General Information: Other GMC Cutaway G3500

Arrows and Symbols

This service manual uses various symbols in order to describe different service operations.

Scheme 2

Customer Concern Verification Sheets

The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time.

The GM-wide Customer Concern Verification Sheets are available in GM GlobalConnect. The Customer Concern Verification Sheets may be printed and reproduced locally.

Dealers

All U.S. Dealers participating in the Common Training Program can enroll through the Common Training System Website at https://www.gmtraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about Common Training should contact the Common Training help desk at 1-888-748-2687. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010.

Fleets

GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through Common Training/GM Service Technical College (STC).

Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmtraining.com using the "Contact Us" button on the site and/or the Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831.

Most GM STC course materials have associated charges.

To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831.

Non-GM Dealer Technicians

Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry.

ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information.

Scheme 3

The VIN plate is the legal identifier of the vehicle. The VIN plate (1) is located on the upper left corner of the instrument panel (I/P) and can be seen through the windshield from the outside of the vehicle

Vehicle Identification Number (VIN) System

All engines and transmissions are stamped or laser etched with a partial VIN, which was derived from the complete VIN. A VIN derivative contains the following 9 positions

VIN Derivative

4.3L RPO LU3 Engine ID and VIN Derivative Location

Refer to Engine Identification .

4.8L RPO L20, 5.3L RPO LMF, and 6.0L RPO L96 Engine ID and VIN Derivative Location

Refer to Engine Identification .

6.6L RPO LGH and LML Engine ID and VIN Derivative Location

Refer to Engine Identification .

4L60-E Transmission ID and VIN Derivative Location

Refer to Transmission Identification Information .

6L90 Transmission ID and VIN Derivative Location

Refer to Transmission Identification Information .

Scheme 4

Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label

RPO Code List

The production/process codes provide the description of the regular production options (RPOs). The RPO list is printed on the Service Parts Identification Label.

RPO Code List

Metric Fasteners

This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength.

A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive® or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive® recess head screws.

GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches.

Scheme 5

The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face.

The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following

1. Lower strength
2. No numbered head marking system
3. Wrong thread pitch

The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications

1. M6.0 X 1
2. M8 X 1.25
3. M10 X 1.5
4. M12 X 1.75
5. M14 X 2.00
6. M16 X 2.00

Repair Procedure

1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth.
2. Drill out the damaged threads. Clean out any chips.
3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads.
4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel.
5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert.
6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift.

Registered and Non-Registered Trademarks

Listed below are Registered Trademarks (®) or Non-Registered Trademarks (™) which may appear in this service manual.

Registered and Non-Registered Trademarks

Use Instruction Sheet Supplied

For the lock cylinder coding procedure, refer to the instruction sheet supplied in the lock cylinder kit.

For key cutting information, refer to the instructions provided from the manufacturer of the key cutting equipment used.

Scheme 6

Vehicle Lifting

1. Ensure that the lifting equipment meets weight requirements and is in good working order. Always follow the lift manufacturer's instructions.
2. You may lift and support the front of the vehicle at the front suspension near the wheel assemblies. Ensure that the arms of the front cradle are extended as close to the steering knuckle as possible.
3. Ensure that the vehicle is centered on the hoist before attempting to lift.
4. When using a suspension-contact hoist, ensure that the rear cradle has adequate clearance for the rear stabilizer bar.
5. When lifting or jacking a vehicle, be certain that the lift pads do not contact the exhaust system, brake pipes, cables, HVAC lines, wiring harnesses, fuel lines, or underbody. Such contact may result in damage or unsatisfactory vehicle performance.
6. When using a frame-contact hoist, only place the pads on flat surfaces. Do not place pads within 50 mm (2 in) of any radius.
7. Before lifting the vehicle, verify that the vehicle loads are secure and equally distributed.
8. When major components are removed from the vehicle when supported on a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and secure the vehicle frame to the hoist pads nearest the component to be removed.

Vehicle Jacking

1. Park the vehicle on a clean, hard, level surface before jacking the vehicle.
2. Any time you lift the vehicle on one end, chock the wheels at the opposite end.
3. Use jack stands in order to provide support.
4. When supporting the vehicle using jack stands, place the jack stands under the side rails or the axle.
5. When lifting under the rear differential, do not allow the jack pad to contact the rear stabilizer bar or mounting hardware.