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
Specifications Index
G SERIES VAN SPECIFICATIONS INDEX
| System | Specification/Procedure | ||
|---|---|---|---|
| Air Conditioning | |||
| Service | A/C SYSTEM SPECIFICATIONS | ||
| Torque | TORQUE SPECIFICATIONS | ||
| Axle Nut/Hub Nut | NA | ||
| Battery | CAPACITIES | ||
| Brakes | |||
| Bleeding Sequence | RR, LR, RF, LF | ||
| Disc Brakes | |||
| Service Specifications | DISC BRAKE SPECIFICATIONS | ||
| Torque | TORQUE SPECIFICATIONS | ||
| Drum Brakes | |||
| Service Specifications | DRUM BRAKE SPECIFICATIONS | ||
| Torque | TORQUE SPECIFICATIONS | ||
| Charging | |||
| Generator | SPECIFICATIONS | ||
| Torque | TORQUE SPECIFICATIONS | ||
| Drive Belts | |||
| Adjustment | BELT ADJUSTMENT | ||
| Drive Belt Routing | See appropriate figure under SERPENTINE DRIVE BELT ROUTING | ||
| Engine Cooling | |||
| General Service Specifications | COOLING SYSTEM SPECIFICATIONS | ||
| Radiator Cap Pressure | 15 psi | ||
| Thermostat R & I | NA | ||
| Water Pump R & I | |||
| 4.3L | WATER PUMP | ||
| 5.0L | WATER PUMP | ||
| 5.7L | WATER PUMP | ||
| 6.5L | WATER PUMP | ||
| 7.4L | WATER PUMP | ||
| Engine Mechanical | |||
| 4.3L | |||
| Compression | ENGINE COMPRESSION | ||
| Oil Pressure | 6 psi (41.4 kPa) Minimum at 1,000 RPM 18 psi (124.1 kPa) Minimum at 2,000 RPM 24 psi (165.5 kPa) Minimum at 4,000 RPM |
||
| Overhaul | ENGINE SPECIFICATIONS | ||
| Torque | TORQUE SPECIFICATIONS | ||
| 5.0L | |||
| Compression | ENGINE COMPRESSION | ||
| Oil pressure | 6 psi (41.4 kPa) Minimum at 1,000 RPM 18 psi (124.1 kPa) Minimum at 2,000 RPM 24 psi (165.5 kPa) Minimum at 4,000 RPM |
||
| Overhaul | ENGINE SPECIFICATIONS | ||
| Torque | TORQUE SPECIFICATIONS | ||
| 5.7L | |||
| Compression | ENGINE COMPRESSION | ||
| Oil pressure | 6 psi (41.4 kPa) Minimum at 1,000 RPM 18 psi (124.1 kPa) Minimum at 2,000 RPM 24 psi (165.5 kPa) Minimum at 4,000 RPM |
||
| Overhaul | ENGINE SPECIFICATIONS | ||
| Torque | TORQUE SPECIFICATIONS | ||
| 6.5L | |||
| Compression | ENGINE COMPRESSION | ||
| Oil pressure | 10 psi (.70 kg/cm2 ) at idle and 40-45 psi (2.81-3.16 kg/cm2 ) at 2000 RPM | ||
| Overhaul | ENGINE SPECIFICATIONS | ||
| Torque | TORQUE SPECIFICATIONS | ||
| 7.4L | |||
| Compression | ENGINE COMPRESSION | ||
| Oil pressure | 10 psi (69 kPa) minimum at 600 RPM 25 psi (172 kPa) minimum at 2,000 RPM |
||
| Overhaul | ENGINE SPECIFICATIONS | ||
| Torque | TORQUE SPECIFICATIONS | ||
| Fluid Specifications | See FLUIDS under MAINTENANCE/FLUIDS tab. From within Manager or Service Writer, click the "30/60/90 Interval" or "Maint." button. | ||
| Flywheel/Flex Plate/Drive Plate Torque | |||
| 4.3L, 5.0L, 5.7L | 74 Ft. lbs. (100 N.m) | ||
| 6.5L, 7.4L | 66 Ft. lbs. (90 N.m) | ||
| Fuel System | |||
| Pressure Specification | See table under FUEL PUMP | ||
| Fuel Pressure Test Procedure | |||
| Gasoline | FUEL SYSTEM PRESSURE TEST | ||
| Diesel | FUEL SYSTEM PRESSURE TEST | ||
| Fuel Filter Location | In fuel line ahead of fuel injector system | ||
| Fuel Filter R & I | |||
| Gasoline | IN-LINE FUEL FILTER REPLACEMENT (CARTRIDGE TYPE) or IN-LINE FUEL FILTER REPLACEMENT (NON-CARTRIDGE TYPE FILTER) | ||
| Diesel | FUEL MANAGER/FILTER ELEMENT | ||
| Ignition | |||
| Firing Order & Cylinder Identification | See appropriate figure under FIRING ORDER & TIMING MARKS | ||
| Ignition Wires (Resistance) | 30,000 Ohms Maximum | ||
| Ignition Wires (Routing) | See appropriate figure under FIRING ORDER & TIMING MARKS | ||
| Spark Plug | |||
| Type | AC 41-932 | ||
| Gap | .060 In. (1.52 mm) | ||
| Torque | 15 Ft. lbs. (20 N.m) | ||
| Starting | |||
| Starter | STARTER SPECIFICATIONS | ||
| Torque | TORQUE SPECIFICATIONS | ||
| Wheel Alignment | |||
| Adjustment Specifications | WHEEL ALIGNMENT SPECIFICATIONS | ||
| Torque | TORQUE SPECIFICATIONS | ||
| Wheel & Tire | |||
| Wheel Lug Nut Torque | |||
| 5-Stud Wheels | 100 Ft. lbs. (136 N.m) | ||
| 8-Stud Wheels | With Single Rear Wheels 120 Ft. lbs. (163 N.m) With Dual Rear Wheels 140 Ft. lbs. (190 N.m) |
||
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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