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1996 Chevrolet K3500 Pickup CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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- 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
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 1996 Chevrolet K3500 Pickup car and truck
repair procedures including Chevrolet engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Chevrolet K3500 Pickup automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 1996 Chevrolet K3500 Pickup AUTOMOBILES
Component Replacement & Adjustment -> Light Duty Trucks & Vans -> Adjustments -> A/C -> C & K Series -> Control Cables -> G Series -> Less A/C -> Mode/Temperature/Recirculation Actuators -> S/T Series
Vehicle: 1996 Chevrolet K3500 Pickup 6.5 V8 DIESEL
Control Cables
G Series
Less A/C
- Attach inner cable and sheath to dash panel control.
- Move temperature cable to Cold then attach loop on inner cable to temperature door on heater case.
- Attach cable sheath to heater case, then move temperature lever to full Heat. This will require force to slide inner cable clip to its proper position.
- Move temperature adjusting lever quickly from Cold to Hot. Door should be heard seating at stops.
A/C
The temperature door cable is self-adjusting. Quickly move temperature lever from...
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BRAKE SERVICE PROCEDURES FOR 1996 Chevrolet K3500 Pickup AUTOMOBILES
Power Brake Units -> Bendix Brake Boosters -> General Service
Vehicle: 1996 Chevrolet K3500 Pickup 6.5 V8 DIESEL
Certain general service procedures apply, regardless of whether the brakes are vacuum or hydraulically assisted. Only top quality, clean brake fluid should be used. More seals and valves are used with power brake systems than with ordinary brakes, so an inferior brake fluid will do much more damage. For the same reason, be sure all dirt is kept out of the system. Additionally, care must be taken not to mix the fluids of the booster hydraulic system and brake hydraulic system as the fluids are not compatible.
If the power unit fails, the brakes will still operate, as the conventio...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1996 Chevrolet K3500 Pickup AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> 6.5L Diesel Engine
Vehicle: 1996 Chevrolet K3500 Pickup 6.5 V8 DIESEL
On models equipped with fuel injected engines, relieve fuel system pressure as outlined under "Fuel System Pressure Relief."
On models equipped with metal collar quick disconnect connectors, GM tool No. J37088-A, or equivalent, will be required to disconnect the connector. Prior to reconnecting the connector, apply a few drops of clean motor oil to the male pipe ends.
On models equipped with plastic collar quick disconnect connectors, squeeze the connector plastic retainer release tabs to release the connector. Prior to reconnecting the connector, apply a few drops of clean motor...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1996 Chevrolet K3500 Pickup AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 1996 Chevrolet K3500 Pickup 6.5 V8 DIESEL
Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal.
Disassemble
- Support propeller shaft in a line horizontal with table of a press.
- Mark propeller shaft in order to show which end connects to transmission and which end goes to rear axle.
- On models equipped with external snap ring retainers, proceed as follows:
- Disassemble snap rings by ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1996 Chevrolet K3500 Pickup AUTOMOBILES
Alternator, Replace
Vehicle: 1996 Chevrolet K3500 Pickup 5.7 V8 GAS
- Disconnect battery ground cable.
- Disconnect terminal plug and battery lead from rear of alternator.
- Remove accessory drive belt.
- Remove alternator mounting bolts.
- Separate alternator from mounting bracket.
- Rem...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1996 Chevrolet K3500 Pickup AUTOMOBILES
General Motors Corp./Saturn Trucks -> Change Trans Fluid Indicator ->
Vehicle: 1996 Chevrolet K3500 Pickup 6.5 V8 DIESEL
This message will appear on the DIC (Driver Information Center) when it is time to change the transmission fluid....
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 Chevrolet K3500 Pickup AUTOMOBILES
Heater Hose, Replace -> Bypass -> Inlet -> Outlet
Vehicle: 1996 Chevrolet K3500 Pickup 7.4 V8 GAS
Inlet
- Remove air cleaner.
- Drain cooling system into a suitable container.
- Remove heater hose support clamp bolt.
- Reposition heater core inlet hose clamp at engine.
- Remove hose from engine.
- Reposition heater hose inlet clamp at heater core.
- Remove heater inlet hose from heater core.
- Remove hose from vehicle.
- Reverse procedure to install.
Outlet
- Remove air cleaner.
- Drain cooling system into a suitable container.
- Remove heater hose support clamp bolt.
- Reposition heater hose...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1996 Chevrolet K3500 Pickup AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1996 Chevrolet K3500 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 K3500 Pickup AUTOMOBILES
Component location diagrams for most 1996 Chevrolet K3500 Pickup cars and light trucks sold in the U.S. from 1990+.
 Behind RH Side Of I/P Diagram for 1996 Chevrolet K3500 Pickup 7.4 V8 GASComponents on diagram: |
 Behind Glove Compartment Diagram for 1996 Chevrolet K3500 Pickup 6.5 V8 DIESELComponents on diagram: |
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WIRING DIAGRAMS FOR 1996 Chevrolet K3500 Pickup AUTOMOBILES
OEM drawn wiring diagrams for most 1996 Chevrolet K3500 Pickup cars and light trucks sold in the U.S.
 1996 Chevrolet K3500 Pickup 5.7 V8 GAS Wiring DiagramComponents on diagram: |
 1996 Chevrolet K3500 Pickup 7.4 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1996 Chevrolet K3500 Pickup AUTOMOBILES
OEM TSB listings for most 1996 Chevrolet K3500 Pickup cars and light trucks sold in the U.S. from 1985+.
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Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 1996 Chevrolet K3500 Pickup 5.7 V8 GAS Auto Systems: |
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Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 1996 Chevrolet K3500 Pickup 5.7 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1996 Chevrolet K3500 Pickup AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1996 Chevrolet K3500 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 K3500 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 K3500 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 K3500 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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