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1996 GMC G35/G3500 VAN CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT GMC 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 GMC G35/G3500 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
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A/C & HEATER SERVICE PROCEDURES FOR 1996 GMC G35/G3500 VAN AUTOMOBILES
General Service Domestic Vehicles -> 1996-97 -> System Inspection -> Compressor -> Condenser -> Evaporator -> Receiver/Drier -> Refrigerant Line Restrictions -> Thermostatic Expansion Valve
Vehicle: 1996 GMC G35/G3500 VAN Vandura 5.7 V8 GAS
While a detailed diagnostic procedure for all air conditioning systems would be impractical due to the many variations in construction and operation, there are three fundamental components of a total diagnosis:
- Refrigerant systems must have an adequate, but not excessive charge.
- Determination must be made whether the refrigerant system is governed by a cycling clutch compressor or by valves which control evaporator pressure.
- The air distribution system (blower motor, switches, vacuum lines and air ducts) must be operational before checking the ...
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BRAKE SERVICE PROCEDURES FOR 1996 GMC G35/G3500 VAN AUTOMOBILES
Disc Brakes -> Delco-Moraine Single Piston Caliper -> Brake Pad Service -> Installation -> Removal
Vehicle: 1996 GMC G35/G3500 VAN Special 4.3 V6 GAS
Removal
- Remove caliper assembly as outlined above.
- Remove inboard pad with retainer spring. Dislodge outboard pad and position caliper on the front suspension so the brake hose will not support the weight of the caliper.
- Remove two sleeves from inboard ears of the caliper.
- Remove four rubber bushings from the grooves in each of the caliper ears.
Installation
- Lubricate new sleeves, rubber bushings, bushing grooves and mounting bolt ends with Delco Silicone Lube or equivalent.
- Install new bushings and sleeves in caliper ears. Position the sleeve so that the end toward the pad is flush ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1996 GMC G35/G3500 VAN AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 1996-03 C/K, G & R/V Series w/Gasoline Engine -> Heavy Duty Emissions -> Light Duty Emissions -> Normal Service -> Severe Service
Vehicle: 1996 GMC G35/G3500 VAN 5.7 V8 GAS
Light Duty Emissions
Normal Service
Replace every 30,000 miles
Severe Service
Rep...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1996 GMC G35/G3500 VAN AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble -> External Snap Ring Type -> Nylon Injected Ring Type
Vehicle: 1996 GMC G35/G3500 VAN Savana 6.5 V8 DIESEL
Nylon Injected Ring Type
Never clamp propeller shaft tubing In a vise. Clamping could dent or deform tube causing an Imbalance or unsafe condition. Always clamp on one of yokes and support shaft horizontally. Avoid damaging slip yoke sealing surface. Nicks may damage bushing or cut lip seal.
Disassemble
- Place universal joint so that lower ear of yoke is supported on a 30 mm (1 1/8 inch) socket.
- In order to shear plastic retaining ring on bearing cup, place special tool J 9522-3 or equivalent on open horizontal bearing cups and press lower bearing cup out of yoke ear. If ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1996 GMC G35/G3500 VAN AUTOMOBILES
Alternator, Replace
Vehicle: 1996 GMC G35/G3500 VAN Vandura 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 G35/G3500 VAN AUTOMOBILES
General Motors Corp./Saturn Trucks -> Anti-Lock Brake System Warning Lamp ->
Vehicle: 1996 GMC G35/G3500 VAN 5.7 V8 GAS
This lamp should light for approximately 6-8 seconds when the ignition is turned On as a bulb check. If the warn...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 GMC G35/G3500 VAN AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1996 GMC G35/G3500 VAN Vandura 4.3 V6 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 G35/G3500 VAN AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1996 GMC G35/G3500 VAN 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 GMC G35/G3500 VAN AUTOMOBILES
Component location diagrams for most 1996 GMC G35/G3500 VAN cars and light trucks sold in the U.S. from 1990+.
 Engine Compartment Locations Diagram for 1996 GMC G35/G3500 VAN Rally 7.4 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 1996 GMC G35/G3500 VAN AUTOMOBILES
OEM drawn wiring diagrams for most 1996 GMC G35/G3500 VAN cars and light trucks sold in the U.S.
 1996 GMC G35/G3500 VAN 7.4 V8 GAS Wiring DiagramComponents on diagram: |
 1996 GMC G35/G3500 VAN 6.5 V8 DIESEL Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1996 GMC G35/G3500 VAN AUTOMOBILES
OEM TSB listings for most 1996 GMC G35/G3500 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 G35/G3500 VAN Savana 5.7 V8 GAS Auto Systems: |
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Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 1996 GMC G35/G3500 VAN Savana 5.7 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1996 GMC G35/G3500 VAN AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1996 GMC G35/G3500 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 G35/G3500 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 G35/G3500 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 G35/G3500 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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