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 MANUALSCHEVROLET1996SPORTVAN VAN PASSENGER EXTENDED, 6.5 YREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 57 (ENGINE CONTROLS - REMOVE/INSTALL/OVERHAUL - 6.5L DIESEL.)FUEL SYSTEMINJECTION PUMPREMOVAL
1996 Chevrolet Sportvan Van Passenger Extended, 6.5 Y
Injection Pump: Removal
1996 Chevrolet Sportvan Van Passenger Extended, 6.5 YSECTION Removal
WARNING: This page does not describe the selected car, but rather 21 other vehicles, including the 1996 Chevrolet Chevy Van, 1995 GMC Yukon, 1995 GMC Vandura Special, 1995 GMC Vandura, and 1995 GMC Suburban. However, it is still accessible from the selected car via links, so may be relevant.
- 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.
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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.