1996 Chevrolet G30 Service and Repair Manual

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Factory-Grade Data

1996 Chevrolet G30 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Sportvan Standard Passenger Van 3-Door
  • Chevy Van Cutaway Van 2-Door
  • Beauville Standard Passenger Van 3-Door
  • Sportvan Extended Passenger Van 3-Door
  • Beauville Extended Passenger Van 3-Door
  • Chevy Van Standard Cargo Van 3-Door
  • Chevy Van Extended Cargo Van 3-Door
  • Hi-Cube Cutaway Van 2-Door

Engines covered

  • 5.7L 350Cu. In. V8 CNG OHV Naturally Aspirated
  • 7.4L 454Cu. In. V8 GAS OHV Naturally Aspirated
  • 5.7L 350Cu. In. V8 GAS OHV Naturally Aspirated
  • 6.5L 395Cu. In. V8 DIESEL OHV Naturally Aspirated
  • 4.3L 262Cu. In. V6 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1996 Chevrolet G30 Recalls & Complaints

NHTSA #96V18700026/09/1996Component: STEERING:LINKAGES

THE STEERING LINKAGE ASSEMBY CONTAINS A RELAY ROD TAPERED-STUD ATTACHMENT NUT THAT WAS NOT TORQUED TO PROPER SPECIFICATIONS.

Consequence

THE TAPERED STUD CAN LOOSEN AND THE DRIVER WOULD NOTICE A LAG IN THE RESPONSIVENESS TO STE

Remedy

DEALERS WILL REMOVE THE EXISTING CRIMPED NUT AND INSTALL A NEW NUT TORQUED TO SPECIFICATIO

NHTSA #96V18600026/09/1996Component: ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS

WATER INTRUSION INTO THE KICK PANEL AREAS IN FRONT OF BOTH THE DRIVER AND PASSENGER DOORS CAN CAUSE A CORROSION PATH BETWEEN THE BATTERY FEED AND THE ELECTRICAL GROUND.

Consequence

THIS CONDITION CAN CAUSE AN ELECTRICAL SHORT LEADING TO IGNITION AND COMBUSION OF THE PLAS

Remedy

DEALERS WILL REPLACE THE 25 AMP CIRCUIT BREAKERS WITH 25 AMP FUSES IN THE FUSE BLOCK; REMO

NHTSA #07E08800024/10/2007Component: EQUIPMENT

CERTAIN HONEYWELL FRAM RACING BRAND HP4 AND HP8 OIL FILTERS THAT WERE MANUFACTURED FROM MAY 25, 2006, THROUGH SEPTEMBER 14, 2007, AND SOLD FOR USE AS REPLACEMENT EQUIPMENT FOR VEHI

Consequence

THIS CONDITION MAY CAUSE INADEQUATE SEALING AND LOSS OF ENGINE OIL, POSSIBLY RESULTING IN

Remedy

HONEYWELL WILL REPLACE THE AFFECTED OIL FILTERS FREE OF CHARGE. THE RECALL BEGAN DURING N

NHTSA #06E04300019/05/2006Component: FUEL SYSTEM, GASOLINE

CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER

Consequence

THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FU

Remedy

HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGA

NHTSA #96V09200003/06/1996Component: SUSPENSION:REAR:SPRINGS:LEAF SPRING ASSEMBLY:U-BOLT, LEAF SPRING TO AX

ONE OF THE FOUR REAR AXLE U-BOLTS CAN BREAK. THIS CAN POTENTIALLY LEAD TO THE SPRING LIFTING FROM THE AXLE UNDER CERTAIN REBOUND, BRAKING OR CORNERING MANEUVERS.

Consequence

THIS CONDITION COULD RESULT IN SUDDEN LOSS OF VEHICLE CONTROL INCREASING THE POTENTIAL FOR

Remedy

DEALERS WILL REPLACE THE FOUR REAR AXLE U-BOLTS ON THE AFFECTED VEHICLES.

NHTSA #96V11700001/07/1996Component: TIRES:BEAD

THESE TIRES HAVE BEAD DAMAGE WHICH OCCURED DURING TIRE MOUNTING.

Consequence

THIS DAMAGE TO THE TIRE REINFORCING STRUCTURE IN THE BEAD "TOE" AREA CAUSES A BULGE IN THE

Remedy

DEALERS WILL DEMOUNT EACH TIRE AND INSPECT FOR BEAD DAMAGE. IF BEAD DAMAGE IS FOUND, THE T

TSB #10232287

This warranty administration bulletin provides information regarding the field action courtesy transportation policy.

TSB #10246631

Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules

19970506Component: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITEDCrash reported

APPLIED BRAKES HARD, PEDAL WENT TO FLOOR, REARENDED ANOTHER MOVING VEHICLE; DEALER WILL REPLACE ENTIRE BRAKING SYSTEM. *AK

20010730Component: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITEDFire reported

DESCENDING 11-13% GRADE, GEAR DOWN 1 BELOW DRIVE, FIRE OCCURRED IN BOTH FRONT WHEEL WELLS DUE TO FAILURE OF MATERIAL USED IN CONSTRUCTION OF ABS SENSOR HOLDER (BAKELITE-LIKE) ,

20040416Component: SUSPENSION:FRONT:SPRINGS:LEAF SPRING ASSEMBLY:U-BOLT, LEAF SPRING TO A

WHILE DRIVING 55 MPH A LOUD BANGING NOISE WAS HEARD COMING FROM THE REAR. CONSUMER TOOK VEHICLE TO REPAIR SHOP, AND MECHANIC DETERMINED THAT DRIVER'S SIDE LEAF SPRING BROKE.

20040416Component: SUSPENSION:FRONT:SPRINGS:LEAF SPRING ASSEMBLY

WHILE DRIVING 55 MPH A LOUD BANGING NOISE WAS HEARD COMING FROM THE REAR. CONSUMER TOOK VEHICLE TO REPAIR SHOP, AND MECHANIC DETERMINED THAT DRIVER'S SIDE LEAF SPRING BROKE.

Showing the 4 most serious of 10 complaints filed with NHTSA.

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