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1996 Chevrolet K2500 Pickup CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 1996 Chevrolet K2500 Pickup AUTOMOBILES
Vacuum & Wiring Diagrams -> Light Duty Trucks & Vans -> Air Conditioning Compressor Controls
Vehicle: 1996 Chevrolet K2500 Pickup 7.4 V8 GAS
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BRAKE SERVICE PROCEDURES FOR 1996 Chevrolet K2500 Pickup AUTOMOBILES
Power Brake Units -> Delco-Moraine Brake Boosters -> Troubleshooting -> Brakes Grab -> Hard Pedal -> Slow Or No Release
Vehicle: 1996 Chevrolet K2500 Pickup 7.4 V8 GAS
Hard Pedal
- Internal vacuum leak.
- Faulty control valve.
- Broken or damaged hydraulic brake lines.
- Collapsed or damaged vacuum hose.
- Plugged or loose vacuum fitting.
- Bad stud welds on front or rear housing on power head.
- Faulty booster diaphragm.
- Restricted air filter element.
- Worn or distorted reaction plate or levers.
- Cracked or broken pow...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1996 Chevrolet K2500 Pickup AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Except Montana SV6, Relay, Rendezvous w/3.6L Engine, Terraza, Tracker & Uplander -> Engine Fuel Pressure Service Port -> Engines Less Fuel Pressure Service Port
Vehicle: 1996 Chevrolet K2500 Pickup 6.5 V8 DIESEL
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while the vehicle relearns its adaptive strategy.
Engines Less Fuel Pressure ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1996 Chevrolet K2500 Pickup AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 1996 Chevrolet K2500 Pickup 6.5 V8 DIESEL
- Raise and support vehicle.
- Remove wheel and tire assembly.
- Remove drive axle center cap, if equipped.
- Insert a drift or large screwdriver through brake caliper into one of the brake rotor vanes in order to prevent drive axle wheel drive shaft from turning.
- Remove nut and washer from hub. Do not reuse nut. A new nut must be used when installing wheel drive shaft.
- Using axle remover tool No. J 45859 or equivalent, press wheel drive shaft from hub.
- Remove bolts securing wheel dr...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1996 Chevrolet K2500 Pickup AUTOMOBILES
Starter, Replace
Vehicle: 1996 Chevrolet K2500 Pickup 5.7 V8 GAS
- Disconnect battery ground cable.
- Remove starter braces or heat shields, if equipped.
- Disconnect starter solenoid electrical connectors.
- Raise and support vehicle.
- Remove at...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1996 Chevrolet K2500 Pickup AUTOMOBILES
General Motors Corp./Saturn Trucks -> Diesel Engine Water In Fuel Or Drain Fuel Filter Warning Lamp ->
Vehicle: 1996 Chevrolet K2500 Pickup 6.5 V8 DIESEL
The "Water in Fuel" indicator will light when excessive water has entered the fuel system. A low pressure sensor activates the lamp as the fuel filter becomes plugged. The lamp will light during engine starting as a bulb check.
Once engine has started, the lamp should go Off. If the lamp is lit intermittently or remains lit, drain fuel filter. If the lamp still remains On after fuel filter has been drained, replace fuel filter. If lamp is lit during high speed opera...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 Chevrolet K2500 Pickup AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1996 Chevrolet K2500 Pickup 6.5 V8 DIESEL
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp from radiator.
- Remove radiator outlet hose from radiator.
- Reposition hose clamp from coolant pump.
- Remove radiator outlet hose from coolant pump and from vehicle.
- Reverse procedure...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1996 Chevrolet K2500 Pickup AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1996 Chevrolet K2500 Pickup 5.7 V8 GAS
- Rotate tensioner counterclockwise, using a 1/2 inch breaker bar with a socket placed on tensioner ...
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COMPONENT LOCATION DIAGRAMS FOR 1996 Chevrolet K2500 Pickup AUTOMOBILES
Component location diagrams for most 1996 Chevrolet K2500 Pickup cars and light trucks sold in the U.S. from 1990+.
Front RH Side Of Vehicle Diagram for 1996 Chevrolet K2500 Pickup 5.7 V8 GAS Components on diagram: |
Above LH Kick Panel Diagram for 1996 Chevrolet K2500 Pickup 7.4 V8 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1996 Chevrolet K2500 Pickup AUTOMOBILES
OEM drawn wiring diagrams for most 1996 Chevrolet K2500 Pickup cars and light trucks sold in the U.S.
1996 Chevrolet K2500 Pickup 6.5 V8 DIESEL Wiring Diagram Components on diagram: |
1996 Chevrolet K2500 Pickup 6.5 V8 DIESEL Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1996 Chevrolet K2500 Pickup AUTOMOBILES
OEM TSB listings for most 1996 Chevrolet K2500 Pickup cars and light trucks sold in the U.S. from 1985+.
Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 1996 Chevrolet K2500 Pickup 5.7 V8 GAS Auto Systems: |
Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 1996 Chevrolet K2500 Pickup 5.7 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1996 Chevrolet K2500 Pickup AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1996 Chevrolet K2500 Pickup cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1996 Chevrolet K2500 Pickup cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1996 Chevrolet K2500 Pickup cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1996 Chevrolet K2500 Pickup cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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