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1996 GMC G25/G2500 VAN CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT GMC REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- 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
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 1996 GMC G25/G2500 VAN car and truck
repair procedures including GMC 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 GMC G25/G2500 VAN automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 1996 GMC G25/G2500 VAN AUTOMOBILES
Component Replacement & Adjustment -> Light Duty Trucks & Vans -> Blower Motor, Replace -> 1996 -> 1997 -> Air Conditioning -> Astro & Safari -> Bravada & S/T Series -> C & K Series -> Front -> G Series -> Heater -> P Series -> Rear -> Silhouette, Trans Sport, 1996 Lumina APV & 1997 Venture -> Tracker
Vehicle: 1996 GMC G25/G2500 VAN Savana 6.5 V8 DIESEL
Astro & Safari
Front
- Disconnect electrical connector.
- Remove recovery and windshield washer fluid reservoir assembly.
- Remove two screws retaining cover in blower motor area.
- Cut acoustic cover between five clip lands, Fig. . Retain piece of acoustic cover for reassembly.
- Remove cooling tube from motor.
- Remove screws retaining blower motor to case.
- Remove blower motor from case.
Rear
Heater
- Remove left body side front lower trim panel.
- Remove cooling tube from case and motor.
- D...
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BRAKE SERVICE PROCEDURES FOR 1996 GMC G25/G2500 VAN AUTOMOBILES
Anti-lock Brakes -> Four Wheel Anti-Lock Brake System -> Precautions -> General Service Precautions
Vehicle: 1996 GMC G25/G2500 VAN Savana 5.0 V8 GAS
General Service Precautions
Avoid contact with brake fluid when servicing the anti-lock brake syste...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1996 GMC G25/G2500 VAN AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 1988-06 C/K, G & R/V Series w/Diesel Engines -> Normal Service -> Severe Service
Vehicle: 1996 GMC G25/G2500 VAN Savana 6.5 V8 DIESEL
Normal Service
Repl...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1996 GMC G25/G2500 VAN AUTOMOBILES
DRIVESHAFT, Replace -> Front -> One Piece -> Rear
Vehicle: 1996 GMC G25/G2500 VAN Savana 5.7 V8 GAS
Rear
One Piece
- Raise and support vehicle.
- Remove bolts from U-joint brackets at differential end of driveshaft.
- Lower differential end of driveshaft enough to clear differential.
- Place a suitable container under output shaft of transmission.
- Push driveshaft slightly forward towards transmission.
- Pull driveshaft rearward towards differential and remove from vehicle.
- Reverse procedure to install, noting following:
- Torque bolts to 27 ft. lbs.
Front
Important: It is essential that positions of all driveline components relative to propeller shaft and axles be observed and accurately referen...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1996 GMC G25/G2500 VAN AUTOMOBILES
Alternator, Replace
Vehicle: 1996 GMC G25/G2500 VAN Savana 6.5 V8 DIESEL
- 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 mount...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1996 GMC G25/G2500 VAN AUTOMOBILES
General Motors Corp./Saturn Trucks -> Check Fuel Cap Lamp ->
Vehicle: 1996 GMC G25/G2500 VAN Savana 5.0 V8 GAS
The Check Fuel Cap Lamp will illuminate momentarily when the ignition switch is placed in the On position as a bulb check. I...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 GMC G25/G2500 VAN AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1996 GMC G25/G2500 VAN Savana 5.0 V8 GAS
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 GMC G25/G2500 VAN AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1996 GMC G25/G2500 VAN Savana 5.7 V8 GAS
These engines use a single serpentine drive belt to drive all engine-mount accessories. All belt drive accessories are rigidly mounted with belt tension maintained by a spring loaded automatic tensioner.
- Rotate tensioner counterclockwise using suitable 1/2 inch break...
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COMPONENT LOCATION DIAGRAMS FOR 1996 GMC G25/G2500 VAN AUTOMOBILES
Component location diagrams for most 1996 GMC G25/G2500 VAN cars and light trucks sold in the U.S. from 1990+.
 RH Side Of Engine Diagram for 1996 GMC G25/G2500 VAN Savana 6.5 V8 DIESELComponents on diagram: |
 LH Side Of Engine Compartment Diagram for 1996 GMC G25/G2500 VAN Savana 5.0 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 1996 GMC G25/G2500 VAN AUTOMOBILES
OEM drawn wiring diagrams for most 1996 GMC G25/G2500 VAN cars and light trucks sold in the U.S.
 1996 GMC G25/G2500 VAN Savana 6.5 V8 DIESEL Wiring DiagramComponents on diagram: |
 1996 GMC G25/G2500 VAN Savana 6.5 V8 DIESEL Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1996 GMC G25/G2500 VAN AUTOMOBILES
OEM TSB listings for most 1996 GMC G25/G2500 VAN 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 GMC G25/G2500 VAN Savana 5.7 V8 GAS Auto Systems: |
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Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 1996 GMC G25/G2500 VAN Savana 5.7 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1996 GMC G25/G2500 VAN AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1996 GMC G25/G2500 VAN 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 GMC G25/G2500 VAN 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 GMC G25/G2500 VAN 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 GMC G25/G2500 VAN 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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