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.
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HOMESERVICE MANUALSCHEVROLET1996CHEVY VAN G3500, VAN CARGO, 6.5 FREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCEREMOVE, OVERHAUL & INSTALLENGINE CONTROLS - REMOVAL, INSTALLATION & OVERHAUL - G SERIES (GASOLINE)FUEL SYSTEMFUEL PUMPREMOVAL & INSTALLATION
1996 Chevrolet Chevy Van G3500, Van Cargo, 6.5 F
Removal & Installation
1996 Chevrolet Chevy Van G3500, Van Cargo, 6.5 FSECTION Removal & Installation
- Relieve fuel system pressure. See FUEL SYSTEM PRESSURE RELIEF (CSI or SFI) under FUEL SYSTEM. Disconnect negative battery cable. Raise vehicle and remove fuel tank. Using Sending Unit Remover (J-36608 or J-24187), remove sending unit and pump by turning cam lock counterclockwise.
- Remove fuel pump from sending unit by pulling pump up into attaching hose while pulling outward from the bottom support. DO NOT damage rubber insulator or strainer. To install, reverse removal procedure.
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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.