1996 GMC G3500 Service and Repair Manual
This factory service and repair manual for the 1996 GMC G3500 documents four engines for the one-ton van, a 5.7L V8 of 350 cubic inches running on compressed natural gas or gasoline, a 7.4L V8 of 454, a 4.3L V6 of 262 and a 6.5L diesel V8 of 395, all naturally aspirated overhead-valve designs. Bodies run to five, including the extended cargo and passenger vans and the 2-door cutaway, and six trims are named. Each system is covered with procedures, specifications, torque values, wiring diagrams and diagnostics.
Engines covered
- 5.7L V8 (350 cu in) — OHV, naturally aspirated, CNG or gasoline
- 7.4L V8 (454 cu in) — OHV, naturally aspirated, gasoline
- 4.3L V6 (262 cu in) — OHV, naturally aspirated, gasoline
- 6.5L V8 (395 cu in) — OHV, naturally aspirated, diesel
Body styles covered
- 3-door standard cargo van
- 3-door extended passenger van
- 2-door cutaway van
- 3-door standard passenger van
- 3-door extended cargo van
Trims covered
- Magnavan
- Rally
- Rally Camper Special
- Rally STX
- Vandura
- Vandura Special
Known issues on the 1996 G3500. One recall is on the federal record for the 1996 G3500, covering replacement oil filters that may not seal adequately and can lose engine oil, with a fire the possible result. One owner complaint is logged with NHTSA, recorded against the fuel and propulsion system. Both land squarely in territory the manual documents: engine lubrication procedures and sealing specifications, fuel system service data for the gasoline, dual-fuel and diesel engines listed, and the torque values and diagnostics that go with those systems.
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 VEHICLES LIST ABOVE. TH
THIS CONDITION MAY CAUSE INADEQUATE SEALING AND LOSS OF ENGINE OIL, POSSIBLY RESULTING IN A FIRE.
HONEYWELL WILL REPLACE THE AFFECTED OIL FILTERS FREE OF CHARGE. THE RECALL BEGAN DURING NOVEMBER 20
This warranty administration bulletin provides information regarding the field action courtesy transportation policy.
Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
CONTINUING FUEL DELIVERY SYSTEM FAILURES DUE TO FUEL PUMP STANADYNE CONTROLLER ETC...JUST QUITS WHILE DRIVING. VERY DANGEROUS! *TR
