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 MANUALSCHEVROLET1996FORWARD CONTROL 6.5 Y, AUTOMATICREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCESYSTEMENGINE CONTROLS - SYSTEM/COMPONENT TESTS - P SERIES (DIESEL)FUEL SYSTEMINJECTION PUMP HOUSING LEAKAGE TEST
1996 Chevrolet Forward Control 6.5 Y, Automatic
Injection Pump Housing Leakage Test
1996 Chevrolet Forward Control 6.5 Y, AutomaticSECTION Injection Pump Housing Leakage Test
- Remove injection pump and drain all fuel. Connect an air supply line to fuel inlet fitting. Ensure air supply is clean and dry. Seal off return line fitting. Completely immerse pump assembly in a container of clean test oil.
- Apply 20 psi (1.4 kg/cm2 ) to pump. Leave pump immersed for 10 minutes to allow trapped air to escape. Watch for leaks after 10 minutes. If no leaks are observed after 10 minutes, reduce air pressure to 2 psi (.14 kg/cm2 ) for 30 seconds.
- If there are still no leaks, increase pressure to 20 psi (1.4 kg/cm2 ) again. If no leaks are observed, pump is ready for use. If leaks are noticed, replace pump.
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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.