Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
1996 Chevrolet Chevy Van G30, Van Cargo Extended, 6.5 YFACTORY OEM SERVICE PROCEDURE
Injection Pump: Removal
- Disconnect negative battery cable. Remove intake manifold. Install Protective Covers (J-29664-1) in intake ports. Remove fuel injection lines. Disconnect electrical wiring, fuel return line, fuel inlet line, and fuel injection lines at pump. Cap all openings.
- Remove oil filler tube and grommet for oil filler tube. Scribe or paint alignment mark on front cover and injection pump flange. Manually rotate engine to access injection pump-to-drive gear retaining bolts through oil filler neck hole. Remove injection pump-to-drive gear retaining bolts. Remove injection pump mounting nuts. Remove injection pump and gasket. See Figure.
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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