69 Cross-member and Body Mount Dimensions (continued) NOTE: Floor sheet metal removed for clarity. : Front of vehicle. A. 1,009 mm (39.7 in) B. 1,134 mm (44.6 in) C. 1,250 mm (49.2 in) D. 1,225 mm (48.2 in) E. 1,331 mm (52.4 in) F. 1,275.4 mm (50.2 in) G. 1,428 mm (56.2 in) H. 70.22 mm (2.7 in) J. 69.74 mm (2.74 in) K. 71.46 mm (2.8 in) L. 96.96 mm (3.8 in) M. 91.31 mm (3.6 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 70 ELECTRICAL Refer to the BODY BUILDER MANUAL 2016 CHEVROLET CITY EXPRESS ELECTRICAL SECTION for detailed electrical information 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 71 FUEL SYSTEMS FUEL SYSTEM PRECAUTIONS General Modifications in the fuel system are not recommended, either in the circuit or the components. WARNING: When replacing fuel line parts, be sure to observe the following: • Put a “CAUTION: FLAMMABLE” sign in the workshop. • Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher. • Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area. WARNING: • Before removing fuel line parts, carry out the following procedures: • Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in safe area. • Release fuel pressure from the fuel lines. Refer to the Fuel Pressure Release Procedure in this section. • Disconnect the battery negative terminal. • Always replace O-rings and clamps with new ones. • Do not kink or twist hoses when they are being installed. • After connecting the fuel tube quick connectors, make sure the quick connectors are secure. Ensure that the connector and resin tube do not contact any adjacent parts. • After installing tubes, make sure there is no fuel leakage at connections in the following steps: • Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections. • Start the engine and rev it up and check for fuel leaks at connections. • Use only a Genuine OEM fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. • For servicing Evaporative Emission System parts, refer to the EC section in the service manual. • For servicing On Board Refueling Vapor Recovery (ORVR) parts, refer to the EC section in the service manual. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Fuel Pressure Release Procedure 1. Intelligent Power Distribution Module (IPDM) 2. Fuel pump fuse 20 (15A) 1. Remove fuel pump fuse (2) located in IPDM E/R (1). • Refer to the Body Builder Manual 2016 Chevrolet City Express Electrical Section for detailed fuse location information. 2. Start engine. 3. After engine stalls, crank it two or three times to release all fuel pressure. 4. Turn ignition switch OFF. 5. Reinstall fuel pump fuse after servicing fuel system. Pa g e | 72 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 73 FILLER NECK AREAS Chassis : Front of vehicle 1. B pillar rear edge A. 195 mm (7.7 in) B. 207 mm (8.1 in) C. 430 mm (16.9 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Fuel Filler Pipe and EVAP Canister Location : Front of vehicle. 1. EVAP canister assembly 2. Fuel tank protector 3. Fuel tank 4. Front tank strap 5. Clamp 6. Fuel filler hose 7. Rear tank strap 8. EVAP vent tube Pa g e | 74 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 75 TANK LOCATION Tank Mounting : Front of vehicle. 1. Fuel tank 2. Rear tank strap 4. EVAP canister assembly A. Fuel tank strap bolts 3. Front tank strap 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 76 Drilling Precaution Area WARNING: Do not damage the fuel tank or lines when drilling through the floor in the area shown or component failure and personal injury may occur. Fuel Tank — Floor Area All dimensions and reference lines are shown with cargo mat removed. : Front of vehicle. 1. Slide door weather-strip pinch weld (reference line) A. 1,366 mm (53.8 in) 2. Fuel tank drill precaution zone B. 730 mm (28.7 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 77 Drilling Precaution Area (continued) All dimensions and reference lines are shown with cargo mat removed. : Front of vehicle. 1. Front door jamb front at floor (reference line) 2. Fuel tank drill precaution zone A. 920 mm (36.2 in) C. 210 mm (38.3 in) B. 1,930 mm (76.0 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Drilling Precaution Area Filler Neck B-Pillar Area : Front of vehicle. 1. Fuel filler area drill precaution zone A. 300 mm (11.8 in) B. 400 mm (15.7 in) Pa g e | 78 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 79 TRAILER TOW Do not tow a trailer with this vehicle. This vehicle is not equipped with trailer tow equipment. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 80 COOLING Engine Cooling System CAUTION: No modification to the engine cooling system (radiator, radiator shroud, cooling fans, liquid cooling circuit, etc.) is allowed. Sufficient air passage to the radiator must be maintained, therefore, do not block the air passage through the radiator grille to the radiator with publicity plates, posters, trim or other decorative elements. Reduced air flow can cause overheating and could lead to component damage. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 81 HVAC Changes to the HVAC System Changes to the HVAC system are not recommended. For liquid connection information, service data and specifications, refer to the service manual. HVAC System Component Locations Manual Air Conditioning System 1. Front air control (shown with optional rear window defroster button). 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 82 EXHAUST Exhaust System Changes to the exhaust system are not recommended. 1. Intermediate exhaust tube 2. Exhaust bolt springs 3. Ring gasket 4. Front exhaust tube 5. Exhaust bolt springs 6. Ring gasket 7. Gasket 8. Main muffler 9. Ring gasket 10. Exhaust bolt springs 11. Tailpipe with secondary muffler 12. Heated oxygen sensor A. Always replace after every d isassembly 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 83 Exhaust Measurements : Front of vehicle . NOTE: Shown as viewed from below. 1. Leading edge of bracket 2. Front edge of main muffler 3. Rear edge of main muffler 4. Rear edge of body channel 5. Front edge of secondary muffler 6. Rear edge of secondary muffler 7. Fuel tank heat shield A. 1,470 mm (57.9 in) B. 745 mm (29.3 in) C. 670 mm (26.4 in) D. 120 mm (4.7 in) E. 265 mm (10.4 in) F. 460 mm (18.1 in) G. 122 mm (4.8 in) H. 297 mm (11.7 in) J. 460 mm (18.1 in) K. 240 mm (9.4 in) L. 730 mm (28.7 in) M. 200 mm (7.9 in) N. 200 mm (7.9 in) P. 1,002 mm (39.4 in) Q. 110 mm (4.3 in) R. 993 mm (39.1 in) S. 64 mm (2.5 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 84 Exhaust System - Precautions CAUTION: To prevent exhaust gas leaks and possible CO poisoning: • Always replace exhaust gaskets and ring gaskets with new ones when reassembling. • Temporarily tighten the nuts on the front and rear of the exhaust tubes. Check each part for interference with other components, and then tighten the nuts and bolts to specification. Inspection after Installation • Check exhaust tube joints for exhaust gas leaks and unusual noises with the engine running. • Check to ensure that mounting brackets and rubber insulators are installed properly and free from undue stress. Improper installation could result in excessive noise and vibration. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 85 WHEEL AND TIRE General The replacement of the tires with those other than the ones indicated by the OEM is not recommended. Using tires of different make, size, type or characteristics on the same axle is not allowed. Using non-recommended tires could affect the performance of the Vehicle Dynamic Control (VDC) or other vehicle components. The Chevrolet City Express Cargo vehicle is designed to use commercial (C) rated tires only. Do not use passenger rated tires. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 86 STEERING AND SUSPENSION Vehicle Handling Information WARNING: • Changes made to the vehicle that significantly affect the ride height may cause vehicle control problems during sharp turns or sudden steering maneuvers. Any maneuvers of this type could result in an accident. The steering gear, intermediate shaft, coupling shaft, linkage, column, and steering wheel should not be altered or relocated. Steering linkage travel should not be restricted. WARNING: • Because the heat from welding on or near the suspension or steering components may damage or weaken the components, it is not authorized. • Welding equipment should not be grounded to any of the suspension components. • Any new components attached to the steering column or its components must not interfere with the steering column performance during either normal operation or crash situations. • New components and/or the vehicle load must not exceed the front and rear GAWRs or the GVWR. NOTE: The aftermarket equipment manufacturer, second stage manufacturer, and upfitter are responsible for maintaining or restoring the front wheel alignment after modifications to the vehicle are complete. The straight ahead orientation of the steering wheel must be maintained when readjusting the front wheel alignment. Changes to the vehicle center of gravity will affect handling. The upfitter is responsible for maintaining compliance with the Federal or Canada Motor Vehicle Safety Standards in regards to the center of gravity and vehicle handling characteristics. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 87 DRIVELINE CAUTION: Any deviation from OEM specifications may adversely affect powertrain operation, including engine, transmission, or component reliability. The aftermarket equipment manufacturer, second stage manufacturer, and upfitter are responsible for maintaining the specifications after the completion of any modifications. TRANSMISSION CAUTION: • • • • The engine and transmission position relative to the shift linkage must not be altered. The transmission vent must not be altered, pinched, collapsed, restricted or relocated. The spacing for tool access for transmission adjustments or removal must be maintained. Transmission oil cooler lines should not be kinked, bent, or restricted. All oil cooler lines must be properly retained with adequate clips. • The shift cable, external transmission shift lever, and shift cable bracket must not be altered. • Transmission identification tags must not be removed or destroyed. • All transmission wire harness routing, locating clips, heat shielding, and clearance to the exhaust must be maintained as installed by the factory. UNIBODY AND FRAME WARNING: Failure to follow the recommendations below may weaken the vehicle structure, which could result in death or serious injury. • Do not modify or alter the front crush horns. Modifications or alterations could adversely affect the vehicle in a crash. The vehicle structure is a unibody design with high strength steel support areas. High strength steel locations are not intended for modification. Refer to HIGH STRENGTH STEEL LOCATIONS within this document. Jacking and Lifting Points Refer to the vehicle owner’s manual for proper jacking and lifting locations and Jack storage location. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 88 HIGH STRENGTH STEEL LOCATIONS Precaution in Repairing High Strength Steel (HSS) WARNING: • While working, suitable work clothes, a work cap and safety shoes must be worn. To prevent burns, a long sleeve shirt and trousers must also be worn and must not be taken off under any circumstance. • Before starting repair work, be sure to disconnect the negative terminal of the battery. • Pay attention to ventilation and health of the operators. • Paint and sealants may generate poisonous gases when heated by fire. WARNING:  Do not heat, bend, or cut high strength steel or the structural integrity of the vehicle may be compromised. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 89 High Strength Steel Locations The grey shading in the following illustrations indicate body areas with high strength steel (HSS). Front Front Left Side Front Right Side 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Right Side Left Side Rear Left Side Rear Right Side Pa g e | 90 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Rear Floor Pa g e | 91 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 92 WELDING WARNING: Do not heat, bend, or cut high strength steel or the structural integrity of the vehicle may be compromised. HSS is used for body panels in order to reduce vehicle weight. Accordingly, precautions in repairing automotive bodies made of HSS are described below: HSS Used in the Chevrolet City Express Cargo Vehicles Tensile strength 440 - 780 MPa 980 - 1310 MPa Major applicable parts • • • • • • Front inner pillar upper Front pillar hinge brace Outer front pillar reinforcement Other reinforcements Outer sill reinforcement Main back pillar Read the following precautions when repairing HSS: 1. Additional points to consider: • The repair of reinforcements (such as side members) by heating is not recommended since it may weaken the component. When heating is unavoidable, do not heat HSS parts above 550° C (1,022° F). Verify heating temperature with a thermometer (Crayontype and other similar type thermometers are appropriate). • When straightening body panels, use caution in pulling any HSS panel. Because HSS is very strong, pulling may cause deformation in adjacent portions of the body. In this case, increase the number of measuring points and carefully pull the HSS panel. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL WARNING: • When cutting HSS panels, avoid gas (torch) cutting if possible. Instead, use a saw to avoid weakening surrounding areas due to heat. If gas (torch) cutting is unavoidable, allow a minimum margin of 50 mm (1.97 in). Changing the material properties could alter performance in the event of a crash. WARNING: • When welding HSS panels, use spot welding whenever possible in order to minimize weakening surrounding areas due to heat. Changing the material properties could alter performance in the event of a crash. • If spot welding is impossible, use MIG welding. Do not use gas (torch) welding because it is inferior in welding strength and could have altered performance in the event of a crash.  The spot weld on HSS panels is harder than that of an ordinary steel panel. Therefore, when cutting spot welds on a HSS panel, use a low speed high torque drill (1,000 to 1,200 rpm) to increase drill bit durability and facilitate the operation.  SP150 HSS panels with a tensile strength of 785 to 981 N/mm 2 (80 to 100 kg/mm 2, 114 to 142 lb/sq in), used as reinforcement in the door guard beams, is too strong to repair. When these HSS parts are damaged, the outer panels also sustain substantial damage; therefore, the assembly parts must be replaced. Pa g e | 93 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 94 2. Precautions in spot welding HSS: This work should be performed under standard working conditions. Always note the following when spot welding HSS: • The electrode tip diameter must be sized properly according to the metal thickness. • The panel surfaces must fit flush to each other, leaving no gaps. • Follow the specifications for the proper welding pitch. NOTE: The minimum welding pitch varies with the thickness of panels to be welded. In general, observe the values in the following table. Note that excessively small pitch allows the current to flow through surrounding portions, resulting in poor welding strength. Thickness (T) Minimum pitch (L) mm (in) mm (in) 0.6 (0.024) 10 (0.39) or over 0.8 (0.031) 12 (0.47) or over 1.0 (0.039) 18 (0.71) or over 1.2 (0.047) 20 (0.79) or over 1.6 (0.063) 27 (1.06) or over 1.8 (0.071) 31 (1.22) or over 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 95 VEHICLE INTERIOR Modifications in the Vehicle Interior General WARNING: The body builder, conversion company or dealer are responsible for making sure the modifications or installed equipment do not affect the safety of the vehicle, including modifications which may result in a collision, property damage, personal injury or death, such as but not limited to: • The modifications should not affect the operation of the control units (pedals, switches, rods, etc.) located in the area affected by the modification. • The ergonomic access to the controls for the driver must not be prevented by the installation of new components. • The aftermarket equipment manufacturer, second stage manufacturer, and upfitter must ensure that any modifications that have been made to the cabin still meet the legal requirements regarding the interior and exterior characteristics. After any modification to the body that affect the acoustic and thermal insulation, the new and/or modified insulation must meet or exceed the original specifications. Any modifications made by the aftermarket equipment manufacturer, second stage manufacturer, and upfitter must be properly sealed to protect against corrosion. No new holes should be drilled to allow for attaching any new components to the roof of the cabin. Modifications in the Roof of the Cabin When attaching equipment to the roof, make sure that the added weight does not exceed the maximum roof load limit. All components that pass through the external sheet metal (for electric cables, telephone aerials, etc.) must be properly sealed. Only OEM approved products should be used. Changes to the center of gravity should not exceed the maximum authorized height. PAINT GENERAL INFORMATION The aftermarket equipment manufacturer, second stage manufacturer, and upfitter are responsible for repairing any damage to the paint incurred while modifying the vehicle. Only OEM specified paint should be used for these repairs. Refer to the Vehicle Service Manual for information about paint. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 96 ADHESIVE INFORMATION MSDS Information Contact the product supplier for the latest MSDS (Material Safety Data Sheet) information. Product Name Code/Number Supplier/Emergency Phone Numbers Sunstar Inc. Sunnex (adhesive for body) SH-310 06-1273HM Terostat (mastic adhesives) SA-461 SA-462 SA-463 www.sunstarea.co m 937-746-8575 Henkel Corporation www.henkel.com USA 1-248-583-9300 Chemtrec emergency 1-800-424-9300 EFTEC North America, L.L.C. Mastic adhesive PCC-13A Stiffener for outer panel PE7000 www.eftec.com 24 hour emergency 1-888-853-1758 Emergency transport 1-800-424-9300 NITTO Denko Betaseal adhesive (Direct glassing) www.nitto.com 81-6-6452-2101 Dow Chemical Co. 57302 www.dow.com 24 hour emergency 1-989-636-4400 Customer Information 1-800-258-2436 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 97 REPLACING BOLTS Tightening Torque Table Grade 4T 7T 9T Bolt size Bolt diameter * mm Tightening torque (Without lubricant) Pitch mm Hexagon head bolt Hexagon flange bolt N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb 1.0 5.5 0.56 4 49 7 0.71 5 62 1.25 13.5 1.4 10 — 17 1.7 13 — 1.0 13.5 1.4 10 — 17 1.7 13 — 1.5 28 2.9 21 — 35 3.6 26 — 1.25 28 2.9 21 — 35 3.6 26 — 1.75 45 4.6 33 — 55 5.6 41 — 1.25 45 4.6 33 — 65 6.6 48 — M6 6.0 M8 8.0 M10 10.0 M12 12.0 M14 14.0 1.5 80 8.2 59 — 100 10 74 — M6 6.0 1.0 9 0.92 7 80 11 1.1 8 97 M8 8.0 1.25 22 2.2 16 — 28 2.9 21 — 1.0 22 2.2 16 — 28 2.9 21 — M10 10.0 1.5 45 4.6 33 — 55 5.6 41 — 1.25 45 4.6 33 — 55 5.6 41 — M12 12.0 1.75 80 8.2 59 — 100 10 74 — 1.25 80 8.2 59 — 100 10 74 — M14 14.0 1.5 130 13 96 — 170 17 125 — M6 6.0 1.0 11 1.1 8 — 13.5 1.4 10 — M8 8.0 1.25 28 2.9 21 — 35 3.6 26 — 1.0 28 2.9 21 — 35 3.6 26 — M10 10.0 1.5 55 5.6 41 — 80 8.2 59 — 1.25 55 5.6 41 — 80 8.2 59 — M12 12.0 1.75 100 10 74 — 130 13 96 — 1.25 100 10 74 — 130 13 96 — 1.5 170 17 125 — 210 21 155 — M14 *Nominal diameter 14.0 1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 98 ADD ON EQUIPMENT ANTI-CORROSION PROTECTION Failure to refinish bare metal will result in corrosion. The basic steps to refinish bare metal are as follows: 1. Prep the metal surface(s) as follows: A. Remove burrs from the edges with a file or sandpaper. B. Thoroughly clean the metal with solvent and allow to completely dry. C. Apply self-etching primer to all bare metal. D. Allow primer to properly dry. 2. Apply base coat paint and allow to properly dry. 3. Apply clear coat and allow to properly dry. 4. Apply OEM approved Wax available at a Chevrolet dealer. SHELVING AND BULKHEAD INSTALLATION Bulkhead The bulkhead should be attached to the OEM supplied weld nuts in the roof cross member and the floor. No new attachment points should be added. Loading should be distributed evenly utilizing as many mounting points as possible. Before bulkhead installation, it is necessary to cut away the rear portion of the headlining to avoid interference with the side curtain air bags deployment zones. The headlining should not be trapped, pinched or glued to the bulkhead. To correctly measure the headlining cut line, refer to HEADLINING CUT — FRONT SIDE CURTAIN AIR BAGS CLEARANCE FOR BULKHEAD INSTALLATION. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 99 : Front of vehicle. * Weld nut locations for bulkhead installation; All bolts are M8 x 1.25 1. Mounting point loading not to exceed 10 kg (22 lbs) per point. Total loading across these 4 mounting points not to exceed 40 kg (88 lbs). 2. Mounting point loading not to exceed 10 kg (22 lbs) per point. Points may be plugged with M8 bolts. 3. Mounting point loading not to exceed 10 kg (22 lbs) per point. Total loading across these 4 mounting points not to exceed 40 kg (88 lbs). A. 165 mm (6.5 in) B. 138 mm (5.4 in) C. 375 mm (14.8 in) D. 255 mm (10.0 in) E. 1,125 mm (44.3 in) F. 1,135 mm (44.7 in) G. 173 mm (6.8 in) H. 193 mm (7.6 in) H Body Side and D-pillar Inner RH body side inner as viewed from inside the vehicle. Loading should be distributed evenly, utilizing as many mounting points as possible. * Weld nut locations; All bolts are M8 x 1.25. 1. Bulkhead mounting weld nut Mounting point loading not to exceed 10 kg (22 lbs). Point may be plugged with M8 bolt. 2. Mounting point loading not to exceed 10 kg (22 lbs) per point. Maximum loading across these 2 mounting points not to exceed 20 kg (44 lbs). 3. Mounting point loading not to exceed 10 kg (22 lbs). A. 925 mm (36.42 in) B. 1,091 mm (42.95 in) C. 1,035 mm (40.7 in) D. 60 mm (2.4 in) G. 795 mm (31.3 in) E. 805 mm (31.7 in) F. 1,092 mm (43.0 in) From weld nut to metal floor 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 100 RH Body Side and D-pillar Inner RH body side inner as viewed from inside the vehicle. Loading should be distributed evenly, utilizing as many mounting points as possible. Front of Vehicle * Weld nut locations; All bolts are M8 x 1.25. 1. Bulkhead mounting weld nut Mounting point loading not to exceed 10 kg (22 lbs). Point may be plugged with M8 bolt. 2. Mounting point loading not to exceed 10 kg (22 lbs) per point. Maximum loading across these 2 mounting points not to exceed 20 kg (44 lbs). 3. Mounting point loading not to exceed 10 kg (22 lbs). A. 925 mm (36.42 in) B. 1,091 mm (42.95 in) C. 1,035 mm (40.7 in) D. 60 mm (2.4 in) G. 795 mm (31.3 in) E. 805 mm (31.7 in) F. 1,092 mm (43.0 in) From weld nut to metal floor 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 101 LH Body Side and D-pillar Inner LH body side inner as viewed from inside the vehicle. Loading should be distributed evenly, utilizing as many mounting points as possible : Front of vehicle. * Weld nut locations; All bolts are M8 x 1.25 1. Mounting point loading not to exceed 10 kg (22 lbs). 2. Mounting point loading not to exceed 10 kg (22 lbs) per point. Total loading across these 2 mounting points not to exceed 20 kg (44 lbs). 3. Bulkhead mounting weld nut Mounting point loading not to exceed 10 kg (22 lbs). Point may be plugged with M8 bolt. A. 795 mm (31.3 in) B. 1,092 mm (43.0 in) C. 805 mm (31.7 in) From weld nut to metal floor D. 60 mm (2.4 in) G. 925 mm (36.42 in) E. 1,035 mm (40.7 in) F. 1,091 mm (42.95 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 102 Floor The shelves bolt to the same location on the floor as the D-rings (if equipped). Loading should be distributed evenly utilizing as many mounting points as possible. : Front of vehicle. * Bolt locations for shelving installation; All bolts are M8 x 1.25 Mounting point loading not to exceed 10 kg (22 lbs) per point. A. 817 mm (32.2 in) B. 845 mm (33.3 in) C. 1,005 mm (39.6 in) D. 840 mm (33.1 in) E. 817 mm (32.2 in) F. 1,138 mm (44.8 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 103 Interior Roof Bow Mounting Points Loading should be distributed evenly, utilizing as many mounting points as possible. Front of Vehicle * Weld nut locations; All bolts are M6 x 1.0 Mounting point loading not to exceed 5 kg (11 lbs) per point. Total loading across all 4 weld nuts not to exceed 20 kg (44 lbs). Do not exceed a depth of 38 mm (1.5 in) for all 4 weld nuts. 1. Roof bow 2. Bulkhead roof bow 4. Slide door opening lower pinch weld 5. Rear door striker weld nuts A. 790 mm (31.1 in) D. 98 mm (3.9 in) B. 420 mm (16.5 in) 3. Windshield header C. 617 mm (24.3 in) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 104 ROOF RACKS WARNING: Drive extra carefully when the vehicle is loaded at or near the cargo carrying capacity, especially if the significant portion of that load is carried on the roof rack. Heavy loading of the roof rack has the potential to affect the vehicle stability and handling during sudden or abnormal handling maneuvers. Roof rack load should be evenly distributed. Do not exceed maximum roof rack load weight capacity. Properly secure all cargo with ropes or straps to help prevent it from sliding or shifting. In a sudden stop or collision, unsecured cargo could cause personal injury. To avoid personal injury, use care when placing or removing items from the roof rack. If you cannot comfortably lift the items onto the roof rack from the ground, use a ladder or stool. CAUTION: Always distribute the cargo evenly on the roof rack. Do not load more than 100 kg (220.5 lbs) for “LS” model and 101 kg (220.5 lbs) for “LT” model utilizing all 3 pairs of roof rack mounting points. The maximum load per pair of roof rack mounting points is 33.3 kg (73.4 lbs) for “LS” model and 33.6 kg (74.1 lbs) for “LT” model. The satellite radio antenna (if equipped) is located on the roof. Do not cover the antenna; it may affect the reception of the device. The factory installed weld nuts are the only OEM approved attachment points for the installation of a roof rack. Use bolts for attaching the roof racks. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 105 Front of vehicle. NOTE: • Weld nut locations, all bolts are M8 x 1.25. • For maximum load strength, ensure the bolt thread depth is at least 12 mm (0.5 in) depth. • Do not exceed a depth of 24 mm (0.9 in) for the two front weld nuts. A. 1,004 mm (39.5 in) B. 630 mm (24.8 in) C. 1,117 mm (44.0 in) D. 1,113 mm (43.8 in) E. 1,128 mm (44.4 in) F. 214 mm (8.4 in) G. 60.3 mm (2.4 in) H. 800 mm (31.5 in) CAUTION: To help prevent water leaks: • Do not reuse plastic plugs or seals. • Use High Performance Thread Sealant 999MP-AM002P (available from a Chevrolet dealer), or equivalent (Permatex 56521 or Loctite 565) on bolts before installing. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL RECOMMENDED FLUIDS AND LUBRICANTS SPECIFICATIONS: *1: For further details, refer to Precaution for Fuel. *2: For further details, refer to Engine Oil Recommendation. *3: For further details, refer to Engine Coolant Recommendation. *4: Available through a CHEVROLET dealer. *5: For further details, see “Air conditioner specification label” on the underside of the hood. *6: For further details, see “Air conditioner specification label” on the underside of the hood. Pa g e | 106 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 107 Precaution for Fuel (Unleaded Regular Gasoline Recommended) Use unleaded regular gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (Research Octane number 91). CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three-way catalyst Do not use E-85 fuel (85% fuel ethanol, 15% unleaded gasoline) unless the vehicle is specifically designed for E-85 fuel (i.e., Flexible Fuel Vehicle — FFV Models). Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity. Engine Oil Recommendation General Motors recommends the use of a resource conserving oil in order to improve fuel economy. Select only engine oils that meet the American Petroleum Institute (API) certification and International Lubricant Standardization and Approval Committee (ILSAC) certification and SAE viscosity standard. These oils have the API certification mark on the front of the container. Oils which do not have the specified quality label should not be used as they could cause engine damage. API certification mark API service symbol Engine Coolant Recommendation The engine cooling system is filled at the factory with a pre-diluted mixture of 50% Genuine OEM Long Life Antifreeze/Coolant (blue) and 50% water to provide year round antifreeze and coolant protection. The antifreeze solution contains rust and corrosion inhibitors. Additional cooling system additives are not necessary. WARNING:  Never remove the radiator or coolant reservoir cap when the engine is hot. Wait until the engine and radiator cool down. Serious burns could be caused by high pressure fluid escaping from the radiator.  The radiator is equipped with a pressure type radiator cap. To prevent engine damage, use only a Genuine OEM radiator cap.  When adding or replacing coolant, be sure to use only OEM Long Life Antifreeze/ Coolant (blue) or equivalent. Genuine OEM Long Life Antifreeze/Coolant (blue) is pre-diluted to provide antifreeze protection to -34° F (-37° C).  If additional freeze protection is needed due to weather where the vehicle is operated, add OEM long life Antifreeze/Coolant (blue) concentrate following the directions on the container. If an equivalent coolant other than OEM Long Life Antifreeze/Coolant (blue) is used, follow the coolant manufacturer’s instructions to maintain minimum antifreeze protection to -34° F (-37° C). The use of other types of coolant solutions other than OEM Long Life Antifreeze/Coolant (blue) or equivalent may damage the engine cooling system.  Mixing any other type of coolant other than OEM Long Life Antifreeze/Coolant (blue), including The OEM Long Life Antifreeze/Coolant (green), or the use of non-distilled water will reduce the life expectancy of the factory filled coolant. CAUTION: 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 108 SUSPENSION General Specification (Front) Front: independent strut Rear: multi-leaf with solid axle Front: twin tube strut Rear: twin tube Front solid stabilizer bar (standard equipment) Suspension type Shock absorber type Stabilizer Front Wheel Alignment (Unladen*1) Camber *2 Degree minute (decimal degree) LH and RH Caster *3 Degree minute (decimal degree) LH and RH Kingpin inclination Degree minute (decimal degree) LH and RH Total toe-in Total toe-in distance (A – B) Minimum Nominal Maximum Minimum Nominal Maximum Minimum Nominal Maximum -1° 05’ (-1.08°) -0° 20’ (-0.33°) 0° 25’ (0.42°) 3° 25’ (3.42°) 4° 10’ (4.17°) 4° 55’ (4.92°) 11° 10’ (11.17°) 11° 55’ (11.92°) 12° 40’ (12.67°) Minimum Out 1.0 mm (Out 0.039 in) In 1.0 mm (In 0.039 in) In 3.0 mm (In 0.118 in) In 0° 01’ (0.02°) In 0° 06’ (0.10°) In 0° 11’ (0.18°) Nominal Maximum Total toe angle (LH and RH) Degree minute (decimal degree) Minimum Nominal Maximum *1: Fuel, radiator coolant, and engine oil are full. Spare tire, jack, hand tools, and mats are in designated positions. *2: The RH camber angle shall be 0° 0’ ±0° 45’ (0.0° ±0.75°) with respect to the LH camber angle. *3: For the caster angle, the difference between right and left against the ground surface shall be ± 0° 45’ (±0.75°) maximum. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 109 Wheel Turning Angle Inner wheel angle (A) Minimum 36° 55’ (36.92°) Degree minute (decimal degree) Nominal 39° 55’ (39.92°) Maximum 40° 55’ (40.92°) Nominal 33° 35’ (33.58°) Outer wheel angle (B) Degree minute (decimal degree) 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 110 General Specification (Rear) Suspension type Rigid axle with semi-elliptic leaf spring Shock absorber type Double-acting hydraulic Rear Wheel Alignment (Unladen*) Camber* Minimum -2° 0’ (-2.0°) Degree minute (decimal degree) Nominal -1° 30’ (-1.5°) Maximum -1° 0’ (-1.0°) Minimum Out 2 mm (0.079 in) Nominal In 3 mm (0.118 in) Maximum In 8 mm (0.315 in) Total toe-in angle Minimum Out 0° 13’ 12’’ (0.22°) Degree minute (decimal degree) Nominal In 0° 16’ 48’’ (0.28°) Maximum In 0° 46’ 48’’ (0.78°) Total toe-in Total toe-in distance (A – B) *: Fuel, radiator coolant, and engine oil are full. Spare tire, jack, hand tools, and mats are in designated positions. 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Pa g e | 111 Wheels and Tires Grade Road wheel Tire Size Spare tire size LS 185/60R15C 94/92T * 15X5.5JJ Steel LT * Use commercial (C) rated tires only. Do not use passenger rated tires. 185/60R15C 94/92T * Wheel Dimensions Diameter 15 in Width 168 mm (6.61 in) Offset 45 mm (1.77 in) Bolt pattern 5 x 114.3 mm Center bore 66 + 0.1 mm / -0.00 mm Lug nut thread pitch M12 X 1.25 Brake caliper clearance 2.5 mm (0.10) Bulbs Exterior Bulbs Wattage (W)* 28/8 Bulb No.* 3457 NAK Headlamp low/high 60/55 Halogen H13 Stop/tail lamp 27/7 3047K Turn signal lamp 27 3157AK Back-up lamp 16 921 High-mounted stop lamp 16 W16W License plate lamp 5 T10 Front combination lamp Item Turn signal/parking lamp Rear combination lamp * Always check with an authorized General Motors dealer for the latest parts information. Interior lamp/Illumination Item Wattage (W)* Bulb No.* Front room/map lamp 5 W5W Cargo lamp 5 W5W Battery Application → Standard Type* GR21R Capacity (20 HR) minimum V-AH 12 - 49 Cold Cranking Current A [For reference value at -18°C (0°F)] 470 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Acronyms Acronym Description 2WD Two Wheel Drive ABS Anti-lock Braking System AC Alternating Current A/C Air Conditioning AKI Anti-Knock Index AM/FM Amplitude Modulated/Frequency Modulated API American Petroleum Institute ARC Accessory Reserve Capacity A/T Automatic Transmission AT Auto Transporter ATV All-Terrain Vehicle BCM Body Control Module BT Bus Trailer CAN Controller Area Network CAN-H Controller Area Network – High CAN-L Controller Area Network – Low CD C-Dolly CG Center of Gravity CMVSS Canadian Motor Vehicle Safety Standards DTCs Diagnostic Trouble Codes ECM Engine Control Module EGI Electronic Gasoline Injection EPS Electric Power Steering EVAP Evaporative Emission FCC Federal Communications Commission (USA) FFV Flexible Fuel Vehicle FMVSS Federal Motor Vehicle Safety Standards GAW Gross Axle Weight Pa g e | 112 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Acronym Description GAWR Gross Axle Weight Rating GCWR Gross Combination Weight Rating GVW Gross Vehicle Weight GVWR Gross Vehicle Weight Rating H.S. Harness Side HSS High Strength Steel HVAC Heating, Ventilation, & Air Conditioning IC Inflatable Curtain IDs Identifications ILSAC International Lubricant Standardization and Approval Committee IPDM E/R Intelligent Power Distribution Module Engine Room LDD Load Divider Dolly MH Motor Home MIL Malfunction Indicator Light MPV Multi-purpose Passenger Vehicle MSDS Material Safety Data Sheet NHTSA National Highway Traffic Safety Administration NNA Nissan North America OEM Original Equipment Manufacturer ORVR On-Board Refueling Vapor Recovery OSHA Occupational Safety and Health Act RF Radio Frequency RFI Radio Frequency Interference RKE Remote Keyless Entry Pa g e | 113 2015-16 CHEVROLET CITY EXPRESS CARGO VAN BODY BUILDER MANUAL Acronym Description RSS Rear Sonar System RPM Revolutions Per Minute SAE Society of Automotive Engineers SB School Bus SgRP Seating Reference Point Acronym Description SRS Supplemental Restraint System SUB Second Unit Body TCD Trailer Converter Dolly TCM Transmission Control Module TPS Throttle Position Sensor TRA Trailer TRU Truck TT Truck Tractor USB Universal Serial Bus UVW Unloaded Vehicle Weight VDC Vehicle Dynamic Control VIN Vehicle Identification Number Pa g e | 114