Owner`s manual

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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
Section 12 – Electrical Battery and Battery Cables...............................................................................................................................11
Accessory Power Supply Feed: ..........................................................................................................................................................12
Section 13 – Cooling ..................................................................................................................................................................................13
Model Symbol Chart...........................................................................................................................................................................................14
S/T SMALL UTILITY – SUV 
(
C
HEVY BLAZER & GMC JIMMY
)
S/T Small Utility – SUV 2004
i
PAGE

Summary of content (39 pages)

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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) i BODY BUILDERS INSTRUCTIONS .................................................................................................................................................................... 1 Section 0 – General Instructions ................................................................................................................................................................1 Section 1 – Body..............................................
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) ii CHASSIS GENERAL CHASSIS ARRANGEMENT 2 Door Utility, General Arrangement – S/T 10516..........................................................................................................................15 4 Door Utility, General Arrangement – S/T 10506..........................................................................................................................16 BODY EXTERIOR GENERAL ARRANGEMENT Outside Mirror Options .............
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) iii AXLE/SUSPENSION Front Axle / Tire Data Chart – S 10000 ....................................................................................................................................................30 Front Axle / Tire Data Chart – T 10000 ....................................................................................................................................................
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 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).
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 2 (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.
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 3 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.
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 4 (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.
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 5 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.
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 6 (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.
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 7 (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.
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 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.
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 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.
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 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.
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 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.
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 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.
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 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.
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 14 Model Symbol Chart TRUCK (Optional) ENGINEERING MODEL MODEL / MERCHANDISING DESCRIPTION MODEL / MERCHANDISING DESCRIPTION MODEL / MERCHANDISING DESCRIPTION MODEL / MERCHANDISING DESCRIPTION GVWR (kg/lbs) WHEELBASE (mm/in) S10516 16 With E55 Endgate 2018/4450 2553/100.5 T10516 16 With E55 Endgate 2220/4850 2267/5000 2553/100.
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 15 S/T 10516 — 2 Door Utility, General Arrangement TD005626 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 16 S/T 10506 – 4 Door Utility, General Arrangement TD005626 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 17 Outside Mirror Options TD005723 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 18 S/T Front End Sheet Metal TD005720 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 19 S/T 10506 4 Door Utility Exterior TD005630 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 20 S/T 10516 2 Door Utility Exterior TD005629 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 21 S/T 10516 2 Door Utility Hi-Wider Exterior TD005636 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 22 S/T 10516 – 2 Door Utility, Interior Seating TD000000 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 23 S/T 10506 – 4 Door Utility, Interior Seating TD000000 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 24 S 10506 Rail and Crossmember Arrangement TD005626 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 25 T 10506 Rail and Crossmember Arrangement TD005626 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 26 S 10516 Rail and Crossmember Arrangement TD005960d S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 27 T 10516 Rail and Crossmember Arrangement TD005960c S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 28 S/T 10506 – 4 Door Utility, Spare Tire Carrier TD005626 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 29 S/T 105 (06/16) Utility, Trailer Hitch Mounting TD005620 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 30 S 10000 Front Axle / Tire Data Chart TD005637 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 31 T 10000 Front Axle / Tire Data Chart TD005813 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 32 S/T 105 (05/16) Utility, Rear Axle / Tire Data Chart TD005639 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 33 S/T 10506 Fuel Tank TD005957d S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 34 S/T 10516 Fuel Tank TD005957e S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 35 S/T Tail Pipe Locations TD005736 S/T Small Utility – SUV 2004
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PAGE S/T SMALL UTILITY – SUV (CHEVY BLAZER & GMC JIMMY) 36 Ordering Information Electrical diagrams are available from Chevrolet and GMC through service publications. They have contracted the following companies to handle the ordering and shipping of the manuals. Helm Inc. P.O. Box 07130 Detroit, Michigan 48207 1 (313) 865-5000 for information and inquiries 1 (800) 782-4356 for credit card orders Routine orders will be shipped within 10 days of receipt.