Chevrolet - CK TRUCK - Owners Manual - 2003 - 2003

PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT i BODY BUILDERS INSTRUCTIONS .......................................................................................................................................................... 1 Section 0 – General Instructions ..................................................................................................................................................... 1 Section 1 – Body................................................................................................................................................................................ 2 Conversions ................................................................................................................................................................................ 3 Air Conditioning .......................................................................................................................................................................... 3 Rear Air Conditioning .................................................................................................................................................................. 3 Section 2 – Frame ............................................................................................................................................................................. 4 Flanges ....................................................................................................................................................................................... 4 Holes ........................................................................................................................................................................................... 4 Welding ....................................................................................................................................................................................... 5 Alterations ................................................................................................................................................................................... 5 Shear Plate Attachments ............................................................................................................................................................ 5 Section 3 – Front Suspension .......................................................................................................................................................... 6 Section 4 – Rear Suspension ........................................................................................................................................................... 6 Section 5 – Brakes ............................................................................................................................................................................ 6 Section 6 – Engine............................................................................................................................................................................. 7 Section 7 – Transmission .................................................................................................................................................................. 9 Powertrain Specifications and Line-Up Charts ................................................................................................................... 10 Specifications — Automatic Transmissions ..................................................................................................................... 10 Automatic Transmission/Engine Availability Matrix .......................................................................................................... 10 Specifications — Manual Transmissions .......................................................................................................................... 11 Section 8 – Fuel and Exhaust ......................................................................................................................................................... 11 Fuel Systems ............................................................................................................................................................................ 11 Fuel Fill ...................................................................................................................................................................................... 12 Fuel Lines .................................................................................................................................................................................. 12 Fuel Tank ................................................................................................................................................................................... 13 Gaseous Fuel Conversions ....................................................................................................................................................... 13 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT ii BODY BUILDERS INSTRUCTIONS – Continued Exhaust System ........................................................................................................................................................................ 14 Section 9 – Steering ........................................................................................................................................................................ 15 Section 10 – Tires ............................................................................................................................................................................ 15 Section 12 – Electrical Battery and Battery Cables ..................................................................................................................... 15 Auxiliary Battery (Gasoline Engines Only) ................................................................................................................................. 16 Section 13 – Cooling ....................................................................................................................................................................... 17 Model Symbol Chart ............................................................................................................................................................................... 18 C/K SNOWPLOW PREP .................................................................................................................................... See Special Applications C/K PICKUP BOX REMOVAL ........................................................................................................................... See Special Applications CHASSIS General Arrangement – C/K (15/25)703 ........................................................................................................................................ 20 General Arrangement – C/K 15706 ................................................................................................................................................ 21 General Arrangement – C/K (15/25)906 ........................................................................................................................................ 22 General Arrangement – C/K (15/25)936 ........................................................................................................................................ 23 BODY PICKUP: GENERAL ARRANGEMENT, EXTERIOR Regular Cab with Short Box (Option E63) – C/K 15703 ....................................................................................................... 24 Regular Cab with Long Box (Option E63) – C/K (15/25/25HD)903...................................................................................... 25 Regular Cab, Sportside (Option E62) – C/K 15703 ............................................................................................................... 26 Extended Cab with Short Box (Option E63) – C/K (15/25/25HD)753 .................................................................................. 27 Extended Cab with Long Box (Option E63) – C/K (15/25/25HD)953 ................................................................................... 28 Extended Cab, Sportside (Option E62) – C/K 15753 ............................................................................................................ 29 Crew Cab with Short Box (Option E63) – C/K (15/25HD)743 ............................................................................................... 30 Crew Cab with Long Box (Option E63) – C/K 25943HD ....................................................................................................... 31 Regular Cab with Long Box Dooley (Option E63) – C/K 35903 ........................................................................................... 32 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT iii BODY – PICKUP: GENERAL ARRANGEMENT, EXTERIOR – Continued Crew Cab with Long Box Dooley (Option E63) – C/K 35943 ............................................................................................... 34 CHASSIS CAB: GENERAL ARRANGEMENT, EXTERIOR Regular Cab (Option ZW9) – C/K 25HD/K35903 ................................................................................................................... 35 Crew Cab (Option ZW9) – C/K 25HD/35943 .......................................................................................................................... 36 Regular Cab (Option ZW9) – C/K 36(0/4)03 .......................................................................................................................... 37 Extended Cab (Option ZW9) – C/K 36(0/4)53 ........................................................................................................................ 38 UTILITY: GENERAL ARRANGEMENT, EXTERIOR Tahoe/Yukon – C/K 15706 ...................................................................................................................................................... 39 Suburban/Yukon XL – C/K (15/25)906 ................................................................................................................................... 40 Avalanche – C/K (15/25)936 ................................................................................................................................................... 41 CHASSIS CAB: WHEELBASE AND CA’S Regular Cab CA’s – C/K (25HD/35/36) ................................................................................................................................... 42 Extended Cab CA’s – C/K (25HD/35/36) ................................................................................................................................ 43 Crew Cab CA’s – C/K (25HD/35) ............................................................................................................................................ 44 CAB INTERIOR Regular Cab – C/K (15/25) ...................................................................................................................................................... 45 Regular Cab – C/K (25HD/35/36) ........................................................................................................................................... 46 Extended Cab – C/K (15/25) ................................................................................................................................................... 47 Extended Cab – C/K (25HD/35/36) ........................................................................................................................................ 48 Crew Cab – C/K (15/25) .......................................................................................................................................................... 49 Crew Cab – C/K (25HD/35/36)................................................................................................................................................ 50 SEATING POSITIONS Regular and Extended Cab – C/K (15/25) ............................................................................................................................. 51 Regular and Extended Cab – C/K (25HD/35/36)................................................................................................................... 52 Crew Cab Second Row – C/K (15/25/25HD/35) (743/943) ................................................................................................... 53 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT iv BODY – SEATING POSITIONS – Continued C/K 15706 ................................................................................................................................................................................ 54 C/K (15/25)906 ......................................................................................................................................................................... 55 C/K (15/25)936 ......................................................................................................................................................................... 56 CAB EXTERIOR Regular Cab Chevy – C/K (15/25) .......................................................................................................................................... 57 Regular Cab Chevy – C/K (25HD/35/36)................................................................................................................................ 58 Extended Cab Chevy – C/K (15/25) ....................................................................................................................................... 59 Extended Cab Chevy – C/K (25HD/35/36) ............................................................................................................................. 60 Crew Cab Chevy – C/K (15/25) (43) ....................................................................................................................................... 61 Crew Cab Chevy – C/K (25HD/35/36) (43) ............................................................................................................................. 62 DOOR SWING/OPENINGS Door Openings – C/K (15/25/25HD/35/36) (03/43/53/06/36) ............................................................................................... 63 Rear Door Openings – C/K (15/25) (7/9)06 ............................................................................................................................ 64 FRONT END SHEET METAL Front End Sheet Metal – Utilities – C/K (157/159/259) (06) .................................................................................................. 65 Front End Sheet Metal – Pickups and Chassis-Cab – C/K (15/25) ..................................................................................... 66 Front End Sheet Metal – Pickups and Chassis-Cab – C/K (25HD/35/36) .......................................................................... 67 Front End Sheet Metal – C/K (15/25)936 ............................................................................................................................... 68 MIRRORS Outside, Mirror Options – C/K (15/25) (03/53/06) ................................................................................................................. 69 Outside, Mirror Options – C/K (25HD/35/36) ........................................................................................................................ 70 Outside, Mirror Options – C/K (15/25)936 ............................................................................................................................. 71 BACK OF CAB PROFILE Back of Cab Profile Nominal – C/K (15/25) (03/53) .............................................................................................................. 72 Back of Cab Profile Nominal – C/K (25HD/35/36) ................................................................................................................ 73 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT v BODY – Continued HOODS Hood Profile – Chevy, Tahoe and Suburban – C/K (15/25) (706/906) .................................................................................. 74 Hood Profile – Chevy, Silverado Pickups and Chassis-Cabs ............................................................................................. 75 Hood Profile (GMC) – C/K (15/25) .......................................................................................................................................... 76 Hood Profile (GMC) – C/K (25HD/35/36) ............................................................................................................................... 77 Hood Profile – C/K (15/25)936 ................................................................................................................................................ 78 Hood Inner Panel – C/K (15/25/25HD/35/36) ........................................................................................................................ 79 PICKUP BOXES Fleetside Box – C/K ................................................................................................................................................................ 80 Fleetside Box – C/K (25HD/35)............................................................................................................................................... 81 Fleetside 6.5 Foot with Quad Steering (Opt. NYS) – C/K..................................................................................................... 82 Stake Pockets – C/K (15/25/25HD/35) .................................................................................................................................. 83 Fleetside Box, Top Rail – C/K (15/25/25HD/35) .................................................................................................................... 84 Fleetside Box Inner Side Panel – C/K (15/25) ....................................................................................................................... 85 Box Inner Side Panel – C/K (25HD/35) .................................................................................................................................. 86 Sportside Box – C/K 157(03/53) ............................................................................................................................................. 87 Sportside Box, Top Rail – C/K 157(03/53) ............................................................................................................................. 88 Sportside, Inner Side Panel – C/K 157(03/53) ....................................................................................................................... 89 COMPOSITE PICK BOX, PRO-TECH (Option: E37) Composite Pickup Box – General Arrangement, Cross-sections and Tailgate Composite Pickup Box Equipment Attachment Recommendations ................................................................... 90 Attachments directly to box composite box material ................................................................................... 90 Attachments of equipment support legs to bed of composite box ............................................................. 90 Other Composite Box Equipment Recommendations ................................................................................. 90 General Arrangement ............................................................................................................................................. 91 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT vi BODY – PICKUP BOXES – Continued Forward Cross-sections ........................................................................................................................................ 92 Center and Rear Cross-sections ........................................................................................................................... 93 Second Tier Loading Provisions............................................................................................................................ 94 Composite Pickup Box – Interior Sidewall Features Stake Pockets ......................................................................................................................................................... 95 Bulk Head Divider and Cargo Tie-Downs ............................................................................................................. 96 Tailgate and Spoiler ................................................................................................................................................ 97 Platform Cross Sills – 6.5 Foot Pickup Box, Composite PRO-TECH (RPO E37) ............................................... 98 Platform Cross Sills – 6.5 Foot Pickup Box – Fleetside (RPO E63), Sportside/Stepside (RPO E62) ............................... 99 Platform Cross Sills – 8 Foot Pickup Box – Fleetside (RPO E63) ..................................................................................... 100 Cargo Area – C/K (15/25)936 ................................................................................................................................................ 101 Cargo Area Inner Side Panel – C/K (15/25)936 ................................................................................................................... 102 Side Storage Compartment – C/K (15/25)936 .................................................................................................................... 103 MISCELLANEOUS Luggage Rack and Running Boards – C/K 15706 .............................................................................................................. 104 Luggage Rack and Running Boards – C/K (15/25)906 ...................................................................................................... 105 Running Board Mounting Location – C/K (15/25)936 ........................................................................................................ 106 Clearance Lamps – C/K (25HD/35/36) ................................................................................................................................ 107 Pressure Relief Valve Shield – C/K (36) ............................................................................................................................... 108 Front Floor Seat Mounting Location – C/K (15/25) ............................................................................................................ 109 Front Floor Seat Mounting Location – C/K (25HD/35/36).................................................................................................. 110 Front Floor Structure – C/K (25HD/35/36)........................................................................................................................... 111 FRAME RAIL AND CROSSMEMBER ARRANGEMENT C 15703 .................................................................................................................................................................................. 112 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT vii FRAME – RAIL AND CROSSMEMBER ARRANGEMENT – Continued K 15703 .................................................................................................................................................................................. 113 C 15903 .................................................................................................................................................................................. 114 K 15903 .................................................................................................................................................................................. 115 C/K 25903 .............................................................................................................................................................................. 116 C 15753 .................................................................................................................................................................................. 117 K 15753 .................................................................................................................................................................................. 118 C 15953 .................................................................................................................................................................................. 119 K 15953 .................................................................................................................................................................................. 120 C/K 15706 .............................................................................................................................................................................. 121 C/K 15906 .............................................................................................................................................................................. 122 C/K 25906 .............................................................................................................................................................................. 123 C/K 25936 .............................................................................................................................................................................. 124 C/K 25753 .............................................................................................................................................................................. 125 C/K 25953 .............................................................................................................................................................................. 126 FRONT FRAME Pickup – C (15) ....................................................................................................................................................................... 127 Pickup – C (25) ....................................................................................................................................................................... 128 Utility – K (15) Pickup C/K (15) ............................................................................................................................................. 129 Utility – K (25) Pickup C/K (25) ............................................................................................................................................. 130 C/K (25HD/35/36) .................................................................................................................................................................. 131 W/Dim – C (25HD/35/36) ....................................................................................................................................................... 132 W/Dim – K (25HD/35/36) ....................................................................................................................................................... 133 INTERMEDIATE AND REAR FRAME C/K (25HD/K35)903 ............................................................................................................................................................... 134 W/Dim – C/K (25HD/K35)903 ................................................................................................................................................ 135 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT viii FRAME – INTERMEDIATE AND REAR FRAME – Continued C/K 25753 HD ........................................................................................................................................................................ 136 W/Dim – C/K 25753 HD ......................................................................................................................................................... 137 C/K (25HD/35)953 .................................................................................................................................................................. 138 W/Dim – C/K (25HD/35)953 .................................................................................................................................................. 139 C/K 25743 HD ........................................................................................................................................................................ 140 W/Dim – C/K 25743 HD ......................................................................................................................................................... 141 C/K (25HD/35)943 .................................................................................................................................................................. 142 W/Dim – C/K (25HD/35)943 .................................................................................................................................................. 143 C/K 36003 .............................................................................................................................................................................. 144 W/Dim – C/K 36003 ............................................................................................................................................................... 145 C/K 36403 .............................................................................................................................................................................. 146 W/Dim – C/K 36403 ............................................................................................................................................................... 147 C/K 36053 .............................................................................................................................................................................. 148 W/Dim – C/K 36053 ............................................................................................................................................................... 149 C/K 36453 .............................................................................................................................................................................. 150 W/Dim – C/K 36453 ............................................................................................................................................................... 151 SPARE TIRE CARRIER Pickup – C/K (15/25) ............................................................................................................................................................. 152 Utility – C/K (15/25) ............................................................................................................................................................... 153 C/K (25HD/35/36) .................................................................................................................................................................. 154 PLATFORM HITCH Pickup – C/K (15/25) ............................................................................................................................................................. 155 Utility – C/K (15/25) ............................................................................................................................................................... 156 Short Box Pickup – C/K (25HD) ........................................................................................................................................... 157 Long Box Pickup – C/K (25HD/35) ....................................................................................................................................... 158 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT ix FRAME – PLATFORM HITCH – Continued C/K (15/25)936 ....................................................................................................................................................................... 159 AXLE SUSPENSION Front Axle/Tire Data Pickup – C (15/25) ...................................................................................................................................... 160 Front Axle/Tire Data Pickup – K (15/25) ...................................................................................................................................... 161 Front Axle/Tire Data – C/K (15/25)936 ......................................................................................................................................... 162 Front Axle/Tire Data Utility – C (15/25) ........................................................................................................................................ 163 Front Axle/Tire Data Utility – K (15/25) ........................................................................................................................................ 164 Front Axle/Tire Data – C (25HD/35/36) ........................................................................................................................................ 165 Front Axle/Tire Data – K (25HD/35/36) ........................................................................................................................................ 166 Rear Axle/Tire Data – C/K (15/25) ................................................................................................................................................ 167 Rear Axle/Tire Data – C/K (25HD/35) .......................................................................................................................................... 168 Rear Axle/Tire Data – C/K (36) ..................................................................................................................................................... 169 FUEL TANK 26 Gallon Fuel Tank – C/K (15/25) (7) (03/53) .............................................................................................................................. 170 34 Gallon Fuel Tank – C/K (15/25) (9) (03/53) .............................................................................................................................. 171 26 Gallon Fuel Tank – C/K 15706 ................................................................................................................................................. 172 33 Gallon Fuel Tank – C/K 15906 ................................................................................................................................................. 173 36 Gallon Fuel Tank – C/K 25906 ................................................................................................................................................. 174 26 Gallon Fuel Tank – C/K (25HD) (7) (43/53) .............................................................................................................................. 175 34 Gallon Fuel Tank – C/K (25HD/35) (9) (03/43/53) .................................................................................................................... 176 23/27 Gallon Fuel Tank – C/K 36 .................................................................................................................................................. 177 EXHAUST 4.3 L V6 Gas Engine, Pickup, Option LU3 and L35..................................................................................................................... 178 4.8 L and 5.3 L V8 Gas Engine, Pickup, Option LR4 and LM7 ................................................................................................... 179 6.0 L V8 Gas Engine, Pickup, Option LQ4 ................................................................................................................................... 180 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT x EXHAUST – Continued 6.0 L V8 Gas Engine, Pickup, Option LQ4 w/NYS (Quad Steering)........................................................................................... 181 5.3 L V8 Gas Engine, Utility, Option LM7 ..................................................................................................................................... 182 6.0 L V8 Gas Engine, Utility, Option LQ4 and LQ9 ...................................................................................................................... 183 8.1 L V8 Gas Engine, Pickup, Option L18 .................................................................................................................................... 184 8.1 L V8 Gas Engine, Chassis Cab, Option L18 – C/K 36 (03) ................................................................................................... 185 8.1 L V8 Gas Engine, Chassis Cab, Option L18 – C/K 36 (53) ................................................................................................... 186 8.1 L V8 Gas Engine, Utility, Option L18 (Federal) ...................................................................................................................... 187 8.1 L V8 Gas Engine, Utility, Option L18 (California) .................................................................................................................. 188 8.1 L V8 Gas Engine, Utility, Option L18 (Export) ....................................................................................................................... 189 6.6 L V8 Diesel Engine, Pickup, Option LB7 ............................................................................................................................... 190 6.6 L V8 Diesel Engine, Chassis Cab, Option LB7 ...................................................................................................................... 191 PTO Power Take Off (Chelsea) 6 Speed Manual Transmission – C/K 36 ......................................................................................... 192 Power Take Off (Muncie) 6 Speed Manual Transmission – C/K 36 ........................................................................................... 193 Power Take Off Manual Transmission – C/K 36 ......................................................................................................................... 194 Power Take Off (Chelsea) 5 Speed Auto Transmission – C/K 36 .............................................................................................. 195 Power Take Off (Muncie) 5 Speed Auto Transmission – C/K 36 ............................................................................................... 196 Power Take Off Automatic Transmission – C/K 36 .................................................................................................................... 197 MID BUSSED ELECTRICAL CENTER (MBEC) Mid Bussed Electrical Center (MBEC) ........................................................................................................................................ 198 MBEC, SEO and Trailer Connector .............................................................................................................................................. 199 MBEC, Upfit and Cell Phone Connector ..................................................................................................................................... 200 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 1 BODY BUILDERS INSTRUCTIONS The Incomplete Vehicle Document (IVD) is supplied with each incomplete vehicle, and provides information that should be used by intermediate and final stage manufacturers in determining conformity to applicable Federal Motor Vehicle Safety Standards (FMVSS). The IVD also includes information which must be followed in order to ensure that Environmental Protection Agency (EPA) and California emissions certification requirements and NHTSA Fuel Regulations are met. This Body Builders Book contains information that may be used in addition to the IVD for any manufacturer making alterations to a GM complete/incomplete vehicle. No alteration should be made to the incomplete vehicle which either directly or indirectly results in any component, assembly or system being in nonconformance with any applicable Federal Motor Vehicle Safety Standard or Emission Regulation. Intermediate and final stage manufacturers should be familiar with all Federal Motor Vehicle Safety Standards and Emission Regulations and aware of their specific responsibilities as manufacturers. For further assistance contact Upfitter Integration at: 1 (800) 875-4742, or go to our Web site at “http://www.gmupfitter.com.” Section 0 — General Instructions Check for proper clearance between body members and chassis components which may in anyway affect the reliability and performance of the vehicle by developing abrasion and wear points from moving parts or degradation from extreme environment or thermal exposure or may increase interior noise. Check headlamp aim and all vehicle illumination systems for proper operation when the vehicle has been completed. Re-aim head lamps when necessary. Check for proper operation of windshield washer, wipers and defroster system. Extreme care must be taken when working on vehicles equipped with Engine Control Module (ECM), Powertrain Control Module (PCM), Transmission Control Module (TCM), Vehicle Control Module (VCM) or any electronic unit associated with an inflatable restraint system. (See Owner’s Manual). If arc-welding is employed on the chassis, precautions must be taken to protect all vehicle components, especially brake and fuel lines, fuel tank assembly, electrical wiring and ECM/PCM/TCM or VCM. To avoid electronic component damage, disconnect battery (batteries); disconnect the negative cable first, followed by the positive. To reconnect cables; connect the positive first, then the negative. When welding components to the frame assembly, remove the wax coating in the area of the weld in order to obtain secure welds. After completion of the weld, a compatible corrosion protection should be applied to the affected weld areas. (Section 0 — continued on next page) 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 2 (Section 0 — continued from previous page) All labels on the vehicle (any message applied to the vehicle or vehicle component that informs, instructs, or warns) must appear on the completed vehicle so the user can read them easily and without obstruction. Those installing aftermarket systems should provide information as to where and how to obtain service and replacement parts. When installing a Power Take-Off (PTO) with hydraulic lines, the following care should be exercised: • Route and secure all hydraulic lines so that they are not in close proximity to any parts of the exhaust system. Keep all fittings and connections away from the exhaust system. Make sure connections and fittings cannot leak on the exhaust system. • Exhaust system heat can damage and degrade hydraulic lines and components. Oils and hydraulic fluid coming in contact with a hot exhaust system could result in a fire. Section 1 — Body Accessory items, such as refrigerator, hot water heater, furnace, etc., which operate on liquid propane gas should be located and protected to prevent exposure to any flame. GM has established automotive refinishing standards for itself as well as its aftermarket retailers. Each division requires the dealer or retailer to use only materials and methods that meet GM standard GM 4901M when repairing, replacing or refinishing vehicles. Each year, all new paint systems will be tested and evaluated. New or improved products will also be tested. The paint systems that pass this annual testing process will be published in this booklet, and updated annually. If GM 4901M booklets are needed, call 1-800-269-5100. Body structures, interior and accessory arrangements must be designed into the vehicle to provide for proper load distribution on both axles and not to exceed any gross axle weight ratings. Lateral load equalization must also be maintained. The resultant Center of Gravity of the unladen vehicle must be within the limits tabulated in the FMVSS 105 section of the Incomplete Vehicle Document. Body insulation provided by General Motors should not be removed. This includes any thermal or underbody heat shields. This insulation is provided to protect the vehicle body and occupants from excessive heat and/or provide noise attenuation. Any replacement material internal to the occupant compartment must be certified for FMVSS 302 Flammability of Interior Materials. Areas of specific concern, but not limited to are: • Underbody exhaust, muffler and tail pipe shields and insulators. (Section 1 — continued on next page) 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 3 (Section 1 — continued from previous page) • Rear load floor interior insulation. • Front floor interior insulation. • Dash mat insulation. • Engine cowl insulation – interior and exterior. • Engine cover insulation. • Hood Insulation Conversions A minimum of 10º departure angle should be maintained if frame and/or body is extended. Selected trim components above the belt line have energy absorbing foam added behind the trim (headliners, A, B and C garnish moldings), to comply with MVSS 201. Any modification could affect compliance. If body builder installs seating other than that supplied with vehicle, it is the body builder’s responsibility to ensure that the seating and restraint systems comply with FMVSS requirements. The restraint systems supplied with the vehicle were designed to accommodate the seating reference points and seat travel of the original equipment seats only. Air Conditioning For additional information refer to Engine - Section 6. NOTE: Air conditioning systems using R-134A refrigerant are equipped with metric fittings to prevent interchange with R-12 refrigerant components. Do not interchange R-134A components, refrigerant oil or service equipment with R-12 components, refrigerant oil or service equipment. Rear Air Conditioning This unit may be equipped with A/C quick-connect fittings (Option YF7) on the liquid tube (high pressure) and the suction (low pressure) return tube. These fittings are designed to accept matching Aeroquip connecting fittings attached to pre-charged lines. This allows a one time only connection to the O.E.M. charged A/C system without having to discharge, evacuate and recharge for the connection of a rear A/C system. (Section 1 — continued on next page) 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 4 (Section 1 — continued from previous page) A modification to the A/C system which causes the A/C plumbing lines to increase in length (such as the addition of a rear after-market evaporator and blower assembly) will necessitate the following changes: • Lubrication – PAG refrigerant oil must be added to rear system to provide lubrication for compressor. Refer to Service Manual for specifications. • Refrigerant – Add R-134A refrigerant to system based on sizing of new tubes, hoses and evaporator. Contact your A/C supplier for recommended charge. • Label – Revise/modify GM charge label (located on top of front evaporator or A/C bottle) from factory recommended charge for a front system only to body builder’s new recommended dual system per SAE J639. This is important for servicing the A/C system so that the technician knows the correct amount to add to the modified system. Section 2 — Frame Hole drilling, welding, modifications, or alterations to the frame assembly are the responsibility of persons performing these operations. These same individuals assume complete responsibility for frame assembly, reliability, performance after alterations and compliance to applicable FMVSS requirements. The following procedures and specific precautionary instructions are recommended for proper installation of special bodies and/or equipment on GM frames. Failure to follow these recommendations could result in serious damage to the basic vehicle. Flanges Do not drill holes in frame flanges. Holes Holes to mount brackets, supports, and out-riggers must be drilled in the vertical side rail web with the following restrictions: • Material between edge of hole and inside of upper or lower flange must not be less than 37 mm (1.50 in.) for HSLA (40,000 PSI yield). • The minimum edge distance between any two (2) holes must be larger than twice the diameter of the larger hole. • No holes should exceed 20 mm (0.75 in.) in diameter. • All holes should be drilled in the frame using appropriate drilling practice and safety precautions. (Section 2 — continued on next page) 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 5 (Section 2 — continued from previous page) Welding CAUTION: Fuel tank and fuel lines must be drained and all vapors purged to ensure non-combustible mixture before any welding, brazing or soldering. When welding high-strength, low-allow (HSLA 40,000 PSI yield strength) side rails or crossmembers and brackets (32,000 or 36,000 PSI yield strength), emphasis is placed upon weld application techniques to avoid stress risers that may adversely affect frame operating stresses. When welding is performed anywhere on the vehicle, precautionary measures should be taken to prevent damage to electrical system wiring or components. Prior to any welding, parts or components which could be damaged by excessive temperatures must be removed or adequately shielded; the battery cables should be disconnected at the battery. Also prior to welding, the area to be welded and surrounding area must be cleaned of all frame protective coating. After welding, when parts are cool, carefully inspect wiring and electrical components for shorts or other damage which could draw excessive currents and possibly cause an electrical system short when the battery is reconnected. Apply protective coating to areas where coating was removed. Alterations If the wheelbase is modified the alterer must take responsibility for compliance with affected FMVSS and for warranty on items such as driveshafts, universal joints, center bearings and rear transmission tailshaft, transfercase and transmission case fractures, output shaft bushings, bearings, brakes, fuel systems and any other related component failures. Additionally, the customer must be alerted in the modifier’s owner’s manual that parts for the reworked area are not available through the General Motors service parts system. Shear Plate Attachments Attachments of shear plates should be accomplished by using existing manufacturing holes already available in the frame side rails. Manufacturing holes, normally 25 mm in diameter, are consistently placed along the frame side member in the center of the web on each frame. When additional holes are required for shear plate attachment, they should be no larger than 19 mm (0.75 in.) in diameter. Holes are to be drilled no closer than 63.5 mm (2.5 in.) apart. For holes drilled forward of the rear axle, centers are to be no closer than 63.5 mm (2.5 in.) from the top or bottom flanges and no closer than 89 mm (3.5 in.) from any suspension attachments. For frame holes drilled rearward of the rear axle, hole centers are to be no closer than 51 mm (2.0 in.) from the top or bottom flange and no closer than 89 mm (3.5 in.) from suspension attachments. No additional holes or notching of either top or bottom frame flanges is allowed. 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 6 Section 3 — Front Suspension Since there is a large variation in completed vehicle front weight due to differences in body weight and equipment, the front suspension alignment must be checked and reset if necessary after the vehicle is completed. Caster and camber should be set with reference to the “A” dimensions. See Truck Service Manual for complete alignment procedure, specifications and measurement of the “A” dimension under “Diagnosis and Front Alignment” section. C/K Models are designed such that camber and caster do not need adjustment unless severe road impact or accident deformation occurs. Toe should be reset after the vehicle is completed and while at normal operating load with trim height as specified (K-Model). Section 4 — Rear Suspension Clearance to body should be provided for the suspension, axle, driveshaft and tires under the following conditions: (1) Axle in full jounce against the metal-to-metal stop, (2) Axle at 4.5º roll with one side of axle in full jounce at the metal-to-metal stop and (3) Axle at design position. Allowance for the tire chain clearance shown on a maximum grown tire must allow for 42.2 mm (1.66 in.) clearance to the sides of the tire and 63.5 mm (2.5 in.) to the top of the tire. Be sure sufficient clearance is provided for suspension, axle and tire and wheel in full vertical travel (up and down). NOTE: Notification to the consumer may be required in certain states if tire chains cannot be used. Pipes, wiring, conduits and any other related components must not be placed where they cross the path of motion of the rear axle, driveshaft, axle brake pipes, hoses, spring or tires. Such crossing could result in rupture, wear-through, or separation due to normal axle motion. See chassis data information for additional clearances and for assistance in calculating trim heights. Section 5 — Brakes See Truck Service Manual for brake specifications. Due to the critical nature of brake systems, anyone making modifications or alterations must assume complete responsibility for system reliability, performance and certification to FMVSS 105 or FMVSS 121. (Section 5 — continued on next page) 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 7 (Section 5 — continued from previous page) It is mandatory that no change be made to the brake main cylinder location, brake pedal push rod length or pedal position. Ensure that the hydraulic brake system is free of air and hydraulic leaks. Bleed brakes if required, following procedures as outlined in truck chassis service manual. Ensure that the vacuum booster system or hydraulic brake booster system is functional and free of leaks. Check master cylinder fluid level and fill as necessary. (Refer to Owner’s Manual). Check power steering fluid level for models equipped with hydroboost brake. (Refer to Owner’s Manual). Added floor covering or carpeting must not restrict service or parking brake pedal travel from released position to full pedal travel. No body part or chassis-mounted component may be located within 2.0 in. of brake hose routing in all wheel and axle positions. All exhaust system components must also have a minimum of 2.0 in. clearance to brake hoses in closest positions. (Be sure to account for brake hose travel with suspension.) Body builder is to verify that the brake warning switch is operative. The brake warning switch on models equipped with vacuum-hydraulic brakes is located on the master cylinder. This includes both the brake system fluid level and parking brake actuator switch. Section 6 — Engine For additional information refer to Body - Section 1. Air conditioning and auxiliary belt-driven equipment installation recommendations: No alterations or additions to the accessory drive belt system will be warranted on serpentine belt systems. The serpentine belt type of drive is designed as a total system, incorporating a single poly-V belt and an automatic tensioner. In this type of system, degrees of pulley wrap, belt tension, and pulley alignment are very critical factors. Modification is not recommended. In some single belt serpentine systems, belt tension is determined by the automatic tensioner and its position relative to the belt. No adjustment required. Due to the critical nature of the accelerator system, anyone making modifications or alterations assumes complete responsibility for system reliability, performance and compliance to FMVSS 124. Caution must be exercised so that the accelerator cable is properly routed. Specifications are as follows: • Route cable to maximize all bend radii. In no case should bend radii be less than 3 in. (76 mm). (Section 6 — continued on next page) 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 8 (Section 6 — continued from previous page) • Minimum distance from exhaust manifold to be 6.0 in. (150 mm), unless a heat shield is provided. • Do not use accelerator cable or clips to route wires, harnesses or other cables. Cable sheath must be clipped so as not to pinch inner cable. Cable must not be loose in clip allowing sheath to move when accelerator pedal is applied and released. • Cable must not be subjected to kinking or routing across any sharp edges. • Cable routing must be perpendicular to the surface of the front-of-dash at the dash fitting. No objects or routings should force cable to have a bend at the dash fitting. Flexible components (hoses, wires, conduits, etc.) must not be routed within 2.0 in. (50 mm) of moving parts or accelerator linkage unless routing is positively controlled. • Caution must be taken so that the accelerator pedal remains properly located. Guidelines for accelerator pedal locations are as follows: 1) Ensure that the accelerator can freely operate from idle to wide-open throttle position and return. Make sure that the pedal will not hang up on any nearby items such as carpets, floor, screws, wiring harnesses, etc. Engine cover should have at least one inch (25 mm) clearance to side of accelerator pedal with the carpet mat installed. 2) Accelerator to brake pedal relationship has been designed to provide minimum driver movement and should not be altered in any way. Gasoline engine induction and/or ignition system is certified in compliance with the Federal Vehicle Emission Standards. Any alterations to the systems or components could void compliance and render the vehicle illegal. System includes: • Fuel system – throttle body injector (TBI) or central port injector (CPI) and associated tubes, hoses and pipes, air cleaner, outside air hose and spacer heat stove and heat stove pipe, fuel pump and inlet manifold, fuel vapor canister. • Exhaust system. • Ignition system distributor and initial spark timing setting, spark plugs, spark plug wires. • Crankcase ventilation system. Diesel engine induction and injector pump system is certified to be in compliance with the Federal Vehicle Emission Standards and/or Noise Standards. Any alterations to the system or components could void compliance and render the vehicle illegal. System includes: • Fuel system – Injection pump, injector lines and injectors, fuel return hoses and pipes, air cleaner, outside air hose, fuel pump, fuel filter, fuel heater assembly and intake manifold. • Exhaust system. (Section 6 — continued on next page) 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 9 (Section 6 — continued from previous page) • Crankcase pressure regulation system. • Charge air cooler system. • External engine components, such as air cleaner, crankcase pressure regulator valve, alternator, injection pipes, fuel return hoses from injectors, exhaust manifolds, oil fill pipe, etc., must be provided with sufficient clearance for engine roll and torque. • When a vehicle is equipped with a electronic fuel injection (EFI) engine, it has an engine control module ECM/PCM/TCM or VCM. This ECM/PCM/TCM or VCM must be maintained at a temperature below 185ºF at all times. This is most essential if the vehicle is put through a paint baking process. The ECM/PCM/TCM or VCM will become inoperative if its temperature exceeds 185ºF. Therefore, it is recommended that temporary insulation be placed around the ECM/PCM/TCM or VCM during the time the vehicle is in a paint oven or undergoing another high temperature process. Section 7 — Transmission Light duty models equipped with manual transmission have a clutch-operated start safety switch. Starter should operate whenever the ignition is turned to start and the clutch is fully depressed. Readjust if necessary as outlined in the Truck Service Manual. Models equipped with automatic transmissions have a steering column mounted neutral/park start safety mechanical lockout feature, which interfaces with the steering column ignition switch. Starter should operate only when gearshift lever is in neutral or park position. Readjust the shift linkage if necessary as outlined in the Truck Service Manual. Power Take-Off (PTO) systems refer to General - Section 0. • The NV4500 manual 5-speed heavy-duty overdrive transmission (RPO MW3) requires the use of special synthetic lubricant to reduce transmission internal operating temperatures. The lubricant is installed in all NV4500 transmissions at the factory. • In instances where it is necessary to drain and refill or add fluid to the transmission, such as when installing PTO, DO NOT substitute any other lubricant. Installation of other lubricants may result in internal transmission damage. • Castrol Syntroq GL4 is the only synthetic lubricant currently approved for use in the NV4500. This product can be secured through your local GM dealer under GM part number 12346190 per quart. • Transmission lubricant capacity is 8.5 pints. Models equipped with manual transmission use a hydraulic clutch actuator. Check fluid level as outlined in the vehicle owner’s manual. (Section 7 — continued on next page) 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 10 (Section 7 — continued from previous page) It is mandatory that no change be made to the clutch master cylinder location, clutch master or slave cylinder push rod length, or pedal position. POWERTRAIN SPECIFICATIONS AND LINE-UP CHARTS SPECIFICATIONS — AUTOMATIC TRANSMISSIONS RPO MAKE CASE MATERIAL TORQUE RATING (LB.-FT.) RATIO (:1) 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Reverse OUTPUT SHAFT SPLINE # OF TEETH PITCH DIAMETER TORQUE CONVERTER CLUTCH SIZE “K” FACTOR STALL TORQUE RATIO PTO OPENING Two automatic transmissions are used in 25HD/35/36 C/K series trucks: MT1/4L80-E: Used on all 9,200 LB GVWR M74/ALLISON: Used on all 11,400 LB and 12,000 LB GVWR 4-SPEED MT1 4L80E ALUMINUM 440 2.48 1.48 1.00 0.75 N/A 2.08 32 33.87 mm YES 310 mm 6.0L = 117 6.0L = 2.3 NONE 5-SPEED M74 ALLISON ALUMINUM 450 3.10 1.81 1.41 1.00 0.71 4.49 34 43.18 mm YES 310 mm 8.1L = 114 6.6L = 107 8.1L = 2.05 6.6L = 2.0 YES AUTOMATIC TRANSMISSION/ENGINE AVAILABILITY MATRIX ENGINE / TRANSMISSION 6.0L GEN III 8.1L 6.6L DIESEL MT1 BASE N/A N/A M74 N/A BASE BASE (Section 7 — continued on next page) 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 11 (Section 7 — continued from previous page) SPECIFICATIONS — MANUAL TRANSMISSIONS 5-SPEED MW3 CAST IRON 410 5.61 3.04 1.67 1.00 0.75 N/A 5.04 109 mm 12” (302 mm) YES – Left or Right RPO CASE MATERIAL TORQUE RATING (LB.-FT.) RATIO (:1) 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Gear Reverse (Synchronized) SHAFTS CENTER DISTANCE CLUTCH PLATE DIAMETER PTO OPENING Two manual transmissions are available in 25HD/35/36 C/K series trucks: MW3: Available for 9,200 LB GVWR. See specific powertrain charts for details. ML6: Available for 11,400 LB and 12,000 LB GVWR. See specific powertrain charts for details. 6-SPEED ML6 ALUMINUM 520 5.79 3.30 2.10 1.30 1.00 0.72 5.23 105 mm 12” (303 mm) YES – Left or Right Section 8 — Fuel and Exhaust Fuel Systems The fuel evaporative emission control equipment is certified to be in compliance with the Federal and California Vehicle Emission Standards. The fuel tank is molded from multilayer plastic and should not be repaired or altered. Metal fuel lines have a surface coating to reduce corrosion on inside and outside surfaces to comply with useful life requirements. All fuel hoses, including plastic lines, are made of a low permeation multi-layer material to comply with enhanced evaporative emission requirements. Any alterations to systems or components including materials, hose lengths and their location, except as described in the fuel fill system modifications section, could void compliance. The system includes: • Fuel tank, fuel level sender, fuel fill and vent hoses and pipes, emission canisters, fuel feed, fuel return and vapor lines, purge control solenoids, fuel fill cap, canister vent solenoid. (Section 8 — continued on next page) 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 12 (Section 8 — continued from previous page) For these reasons, NO ALTERATION OF THE FUEL SYSTEM IS RECOMMENDED. Fuel Fill It is recommended that when mounting the fuel filler pipe assembly and vent hose that a minimum of 3.0 in. clearance be provided to any body component to prevent contact between hoses and/or mating parts and that retention be provided to ensure routing and prevent failure due to wear and fatigue. Both the fill and vent hoses must be routed (and supported, if needed) such that there are no sags or kinks. As viewed from the filler neck, pipes and hoses must have a downward slope toward the tank. There should be a minimum of 4º of downward slope in the fill and vent pipe at any location. No fuel traps are allowed. Alterations of fuel line routings could affect the ability of the completed vehicle and are, therefore, not desirable. The complete fuel system must comply with FMVSS 301. If additional new hose is required when installing fuel tank filler neck, this hose must be suitable for use with unleaded fuels or diesel fuel respectively and must allow the vehicle to meet enhanced evaporative emissions requirements. Fuel Lines Fuel line routing precautions: • 5 in. minimum clearance to exhaust system is required or a metal shield must be provided. • Fuel lines should be clipped to chassis to prevent chafing. Metal clips must have rubber or plastic liners. • Use corrosion resistant steel tubing with short sections of approved hose to connect components. Hose-to-tube connections should be clamped for diesel systems. Steel tube ends should be beaded for hose retention. Fuel supply is pressurized by an in-tank pump for MPFI and SCPI systems. Coupled hose or nylon quick-connects must be used. Clamped hose is not acceptable for MPFI and SCPI systems. All engines require a fuel return system which returns excess fuel from the injection pump and injector nozzles back to fuel tanks. Care should be taken that these lines are not blocked nor their hoses pinched. The engine may run poorly or stall if these lines are restricted or blocked. All gasoline engine vehicles are equipped with fuel evaporative emission control equipment which is certified to be in compliance with the Federal or applicable California Vehicle Emission Standards. Alterations to fuel tank and metering unit, lines, canister or canisters, canister filters, canister purge control valves, relay switches, tank auxiliary vent valve, engine speed controller, or other devices/systems are therefore not allowable since vehicle adherence to C.A.R.B. and Federal regulations may be affected. Diesel powered vehicles incorporate water drain provisions in the fuel system. These valves are only to be opened when siphoning water and contaminants from the fuel system. (Section 8 — continued on next page) 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 13 (Section 8 — continued from previous page) Body attachment brackets and u-bolts must be located such that there is adequate clearance to all fuel system components, such as the fuel lines and the fuel level sending unit, under all operating conditions. Fuel Tank For vehicles with full frames, the tank must have a minimum clearance of 2 in. top, front, rear and sides to body and other supports. Tank may be pressurized to 1.25 PSI maximum to check for final line leakage or for forcing fuel through the system. Pressures greater than this amount may be detrimental and affect tank durability. The use of auxiliary fuel tanks is not recommended. If an auxiliary fuel tank is added, the alterer must take responsibility for compliance with affected motor vehicle safety standards. Also, if an auxiliary fuel tank is added to a gasoline-powered vehicle, the fuel must be drawn through a pipe at the top of the tank (balance line between tanks is not permitted). Gasoline fueled vehicles are equipped with a fuel pump return line. If an auxiliary tank is added, the tank selector valve must include a return port which returns fuel to the tank from which the fuel is being drawn. In gasoline engines the fuel pump is located in the fuel tank. The battery must be disconnected before starting any work on the fuel system. Gaseous Fuel Conversions All truck gasoline engines may be converted to use liquified petroleum gas (LPG) or natural gas (NG); GM only approves the conversion of vehicles with option KL5. However, some conversions may cause harmful effects to the engine. Such fuel systems may require assurances from alternate fuel system manufacturers and/or installers that the equipment will not cause damage to the engine or the exhaust system. In the use of dual fuel systems, the vehicle operator should strictly adhere to the manufacturer’s procedures for switching from gasoline to gaseous fuel operation. Improper switching procedures may result in overheating and damage to the exhaust system and the vehicle. The gaseous fuel tank should not be mounted in an enclosed area of the vehicle, such as the passenger compartment, truck, etc., and the system should be vented to the outside of the vehicle. In addition, vehicles converted to gaseous fuels should not be stored in enclosed places such as garages. Further, General Motors cautions purchasers that the design, location and installation of any type of fuel storage system involves significant technical and engineering considerations and that these statements on gaseous fuel conversions should not be interpreted to be an approval by General Motors of any modification to the original equipment fuel system. Conversions to gaseous fuel should be made in conformance with applicable Federal and State regulations. Removal of emission-control components or the addition of gaseous fuel systems, which could damage or reduce the longevity of those components could also cause the mechanical and emission performance warranty to be voided. (Section 8 — continued on next page) 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 14 (Section 8 — continued from previous page) Exhaust System Particular care should be taken to prevent the possibility of exhaust fumes and carbon monoxide exposure to vehicle occupants in units completed by body builders. Holes and openings through the floor and all other parts of the body must be permanently and adequately sealed by the body builder to avoid exhaust intrusion into any occupant area. If it is necessary to change the exhaust outlet location, the exhaust discharge must be unobstructed and directed away from occupant areas. Alteration of the exhaust outlet or its position may increase exhaust noise and render the vehicle illegal in those areas with pass-by noise regulations. All vehicles >10,000 lbs. GVWR come under Federal noise regulations, vehicles ≤10,000 lbs. GVWR are regulated by various state and local regulations of the Environmental Protection Agency; see those regulations for rules, test procedure and noise levels permitted. Tail pipe outlet location must be tested statically and with the vehicle in motion to ensure that exhaust gases do not penetrate side or rear windows or under body seams and holes. Auxiliary power plants should also be tested under the same conditions. Tail pipe exit ahead of rear wheels is not recommended. Check for leaks in exhaust systems and repair as required. Exhaust temperatures can exceed 1600ºF under extreme operating conditions, with pipe surface temperatures slightly less than this. Extreme care must be used when placing body components in the proximity of the exhaust system so as not to exceed the rated temperature limits of the components. Due to variants in underbody configurations of the vehicles, we are not in a position to make recommendations on how to insulate or design components in the proximity of the exhaust system. Each manufacturer must make temperature checks of critical areas of his vehicle and adjust his design accordingly, or provide shielding to ensure safe operation of his body components. The same can be said for the engine compartment. Obviously there will be additional heat radiated from the engine. How much is retained in the area will depend on how well this area is ventilated in your individual designs. Here again, temperature checks of interior areas surrounding the engine should be made to determine if your insulation is adequate. This is the same engineering practice we have followed on our complete vehicles incorporating these exhaust systems. Exhaust system materials are selected and tested to withstand the operating environment of the vehicle. Do not modify the exhaust system in any way. The tail pipes are made of 409 stainless steel. Heat shields are mounted to the underbody and/or exhaust system components (catalytic converter and muffler). Shields for the propshaft hanger bearings are also provided in some vehicles. 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 15 Section 9 — Steering Check power steering fluid level and system operations. (Refer to Owner’s Manual). Steering wheel and horn pad must not be altered or replaced. The steering column mast jacket must not be altered. Section 10 — Tires Check wheel lug nuts for proper torque; specifications are provided in the Owner’s Manual. Substitution of tires of greater capacity than those offered as original equipment by vehicle manufacturer is not approved for use on original equipment wheels. Any usage of higher capacity tires must be accompanied by higher capacity wheels. However, the wheel offset (the distance from centerline of rim to wheel mounting face) must be the same as the replaced original equipment wheel to ensure proper wheel bearing loading and clearance of tires to body and chassis components. Increasing tire and wheel capacity does not necessarily increase vehicle GVW ratings. Any substitution of tires may affect Speedometer/Odometer accuracy. It is recommended that tire chain clearance guideline J683, from the Society of Automotive Engineers, be adhered to in designing rear wheelhouse clearance. Check tires and inflate to recommended tire pressure according to the tire pressure information provided in Owner’s Manual and tire inflation label provided with vehicle. Section 12 — Electrical Battery and Battery Cables The vehicle battery should be located and positioned to make use of the existing battery cables. If the battery requires relocation and longer cables are required, a proportionately larger gauge wire must be used. If, in relocating the battery the negative ground cable is attached to the frame rail, a cable of similar gauge must be provided between the frame rail and the engine. This is required due to the heavy electrical loads imposed by the starting circuit. To ensure proper operation of the battery cables the following chart on length, gauge and materials must be strictly adhered to: (Section 12 — continued on next page) 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 16 (Section 8 — continued from previous page) Combined length of positive and negative Cable Gauge 4 2 0 Cable in Inches (Copper) 66 107 170 The All New C/K is equipped with a Remote Positive (+) Jump Starting terminal which is located behind a red plastic cover near the engine accessory drive bracket. This terminal is intended for jump starting only and should NOT be used by upfitters to obtain battery power. Three fused studs, however, are available on the Underhood Electrical Center and, if available, may be used by upfitters to obtain battery power. If the battery is remotely mounted (other than in the engine compartment), the ‘sense’ circuit in the generator regulator shall be used. The sense circuit consists of a 7.76 OHM 1/4 watt resistor connected in series between the ‘S’ terminal of the generator and the B+ terminal of the battery. Auxiliary Battery (Gasoline Engines Only) If an auxiliary battery is to be retro-fitted, the electrical schematic for option TP2 is recommended as a guide. This will result in the auxiliary battery being connected to the vehicle load and charging circuit when the ignition switch is ‘on’ (fuse block terminal “Acc. Ign. Fused”). When the ignition switch is turned off, the interlocking relay is disengaged and the auxiliary battery is disconnected from the vehicle circuit. Modifications/add-on wiring must be carefully reviewed to ensure compatibility with the base vehicle wiring by reviewing system schematics, wire routing paths, harness connections, etc. Due to the wide range of modifications that may be required for vocational needs, it is not feasible for the O.E.M. to take into account all potential revisions. For this reason, any person modifying existing vehicle wiring must assume responsibility that the revisions have not degraded the electrical system performance. Any add-on wiring must be properly fused and routed to prevent cut, pinch, and chafe problems, as well as avoid exposure to excessive heat. Care must be exercised that existing vehicle interfaces do not have their current load capabilities exceeded and the respective control devices are not overloaded. Added wire size should be at least as large as the wire to which it is attaching in order for fuse protection to be maintained. A Packard Electric wiring repair kit is available through Kent-Moore (GM P/N 12085264, Kent-Moore P/N J38125-4). This kit contains instructions, tools and components for making repairs to wiring harness components. This kit would also greatly assist in accomplishing necessary add-on wiring, such as body marker lamps, so that system reliability/durability is maintained. Electrical wiring components can be obtained through your authorized GM dealer. Many Packard Electric components are also available through Pioneer Standard Company (1-800-PACKARD). Pioneer may also be able to assist in making necessary wiring additions by providing custom wiring stubs or jumpers to your specifications. 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 17 Section 13 — Cooling To provide satisfactory engine cooling, the following conditions must be met: 1. Do not locate any large objects in front of the radiator core or grille, such as batteries, spare tires, lights/sirens, etc. They restrict air flow into the radiator core and influence fan blade stress. 2. Grille opening, size configuration and the external baffles provided should not be altered in any manner. Any reduction in cooling ability may adversely affect engine/transmission performance. 3. Fan clutches not conforming to the original equipment specifications may not operate correctly and may stay “on” continuously, never come on, or cycle on and off excessively. This will result in a reduction of fuel economy, engine overheat at times, and annoying cycling respectively. 4. Heavy duty cooling equipment is required when snow plows, winches, etc., are installed. 5. If a heater unit is not installed in the vehicle or a heater shut-off valve is required, a line connecting the heater connection on the engine to the heater connection on the radiator must be installed. When a shut-off valve is required in the heating system, it must be teed into the system in such a manner as to maintain continuous flow between engine heater connection – radiator heater connection at all times. Do not install any internal flow restrictors. • Heater hose: 3-way or 4-way valves must be used to provide constant water flow through the intake manifold pad area used to mount the TBI unit (L35 only). NOTE: TBI unit does not have internal coolant passages. 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 18 Model Symbol Chart Series 2-Door 2-Door Pickup Fleetside/ Pickup Wideside Sportside 03 + E63 03 + E62 (6.5’ Box) (6.5’ Box) 2-Door ChassisCab 4-Door Ext’d Cab 4-Door Wideside/ Ext’d Cab Fleetside Sportside 53 + E63 (6.5’ Box) C/K 157 4-Door 4-Door 4-Door Extended Crew Cab Crew Cab Chassis- Fleetside/ ChassisCab Wideside Cab 4-Door Utility Suburban 4-Door Ultimate Utility 53 + E62 (6.5’ Box) 43 + E63 (6.5’ Box) 06 03 + E63 (8’ Box) 53 + E63 (8’ Box) C/K 159 06 36 53 + E63 (6.5’ Box) 53 + E63 (6.5’ Box) K 257 C/K 257HD C 259 K 259 43 + E63 (6.5’ Box) 03 + E63 (8’ Box) 03 + E63 (AFV)(8’ Box) 2003 C/K Truck MCE 03 + ZW9 GVWR (Lbs) Nominal Ton Rating Wheel Base (Inches) Cab To Axle (Inches) C/K 6100 1/2 119.0 42 C 6200 K 6400 1/2 143.5 42 C/K 8600 1/2 153.0 42 C 6300/6600 K 6800/6900 C 6400 K 6100 1/2 116.0 1/2 133.0 56 C/K 6400 1/2 157.5 56 C 6800 K 7200 1/2 130.0 C/K 7000 1/2 130.0 K 8600 3/4 143.5 42 C/K 9200 3/4 143.5 42 C/K 9200 3/4 153.0 42 C 8600 3/4 133.0 56 K 8500 3/4 133.0 56 PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 19 Model Symbol Chart (continued) Series 2-Door 2-Door Pickup Fleetside/ Pickup Wideside Sportside 2-Door ChassisCab K 259 03 + E63 (8’ Box) 4-Door Ext’d Cab 4-Door Wideside/ Ext’d Cab Fleetside Sportside 53 + E63 (AFV)(8’ Box) 4-Door 4-Door 4-Door Extended Crew Cab Crew Cab Chassis- Fleetside/ ChassisCab Wideside Cab 4-Door Utility Suburban 4-Door Ultimate Utility 03 + ZW9 53 + E63 (8’ Box) C/K 259HD 43 + E63 (8’ Box) 43 + ZW9 06 GVWR (Lbs) Nominal Ton Rating Wheel Base (Inches) Cab To Axle (Inches) K 8500 3/4 157.5 56 C/K 9200 3/4 133.0 56 C/K 9200 3/4 157.5 56 C/K 9200 3/4 167.0 56 C/K 8600 3/4 130.0 C/K 8600 3/4 130.0 K 11400 1 133.0 56 C/K 11400 1 157.5 56 C/K 11400 1 167.5 56 1 137.0 60 1 161.5 60 1 161.5 84 1 185.5 84 C/K 259 36 K359 03 + E63 (8’ Box) 03 + ZW9 53 + E63 (8’ Box) C/K 359 43 + E63 (8’ Box) 03 + ZW9 C/K 360 53 + ZW9 03 + ZW9 C/K 364 53 + ZW9 2003 C/K Truck MCE 43 + ZW9 C 11400 K 12000 C 11400 K 12000 C 11400 K 12000 C 11400 K 12000 PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 20 C/K (15/25)703 General Arrangement TD005306 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 21 C/K 15706 General Arrangement TD005357 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 22 C/K (15/25)906 General Arrangement TD003358 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 23 C/K (15/25)936 General Arrangement TD005798 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 24 C/K 15703 Regular Cab with Short Box (Option E63) TD006012 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 25 C/K (15/25/25HD)903 Regular Cab with Long Box (Option E63) TD006013 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 26 C/K 15703 Regular Cab, Sportside (Option E62) TD006014 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 27 C/K (15/25/25HD)753 Extended Cab with Short Box (Option E63) TD006019 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 28 C/K (15/25/25HD)953 Extended Cab with Long Box (Option E63) TD006022 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 29 C/K 15753 Extended Cab, Sportside (Option E62) TD006023 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 30 C/K (15/25HD)743 Crew Cab with Short Box (Option E63) TD006024 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 31 C/K 25943HD Crew Cab with Long Box (Option E63) TD006026 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 32 C/K 35903 Regular Cab with Long Box Dooley (Option E63) TD005983a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 33 C/K 35953 Extended Cab with Long Box Dooley (Option E63) TD005983b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 34 C/K 35943 Crew Cab with Long Box Dooley (Option E63) TD006027 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 35 C/K 25HD/K35903 Regular Cab (Option ZW9) TX35903a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 36 C/K 25HD/35943 Crew Cab (Option ZW9) General35943 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 37 C/K 36(0/4)03 Regular Cab (Option ZW9) TX005572 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 38 C/K 36(0/4)53 Extended Cab (Option ZW9) TX005573 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 39 C/K 15706 Tahoe/Yukon TD005557 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 40 C/K (15/25)906 Suburban/Yukon XL TD005558 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 41 C/K (15/25)936 Avalanche TD005701a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 42 C/K (25HD/35/36) Regular Cab CA’s TD006030a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 43 C/K (25HD/35/36) Extended Cab CA’s TD006030b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 44 C/K (25HD/35) Crew Cab CA’s TD006030c 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 45 C/K (15/25) Regular Cab Interior TD006036a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 46 C/K (25HD/35/36) Regular Cab Interior TD006036b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 47 C/K (15/25) Extended Cab Interior TD006036c 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 48 C/K (25HD/35/36) Extended Cab Interior TD006036d 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 49 C/K (15/25) Crew Cab Interior TD006036e 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 50 C/K (25HD/35/36) Crew Cab Interior TD006036f 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 51 C/K (15/25) Regular and Extended Cab Seating Positions TD005545 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 52 C/K (25HD/35/36) Regular and Extended Cab Seating Positions TD005545R 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 53 C/K (15/25/25HD/35) (743/943) Crew Cab Second Row Seating Positions TD006068a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 54 C/K 15706 Seating Positions TD005562 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 55 C/K (15/25)906 Seating Positions TD005561 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 56 C/K (15/25)936 Seating Positions TD005707 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 57 C/K (15/25) Regular Cab Chevy Exterior TD006010a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 58 C/K (25HD/35/36) Regular Cab Chevy Exterior TD006010b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 59 C/K (15/25) Extended Cab Chevy Exterior TD006010d 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 60 C/K (25HD/35/36) Extended Cab Chevy Exterior TD006010e 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 61 C/K (15/25) (43) Crew Cab Chevy Exterior TD006010f 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 62 C/K (25HD/35/36) (43) Crew Cab Chevy Exterior TD006010g 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 63 C/K (15/25/25HD/35/36) (03/43/53/06/36) Door Openings TD005578 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 64 C/K (15/25) (7/9)06 Rear Door Openings TD005567 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 65 C/K (157/159/259) (06) Front End Sheet Metal – Utilities TD005540 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 66 C/K (15/25) Front End Sheet Metal – Pickups and Chassis-Cab TD006009a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 67 C/K (25HD/35/36) Front End Sheet Metal – Pickups and Chassis-Cab TD006009b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 68 C/K (15/25)936 Front End Sheet Metal TD005705 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 69 C/K (15/25) (03/53/06) Outside, Mirror Options TD006039a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 70 C/K (25HD/35/36) Outside, Mirror Options TD006039b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 71 C/K (15/25)936 Outside, Mirror Options TD006039c 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 72 C/K (15/25) (03/53) Back of Cab Profile Nominal TD005534 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 73 C/K (25HD/35/36) Back of Cab Profile Nominal TD005534R 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 74 C/K (15/25) (706/906) Hood Profile – Chevy, Tahoe and Suburban TD005544 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 75 Hood Profile – Chevy, Silverado Pickups and Chassis-Cabs TD006010c 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 76 C/K (15/25) Hood Profile (GMC) TD005553 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 77 C/K (25HD/35/36) Hood Profile (GMC) TD005553R 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 78 C/K (15/25)936 Hood Profile TD005706A/B 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 79 C/K (15/25/25HD/35/36) Hood Inner Panel TD005580 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 80 C/K Fleetside Box TD005535 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 81 C/K (25HD/35) Fleetside Box TD005535R 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 82 C/K Fleetside 6.5 Foot with Quad Steering (Option NYS) TD005992a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 83 C/K (15/25/25HD/35) Stake Pockets TD005581 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 84 C/K (15/25/25HD/35) Fleetside Box, Top Rail TD005536 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 85 C/K (15/25) Fleetside Box Inner Side Panel TD005537 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 86 C/K (25HD/35) Box Inner Side Panel TD005537R 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 87 C/K 157(03/53) Sportside Box TD005541 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 88 C/K 157(03/53) Sportside Box, Top Rail TD005542 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 89 C/K 157(03/53) Sportside, Inner Side Panel TD005543 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 90 Composite Pickup Box Equipment Attachment Recommendations Attachments directly to box composite box material (Commonly used for installation of Cross-Car Tool Boxes, Longitudinal Tool Boxes, and Ladder Racks) • Fasteners threaded directly into the composite material are NOT recommended. • Attachments may be made to the composite material by drilling completely through the composite material and using a bolt, load spreading plate and nut. • Minimum of two fasteners per side are recommended. • Minimum 3/8" or 10mm diameter bolts are recommended. • Load spreading plates 1/8" to 1/4" thick with a minimum area of four square inches (2" x 2", 1.5" x 3", 2.5" diameter, etc.) are recommended to be used between the bolt head or nut and the box inner composite material. • Avoid placement of holes next to features of the box inner panel (corners, radii, etc.) that will preclude the use of a load spreading plate. Attachments of equipment support legs to bed of composite box (Commonly used for support of Longitudinal Side Rail Mounted Tool Boxes) • Avoid disturbance (drilling, bending, etc.) of the bonded surfaces of the composite box inner to the high strength steel cross-sills. • The support leg should contact the composite box bed in the lower surface of the bed longitudinal strengthening ribs. • The support leg mounting surface should have a minimum area of four square inches (2" x 2", 1.5" x 3", 2.5" diameter, etc.) • If possible, the support leg should be placed directly above one of the high strength steel cross-sills beneath the composite box bed surface. • If the support leg cannot be located directly above one of the high strength steel cross-sills, a “load transfer” plate should be placed between the support leg and the composite box bed. • The load transfer plate should be 1/4" thick. • The load transfer plate should be placed in the lower surface of the bed longitudinal strengthening ribs. • The load transfer plate should span the distance between the two closest high strength steel cross-sills. Other Composite Box Equipment Recommendations • Do not let aftermarket equipment touch (to have hard contact) in corners (radii) of the composite box inner walls. • Do not force or wedge equipment into the pickup box – deflecting the side walls. • Points of contact between aftermarket equipment and the composite box panels, that are not securely fastened, may cause undesirable wear to the box panels. • Maximum load limits for Composite Box equipment are as follows: • Ladder Rack and Cargo – 800 lbs. (364 kg) • Cross Toolbox and Cargo – 400 lbs. (181 kg) • Side Boxes and Cargo – 350 lbs. Per side (159 kg per side) • The combined weight for all rail-mounted equipment should not exceed 1,200 lbs. (545 kg). 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 91 General Arrangement TD006032a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 92 Forward Cross-sections TD006032b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 93 Center and Rear Cross-sections TD006032c 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 94 Second Tier Loading Provisions TD006032d 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 95 Stake Pockets TD006032e 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 96 Bulk Head Divider and Cargo Tie-Downs TD006032f 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 97 Tailgate and Spoiler TD006032g 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 98 Platform Cross Sills – 6.5 Foot Pickup Box, Composite PRO-TECH (RPO E37) TD005987a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 99 Platform Cross Sills – 6.5 Foot Pickup Box, Fleetside (RPO E63), Sportside/Stepside (RPO E62) TD005987b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 100 Platform Cross Sills – 8 Foot Pickup Box, Fleetside (RPO E63) TD005987c 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 101 C/K (15/25)936 Cargo Area TD005702 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 102 C/K (15/25)936 Cargo Area Inner Side Panel TD005708 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 103 C/K (15/25)936 Side Storage Compartment TD005700 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 104 C/K 15706 Luggage Rack and Running Boards TD005565 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 105 C/K (15/25)906 Luggage Rack and Running Boards TD005566 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 106 C/K (15/25)936 Running Board Mounting Location TD005701b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 107 C/K (25HD/35/36) Clearance Lamps TD005579 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 108 C/K (36) Pressure Relief Valve Shield TD005797 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 109 C/K (15/25) Front Floor Seat Mounting Location TD005547 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 110 C/K (25HD/35/36) Front Floor Seat Mounting Location TD005547R 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 111 C/K (25HD/35/36) Front Floor Structure TD005582 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 112 C 15703 Rail and Crossmember Arrangement TD05970a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 113 K 15703 Rail and Crossmember Arrangement TD005970b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 114 C 15903 Rail and Crossmember Arrangement TD005973a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 115 K 15903 Rail and Crossmember Arrangement TD005973b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 116 C/K 25903 Rail and Crossmember Arrangement TD005976 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 117 C 15753 Rail and Crossmember Arrangement TD005972a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 118 K 15753 Rail and Crossmember Arrangement TD005972b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 119 C 15953 Rail and Crossmember Arrangement TD005974a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 120 K 15953 Rail and Crossmember Arrangement TD005974b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 121 C/K 15706 Rail and Crossmember Arrangement TD005981a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 122 C/K 15906 Rail and Crossmember Arrangement TD005348 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 123 C/K 25906 Rail and Crossmember Arrangement TD005977a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 124 C/K 25936 Rail and Crossmember Arrangement TD005977b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 125 C/K 25753 Rail and Crossmember Arrangement TD005975a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 126 C/K 25953 Rail and Crossmember Arrangement TD005975b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 127 C (15) Front Frame Pickup TD005324 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 128 C (25) Front Frame Pickup TD005323 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 129 K (15) Pickup C/K (15) Utility Front Frame TD005325 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 130 K (25) Pickup C/K (25) Utility Front Frame TD005326 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 131 C/K (25HD/35/36) Front Frame 15753457 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 132 C (25HD/35/36) Front Frame W/Dim 15753457 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 133 K (25HD/35/36) Front Frame W/Dim 15753919 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 134 C/K (25HD/K35)903 Intermediate and Rear Frame 15753460 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 135 C/K (25HD/K35)903 Intermediate and Rear Frame W/Dim 15753460 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 136 C/K 25753 HD Intermediate and Rear Frame 15753459 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 137 C/K 25753 HD Intermediate and Rear Frame W/Dim 15753459 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 138 C/K (25HD/35)953 Intermediate and Rear Frame 15753462 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 139 C/K (25HD/35)953 Intermediate and Rear Frame W/Dim 15753462 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 140 C/K 25743 HD Intermediate and Rear Frame 15753458 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 141 C/K 25743 HD Intermediate and Rear Frame W/Dim 15753458 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 142 C/K (25HD/35)943 Intermediate and Rear Frame 15753461 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 143 C/K (25HD/35)943 Intermediate and Rear Frame W/Dim 15753461 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 144 C/K 36003 Intermediate and Rear Frame 15753471 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 145 C/K 36003 Intermediate and Rear Frame W/Dim TD005751 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 146 C/K 36403 Intermediate and Rear Frame 15754173 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 147 C/K 36403 Intermediate and Rear Frame W/Dim TD005754 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 148 C/K 36053 Intermediate and Rear Frame 15754172 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 149 C/K 36053 Intermediate and Rear Frame W/Dim TD005752 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 150 C/K 36453 Intermediate and Rear Frame 15754174 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 151 C/K 36453 Intermediate and Rear Frame W/Dim TD005755 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 152 C/K (15/25) Spare Tire Carrier Pickup TD006070c 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 153 C/K (15/25) Spare Tire Carrier Utility TD006070b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 154 C/K (25HD/35/36) Spare Tire Carrier TD006070a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 155 C/K (15/25) Platform Hitch Pickup TD005328 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 156 C/K (15/25) Platform Hitch Utility TD005360a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 157 C/K (25HD) Platform Hitch Short Box Pickup TD005360b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 158 C/K (25HD/35) Platform Hitch Long Box Pickup TD005360c 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 159 C/K (15/25)936 Platform Hitch TD005795 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 160 C (15/25) Front Axle/Tire Data Pickup TD005335 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 161 K (15/25) Front Axle/Tire Data Pickup TD005336 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 162 C/K (15/25)936 Front Axle/Tire Data TD005768 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 163 C (15/25) Front Axle/Tire Data Utility TD005368 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 164 K (15/25) Front Axle/Tire Data Utility TD005369 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 165 C (25HD/35/36) Front Axle/Tire Data TD005372 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 166 K (25HD/35/36) Front Axle/Tire Data TD005373 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 167 C/K (15/25) Rear Axle/Tire Data TD005762A/B 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 168 C/K (25HD/35) Rear Axle/Tire Data TD005376 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 169 C/K (36) Rear Axle/Tire Data TD005374 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 170 C/K (15/25)(7)(03/53) 26 Gallon Fuel Tank TD005985a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 171 C/K (15/25)(9)(03/53) 34 Gallon Fuel Tank TD005985b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 172 C/K 15706 26 Gallon Fuel Tank TD005364 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 173 C/K 15906 33 Gallon Fuel Tank TD005365 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 174 C/K 25906 36 Gallon Fuel Tank TD005363 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 175 C/K (25HD) (7) (43/53) 26 Gallon Fuel Tank TD005366 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 176 C/K (25HD/35) (9) (03/43/53) 34 Gallon Fuel Tank TD005367 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 177 C/K 36 23/27 Gallon Fuel Tank TD005362 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 178 4.3 L V6 Gas Engine, Pickup, Option LU3 and L35 TD005984d 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 179 4.8 and 5.3 L V8 Gas Engine, Pickup, Option LR4 and LM7 TD005984c 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 180 6.0 L V8 Gas Engine, Pickup, Option LQ4 TD005332 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 181 6.0 L V8 Gas Engine, Pickup, Option LQ4 w/NYS (Quad Steering) TD005984a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 182 5.3 L V8 Gas Engine, Utility, Option LM7 TD005984b 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 183 6.0 L V8 Gas Engine, Utility, Option LQ4 and LQ9 TD005984e 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 184 8.1 L V8 Gas Engine, Option L18 TD005753 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 185 C/K 36 (03) 8.1 L V8 Gas Engine, Option L18 CK3603ALQ4 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 186 C/K 36 (53) 8.1 L V8 Gas Engine, Option L18 CK3653LQ4 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 187 8.1 L V8 Gas Engine, Utility, Option L18 (Federal) TD005984h 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 188 8.1 L V8 Gas Engine, Utility, Option L18 (California) TD005984f 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 189 8.1 L V8 Gas Engine, Utility, Option L18 (Export) TD005984g 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 190 6.6 L V8 Diesel Engine, Pickup, Option LB7 TD005984j 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 191 6.6 L V8 Diesel Engine, Chassis Cab, Option LB7 CK36LBT 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 192 C/K 36 Power Take Off (Chelsea) 6 Speed Manual Transmission TD005758a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 193 C/K 36 Power Take Off (Muncie) 6 Speed Manual Transmission TD005759a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 194 C/K 36 Power Take Off Manual Transmission TD005758/59B 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 195 C/K 36 Power Take Off (Chelsea) 5 Speed Auto Transmission TD005760a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 196 C/K 36 Power Take Off (Muncie) 5 Speed Auto Transmission TD005761a 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 197 C/K 36 Power Take Off Automatic Transmission TD005760/61B 2003 C/K Truck MCE Mid Bussed Electrical Center (MBEC) 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 198 MBEC 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 199 MBEC 2003 C/K Truck MCE PAGE 2003 C/K TRUCK MID CYCLE ENHANCEMENT 200