Chevrolet 2012Colorado Owner`s manual

PAGE
COLORADO/CANYON S/T P.U. AND CHASSIS-CAB
i
General Information............................................................................................................... See “Light Duty General Information” section
Camper Loading ............................................................................................................. See Online Order Guide — Light Duty Information
Trailering Information .........................................................................................................
.................................................................................................... See “Light Duty Trailering Information” section
Model and Option Weights .........................................................
.................................................... See Online Order Guide — Model & Option Weight–Weight Calculator
BODY BUILDERS INSTRUCTIONS .................................................................................................................................................................. 1
Section 0 – General Instructions ...............................................................................................................................................................1
Section 1 – Body..........................................................................................................................................................................................2
Air Conditioning ....................................................................................................................................................................................2
Section 2 – Frame........................................................................................................................................................................................3
Flanges ..................................................................................................................................................................................................3
Holes .....................................................................................................................................................................................................3
Welding .................................................................................................................................................................................................3
Alterations .............................................................................................................................................................................................4
Shear Plate Attachments ......................................................................................................................................................................4
Section 3 – Front Suspension ....................................................................................................................................................................4
Section 4 – Rear Suspension .....................................................................................................................................................................5
Section 5 – Brakes ......................................................................................................................................................................................5
Section 6 – Engine.......................................................................................................................................................................................6
Section 7 – Transmission............................................................................................................................................................................7
Section 8 – Fuel and Exhaust.....................................................................................................................................................................8
Fuel Systems ........................................................................................................................................................................................8
Fuel Lines ..............................................................................................................................................................................................8
Fuel Tank ...............................................................................................................................................................................................9
Exhaust System ....................................................................................................................................................................................9
Section 9 – Steering ..................................................................................................................................................................................10
Section 10 – Tires ......................................................................................................................................................................................11
2004 GMT355 – Colorado/Canyon – Revised 06/2009
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
ii
BODY BUILDERS INSTRUCTIONS – (Continued)
Section 12 – Electrical Battery and Battery Cables...............................................................................................................................11
Section 13 – Cooling..................................................................................................................................................................................13
Accessory Power Supply Feed:..........................................................................................................................................................12
Model Symbol Chart...........................................................................................................................................................................................14
VEHICLE GENERAL ARRANGEMENT
S/T15403�����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������15
S/T15653�����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������16
S/T15643�����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������17
S/T15603�����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������18
PICKUP WEIGHT DISTRIBUTION
Regular Cab Pickup – S/T15403...............................................................................................................................................................19
Extended Cab Pickup – S/T15653............................................................................................................................................................20
Crew Cab Pickup – S/T15643...................................................................................................................................................................21
Regular Chassis-Cab – S/T15603.............................................................................................................................................................22
BODY
EXTERIOR
Pickup: General Arrangement – S/T15403�������������������������������������������������������������������������������������������������������������������������������������23
Pickup: General Arrangement – S15653����������������������������������������������������������������������������������������������������������������������������������������24
Pickup: General Arrangement – T15653����������������������������������������������������������������������������������������������������������������������������������������25
Pickup: General Arrangement – S/T15643�������������������������������������������������������������������������������������������������������������������������������������26
Chassis-Cab: General Arrangement – S/T15603��������������������������������������������������������������������������������������������������������������������������27
Cab – Crew (43) – H/L/W, Hood Opening, Rear Window..............................................................................................................28
Door Swings – Extended Cab (53)...................................................................................................................................................29
Door Swings – Crew Cab (43)..........................................................................................................................................................30
Cab, Rear Profile – Regular (03).......................................................................................................................................................31
2004 GMT355 – Colorado/Canyon – Revised 06/2009
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
iii
BODY, EXTERIOR — Continued
Cab, Rear Profile – Extended (53)....................................................................................................................................................32
Cab, Rear Profile – Crew (43)...........................................................................................................................................................33
Hood Profile���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������34
Front End Sheet Metal......................................................................................................................................................................35
Pickup Box, Tie Down Loops, Bulkhead Dividers, Two Tier Loading, PU Box Top...................................................................36
Pickup Box, Tie Down Loops, Bulkhead Dividers, Two Tier Loading, PU Box Top...................................................................37
Pickup Box, Tie Down Loops, Bulkhead Dividers, Two Tier Loading, PU Box Top...................................................................38
Pickup Box, Tie Down Loops, Bulkhead Dividers, Two Tier Loading, PU Box Top...................................................................39
INTERIOR
Cab Interior – Regular Cab (03)........................................................................................................................................................40
Cab Interior – Extended Cab (53).....................................................................................................................................................41
Cab Interior – Crew Cab (43)............................................................................................................................................................42
Seating Positions (03 & 53)...............................................................................................................................................................43
Seating Positions (43)........................................................................................................................................................................44
CHASSIS
FRAME AND CROSSMEMBER ARRANGEMENT
Frame and Crossmember – S/T154 (03) Regular Cab Pickup.....................................................................................................45
Frame and Crossmember – S/T156 (43) Crew Cab Pickup..........................................................................................................46
Frame and Crossmember – S/T156 (53) Extended Cab Pickup...................................................................................................47
Frame and Crossmember – S/T156 (03) Regular Cab Chassis-Cab...........................................................................................48
SPARE TIRE
Spare Tire Location (compact) S Truck..........................................................................................................................................49
Spare Tire Location (full size) T Truck.............................................................................................................................................50
TRAILER HITCH
Factory Installed Trailer Hitch, Option VR4....................................................................................................................................51
2004 GMT355 – Colorado/Canyon – Revised 06/2009
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
iv
AXLE SUSPENSION
Front Axle / Tire Data........................................................................................................................................................................... 52-54
Rear Axle / Tire Data............................................................................................................................................................................ 55-58
FUEL SYSTEMS
S/T15403 & S/T15603 & S/T15653............................................................................................................................................................59
S/T15643�����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������60
EXHAUST SYSTEMS
Exhaust System S15403���������������������������������������������������������������������������������������������������������������������������������������������������������������������������61
Exhaust System T15403............................................................................................................................................................................62
Exhaust System S156 (03/43/53)..............................................................................................................................................................63
Exhaust System T156 (03/43/53)�������������������������������������������������������������������������������������������������������������������������������������������������������������64
Exhaust System S/T15653 & S/T15643 with 5.3L V8 Option LH9.........................................................................................................65
Tailpipe Locations S/T 15 (000).................................................................................................................................................................66
2004 GMT355 – Colorado/Canyon – Revised 10/2009
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
BODY BUILDERS INSTRUCTIONS
The Incomplete Vehicle Document (IVD) is supplied with each incomplete vehicle, and provides information that should be used by
intermediate and final stage manufacturers in determining conformity to applicable Federal Motor Vehicle Safety Standards (FMVSS).
The IVD also includes information which must be followed in order to ensure that Environmental Protection Agency (EPA) and California
emissions certification requirements and NHTSA Fuel Regulations are met.
The Body Builders Manual contains information that may be used in addition to the IVD for any manufacturer making alterations to 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 any way 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 headlamps
when necessary. Check for proper operation of windshield washer, wipers and defroster system.
Extreme care must be taken when working on vehicles equipped with Powertrain Control Module (PCM), Body Control Module (BCM) or
any electronic unit associated with an inflatable restraint system. (See Owner’s Manual).
If arc-welding is employed on the chassis, precautions must be taken to protect all vehicle components, especially brake, fuel lines and
fuel tank assembly, electrical wiring and ECM/PCM/TCM or BCM. 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.
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.
2004 GMT355 – Colorado/Canyon
(Section 0 — continued on next page)
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
(Section 0 — continued from previous page)
Service and service replacement parts for your add-on systems may not be available from a GM dealer. Those installing aftermarket systems
should provide information as to where and how to obtain service.
Section 1 — Body
Body structures, interior and accessory arrangements must be designed into the 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 MVSS standard on flammability. Areas of specific concern, but not limited to, are:
• Underbody exhaust, muffler and tail pipe shields and insulators.
• Front floor interior insulation.
• Dash mat insulation.
• Engine cowl insulation – interior and exterior.
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.
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
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 low carbon steel
(36,000 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.
Welding
CAUTION: Fueltank and fuel lines must be drained and all vapors purged to ensure noncombustible mixture before any welding, brazing
or soldering.
When welding low carbon steel side rails, crossmembers and brackets (32,000 or 36,000 PSI yield strength), emphasis is placed upon weld
application techniques to avoid stress risers that may adversely affect frame operating stresses.
When welding is performed anywhere 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.
2004 GMT355 – Colorado/Canyon
(Section 2 — continued on next page)
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
(Section 2 — continued from previous page)
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 motor vehicle safety standards and for warranty
on items such as driveshafts, universal joints, center bearings and rear transmission tailshaft, transfer case 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 16 mm in diameter, are consistently placed along the frame side member in the center of the web on each frame.
When additional holes are required for shear plate attachment, they should be no larger than 20 mm (0.75 in.) in diameter. Holes are to be
drilled no closer than 63.5 mm (2.5 in.) apart. For holes drilled forward of the rear axle, centers are to be no closer than 63.5 mm (2.5 in.)
from the top or bottom flanges and no closer than 89 mm (3.5 in.) from any suspension attachments. For frame holes drilled rearward of
the rear axle, hole centers are to be no closer than 51 mm (2.0 in.) from the top or bottom flange and no closer than 89 mm (3.5 in.) from
suspension attachments.
No additional holes or notching of either top or bottom frame flanges is allowed.
Rear bodies or platforms added to the vehicle must utilize the released attachment points used by the pick-up box, along with fasteners of
the same diameter. These are minimum requirements; additional fasteners are permissible.
Section 3 — Front Suspension
See chassis data information for clearances and assistance in calculating trim heights.
Since there is a large variation in completed vehicle front weight due to differences in body weight and equipment, the front suspension
alignment must be checked and reset if necessary after the vehicle is completed. Caster and camber should be set with reference to the
“A” dimensions.
See Truck Service Manual for complete alignment procedure, specifications and measurement of the “A” dimension under “Diagnosis and
Front Alignment” section.
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
Section 4 — Rear Suspension
Clearance to body should be provided for the suspension, axle, driveshaft and tires under the following conditions: (1) Axle in full jounce
against the metal-to-metal stop, (2) Axle at 4.5˚ roll with one side of axle in full jounce at the metal-to-metal stop and (3) Axle at design
position. Allowance for the tire chain clearance shown on a maximum grown tire must allow for (1.66 in.) clearance to the sides of the tire
and (2.5 in.) to the top of the tire. Be sure sufficient clearance is provided for suspension, axle and tire and wheel in full vertical travel (up
and down).
NOTE: Notification to the consumer may be required in certain states if tire chains cannot be used.
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.
It is mandatory that no change be made to the brake main cylinder location, brake pedal push rod length or pedal position.
Ensure that hydraulic brake system is free of air and hydraulic leaks. Bleed brakes if required, following procedures as outlined in truck
chassis service manual. Ensure that vacuum booster system or hydroboost system is functional and free of leaks.
Check master cylinder fluid level and fill as necessary. (Refer to Owner’s Manual).
Check power steering fluid level for models equipped with hydroboost brake. (Refer to Owner’s Manual).
Added floor covering or carpeting must not restrict service or parking brake pedal 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).
2004 GMT355 – Colorado/Canyon
(Section 5 — continued on next page)
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
(Section 5 — continued from previous page)
Body builder is to verify that the brake warning switch is operative. The brake warning switch on models equipped with vacuum-hydraulic
brakes is located adjacent to the master cylinder vacuum unit. This includes both the brake system differential pressure 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 is 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).
• 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.
2004 GMT355 – Colorado/Canyon
(Section 6 — continued on next page)
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
(Section 6 — continued from previous page)
• Caution must be taken so that the accelerator pedal remains properly located. Guidelines for accelerator pedal locations are as
follows:
— Ensure that the accelerator can freely operate from idle to wide-open throttle position and return. Make sure that the pedal
will not hang up on any nearby items such as carpets, floor, screws, wiring harnesses, etc. Engine cover should have at least
one inch (25 mm) clearance to side of accelerator pedal with the carpet mat installed.
— Accelerator to brake pedal relationship 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 and port fuel injection (PFI) or sequential central port injector (SCPI) and associated tubes, hoses and
pipes, air cleaner outside air hose, mass air flow sensor, fuel pump and inlet manifold, fuel vapor canister.
• Exhaust system.
• Ignition system distributor and initial spark timing setting, spark plugs, spark plug wires.
• Crankcase ventilation system.
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 gear shift lever is in neutral or park position. Readjust
the shift linkage or neutral start backup switch if necessary as outlined in the Truck Service Manual.
Models equipped with manual transmission use a hydraulic clutch actuator. Check fluid level as outlined in the vehicle owner’s manual.
It is mandatory that no change be made to the clutch master cylinder location, clutch master or slave cylinder push rod length, or pedal
position.
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
8
Section 8 — Fuel and Exhaust
Fuel Systems
Due to the critical nature of sealing the fuel system, anyone making modifications or alterations to the existing system must assume
complete responsibility for the system reliability, performance and compliance to FMVSS 301.
The fuel evaporative emission control equipment is certified to be in compliance with the Federal and California Vehicle Emission Standards.
Any alterations to systems or components and their location could void compliance. System includes but not limited to:
• Fuel tank, metering unit, lines including purge control solenoids and canister or canisters.
For these reasons, NO ALTERATION OF THE FUEL SYSTEM IS RECOMMENDED.
Fuel Lines
Fuel line routing precautions:
• 12 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. Steel tube ends should be
beaded for hose retention. Fuel supply is pressurized by an in-tank pump for PFI and SCPI systems. Coupled hose or nylon
quick-connects must be used. Clamped hose is not acceptable for PFI and SCPI systems.
All engines require a fuel return system which returns excess fuel from the injection pump and injector nozzles back to fuel tanks. Care
should be taken that these lines are not blocked nor their hoses pinched.
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.
2010 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
9
(Section 8 — continued from previous page)
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.
Gasoline fueled vehicles are now 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.
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 and could also
cause the mechanical and emission performance warranty to be voided.
Exhaust System
Particular care should be taken to prevent the possibility of exhaust fumes and carbon monoxide exposure to vehicle occupants in units
completed by body builders. Holes and openings through the floor and all other parts of the body must be permanently and adequately
sealed by the body builder to avoid exhaust intrusion into any 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.
2010 GMT355 – Colorado/Canyon
(Section 8 — continued on next page)
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
10
(Section 8 — continued from previous page)
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 underbody seams and holes. Auxiliary power plants should also be tested under the same conditions. Tail pipe exit ahead of
rear wheels is not recommended.
Check for leaks in exhaust systems and repair as required.
Any exhaust joint which has been disassembled must have the exhaust gasket replaced and the fasteners torqued to specifications.
Re-check exhaust system for leaks.
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 aluminized stainless steel.
Heatshields are mounted to the underbody and/or exhaust system components (catalytic converter, muffler and tail pipe). Shields for the
propshaft hanger bearings are also provided in some vehicles.
Section 9 — Steering
Check power steering fluid level and system operations. (Refer to Owner’s Manual).
The power steering hydraulic system should not be used to drive any other accessories.
Steering wheel and horn pad must not be altered or replaced.
The steering column mast jacket must not be altered.
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
11
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 and
distance from centerline of rim to wheel mounting face must be the same as the replaced original equipment wheel to ensure proper wheel
bearing loading and clearance of tires to body and chassis components.
Increasing tire and wheel capacity does not necessarily increase vehicle GVW ratings. 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.
Any substitution of tires may affect Speedometer/Odometer accuracy.
Section 12 — Electrical Battery and Battery Cables
The vehicle battery should be located and positioned to make use of the existing 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
frame rail, a cable of similar gauge be provided between the frame rail and the engine. This is required due to the heavy electrical loads
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:
Cable Gauge
4
2
0
Combined length of positive and negative
Cable in Inches (Copper)
66
107
170
If the battery is remotely mounted (other than in the engine compartment) the ‘sense’ circuit in the generator regulator shall be used. The
sense circuit consists of a 7.76 OHM 1/4 watt resistor connected in series between the ‘S’ terminal of the generator and the B+ terminal of
the battery.
2004 GMT355 – Colorado/Canyon – Revised 06/2009
(Section 12 — continued on next page)
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
12
(Section 12 — continued from previous page)
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 that 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.
Fusible Link Repair Procedure:
1. Cut damaged fusible link from wiring harness assembly splice.
2. Strip insulation from harness wire as required to splice on new fusible link.
3. Fabricate a new fusible link wire approximately 6 to 8 in. long from the same wire size as the original link. (Acceptable fusible
link material will be imprinted with the wire size and the wording to identify it as fusible link. Fusible link cable is not the same as
normal vehicle wiring.)
4. Terminate fusible link harness wire with a suitable compression splice clip, and solder with an electrical grade rosin core solder.
Wrap splice area with tape to provide electrical insulation, as well as mechanical strain relief at the splice.
5. Strip, terminate, solder, and insulate remaining end of fusible link with appropriate termination to be compatible with the rest of
the electrical system.
6. For further information, refer to the instruction manual in the wiring repair kit referenced elsewhere in this section.
Accessory Power Supply Feed:
For power requirements to service additional devices to be added by body builder/upfitter, the power supply source must be at the junction
block on the front of dash above battery using the small on the left-hand side of junction block.
NOTE: A ground stud has also been provided above the junction block.
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
13
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. Continuous coolant flow is necessary from heater connection on engine-to-heater connection on radiator to control transmission
oil temperatures during closed thermostat (warm-up) operation. Do not alter this flow as it may result in premature engine or
transmission failure.
5. If a heater unit is not installed in the vehicle or a heater shut-off-valve is required, a line connecting the heater connection on the
engine to the heater connection on the radiator must be installed. When a shut-off valve is required in 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.
6. Use GM 6277M Long Life Coolant only.
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.
• If in-line shut-off valve is used in combination with 3-way valves, shut-off valve must not be closed until 3-way valve at engine is
in the proper position.
3
4
Valve Sources
Red-White Valve Corp., Carson, CA
Ranco Controls Div., Delaware, OH
Ranco Controls Div., Delaware, OH
Be sure to add coolant to system after adding capacity to system (heaters).
2004 GMT355 – Colorado/Canyon
(213) 549-1010
(614) 876-8022
(614) 876-8022
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
14
Model Symbol Chart
ENGINEERING
MODEL
TRUCK (Optional)
MODEL /
MODEL /
MODEL /
MODEL /
GVWR
WHEELBASE
MERCHANDISING MERCHANDISING MERCHANDISING MERCHANDISING
(kg/lbs)
(mm/in)
DESCRIPTION
DESCRIPTION
DESCRIPTION
DESCRIPTION
CAB-TO-AXLE
(mm/in)
03
S154
Regular Cab
4,850 C6I
S156
53
43
Extended Cab
Crew Cab
5,000 C5C
5,300 C3H
3199 / 126
5,500 C8S & LH8
53 – 34.24”
43 – 22.54”
03
T154
Regular Cab
5,150 C6F
34.15”
2825 / 111
2825 / 111
34.15”
5,300 C3H
53
43
T156
5,500 C8S & LH83199 / 126
Extended Cab
Crew Cab
53 – 34.24”
43 – 22.54”
03
S156 / T156
Chassis Cab
03 – 48.97”
LH8 – 5.3L V8 SFI
Colorado/Canyon – Revised 05/2008
5,500 C8S
3199 / 126
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
15
­­­S/T15403
TD006074A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
16
S/T15653
TD006074C
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
17
S/T15643
TD006074B
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
18
S/T15603
TD006074D
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
19
Regular Cab Pickup – S/T15403
TD006098A
TD000000A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
20
Extended Cab Pickup – S/T15653
TD006098B
TD000000A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
21
Crew Cab Pickup – S/T15643
TD006098C
TD000000A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
22
Regular Chassis-Cab – S/T15603
TD006098D
2004 GMT355 – Colorado/Canyon – Revised 02/2007
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
23
Pickup: General Arrangement – S/T15403
TD006071A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
24
Pickup: General Arrangement – S15653
TD006072A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
25
Pickup: General Arrangement – T15653
TD006072B
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
26
Pickup: General Arrangement – S/T15643
TD006073A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
27
Chassis-Cab: General Arrangement – S/T15603
TD006099A
2004 GMT355 – Colorado/Canyon – Revised 02/2007
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
28
Cab – Crew (43) – H/L/W, Hood Opening, Rear Window
TD006075A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
29
Door Swings – Extended Cab (53)
TD006308A
TD000000A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
30
Door Swings – Crew Cab (43)
TD006082A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
31
Cab, Rear Profile – Regular (03)
TD006078A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
32
Cab, Rear Profile – Extended (53)
TD006078B
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
33
Cab, Rear Profile – Crew (43)
TD006078C
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
34
Hood Profile
TD006100A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
35
Front End Sheet Metal
TD006076A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
36
Pickup Box, Tie Down Loops, Bulkhead Dividers, Two Tier Loading, PU Box Top
TD006079A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
37
Pickup Box, Tie Down Loops, Bulkhead Dividers, Two Tier Loading, PU Box Top
TD006081A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
38
Pickup Box, Tie Down Loops, Bulkhead Dividers, Two Tier Loading, PU Box Top
TD006079B
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
39
Pickup Box, Tie Down Loops, Bulkhead Dividers, Two Tier Loading, PU Box Top
TD006081B
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
40
Cab Interior – Regular Cab (03)
TD006088A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
41
Cab Interior – Extended Cab (53)
TD006088B
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
42
Cab Interior – Crew Cab (43)
TD006088C
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
43
Seating Positions (03 & 53)
TD006088.6
Colorado/Canyon – Revised 05/2008
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
44
Seating Positions (43)
TD006088.7
Colorado/Canyon – Revised 05/2008
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
45
Frame and Crossmember – S/T154 (03) Regular Cab Pickup
TD006084A
TD000000A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
46
Frame and Crossmember – S/T156 (43) Crew Cab Pickup
TD006084B
TD000000A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
47
Frame and Crossmember – S/T156 (53) Extended Cab Pickup
TD006084C
TD000000A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
48
Frame and Crossmember – S/T156 (03) Regular Cab Chassis-Cab
TD006084D
TD000000A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
49
Spare Tire Location (compact) S Truck
TD006083A
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
50
Spare Tire Location (full size) T Truck
TD006083B
2004 GMT355 – Colorado/Canyon
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
51
Factory Installed Trailer Hitch, Option VR4
22.5 X 8.5 DAI SLOT
[.65] [.60]
CL
OF VEHICLE
533.9
560.0
21.02
22.05
175.0
C
L
REAR AXLE
6.89
904.3
35.6
389.3
15.33
109.0
4.29
150.8
5.94
-36.5
27.5
NORMAL TOP
OF FRAME
C
L
REAR AXLE
35.3 X 15.3 DIA SLOT
[1.39] [.60]
VR4 - TRAILER HITCH
GMT355-TRAILER HITCH
1.08
65.9
2.6
25.0
[.98]
[
]=INCHES
AND31425.3
TD000000A
2004 GMT355 – Colorado/Canyon – Revised 06/2006
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
52
Front Axle / Tire Data
ANE88663.3
TD000000A
2004 GMT355 – Colorado/Canyon – Revised 10/2007
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
53
Front Axle / Tire Data (cont’d)
ANE88663.4
2004 GMT355 – Colorado/Canyon – Revised 10/2007
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
54
Front Axle / Tire Data (cont’d)
ANE88663.5
2004 GMT355 – Colorado/Canyon – Revised 10/2007
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
55
Rear Axle / Tire Data
ANE89377.3
TD000000A
2004 GMT355 – Colorado/Canyon – Revised 10/2007
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
56
Rear Axle / Tire Data (cont’d)
ANE89377.4
2004 GMT355 – Colorado/Canyon – Revised 10/2007
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
57
Rear Axle / Tire Data (cont’d)
ANE89377.5
2004 GMT355 – Colorado/Canyon – Revised 10/2007
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
58
Rear Axle / Tire Data (cont’d)
ANE89377.6
2004 GMT355 – Colorado/Canyon – Revised 10/2007
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
59
Fuel Systems S/T15403 & S/T15603 & S/T15653
TD006085.3
TD000000A
2004 GMT355 – Colorado/Canyon – Revised 02/2007
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
60
Fuel Systems S/T15643
TD006085.4
2004 GMT355 – Colorado/Canyon – Revised 06/2006
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
61
Exhaust System S15403
TD006086.8
TD000000A
2004 GMT355 – Colorado/Canyon – Revised 06/2007
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
62
Exhaust System T15403
TD006086.9
TD000000A
2004 GMT355 – Colorado/Canyon – Revised 06/2007
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
63
Exhaust System S156 (03/43/53)
TD006086.10
TD000000A
2004 GMT355 – Colorado/Canyon – Revised 06/2007
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
64
Exhaust System T156 (03/43/53)­­
TD006086.11
TD000000A
2004 GMT355 – Colorado/Canyon – Revised 06/2007
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
65
Exhaust System S/T 15653 & S/T 15643 With 5.3L V8 Option LH9
TD006086.12
2008 GMT355 – Colorado/Canyon – Revised 10/2009
09 LD MS_S_T_PU_CC_D3.indd 65
10/19/09 2:58:36 PM
PAGE
Colorado/Canyon S/T P.U. and Chassis-Cab
66
Tailpipe Locations S/T15 (000)­­
TD006086.13
2004 GMT355 – Colorado/Canyon – Revised 06/2007