GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Chevy G Van 🢒 Engine 🢒 Engine Mechanical - 6.5L 🢒 Engine Replacement

Removal Procedure
  1. Remove the battery. Refer to Engine Electrical.
  2. Remove the engine cover. Refer to Interior Trim.
  3. Remove the air cleaner assembly and the air intake duct.
  4. Remove the coolant recovery reservoir. Refer to Cooling and Radiator.
  5. Drain the cooling system. Refer to Cooling and Radiator.
  6. Evacuate the A/C system. Refer to HVAC.
  7. Remove the grille. Refer to Sheet Metal and Fiberglass.
  8. Remove the following components of the radiator support assembly:
    9. • Two ground straps
    • Headlight assemblies
    • The radiator and the A/C condenser if equipped (as an assembly)
  9. Remove the front bumper.
  10. Remove the engine cooling fan. Refer to Cooling and Radiator.
  11. Remove the upper intake manifold. Refer to Intake Manifold Replacement .
  12. Remove the turbocharger assembly. Refer to Turbocharger.
  13. Remove the lower intake manifold. Refer to Intake Manifold Replacement .
  14. Remove the exhaust manifolds.
    15. • For the left side, refer to Exhaust Manifold Replacement .
    • For the right side, refer to Exhaust Manifold Replacement .
  15. Remove the coolant cross over and thermostat housing with hoses.
  16. Remove the generator assembly.
  17. Remove the power steering reservoir hose.
  18. Remove the vacuum pump and the bracket. Refer to Vacuum Pumps.
  19. Remove the engine oil fill tube.
  20. Remove the EGR/Boost solenoids.
  21. Remove the glow plug controller.
  22. Remove the upper and lower radiator hoses off of the water pump. Refer to Cooling and Radiator.
  23. Remove the shift cable hold down connection.
  24. Remove the fuel return lines at the engine.
  25. Remove the injector lines. Refer to Diesel Fuel Injection.
  26. Remove the injector pump. Refer to Diesel Fuel Injection.
  27. Remove the air conditioning compressor/power steering pump and line fasteners.
  28. Raise the vehicle.
  29. Remove the engine oil cooler lines.
  30. Replace the retaining clip whenever the oil cooler lines are disconnected from the quick connectors.
  31. Remove the flywheel cover.
  32. Remove the flywheel to torque converter bolts.
  33. Remove the starter. Refer to Cranking System.
  34. Remove the block heater wire.
  35. Remove the transmission oil cooler lines at the transmission.
  36. Remove the transmission to bellhousing bolts.
  37. Lower the vehicle.
  38. Install a length of chain.
  39. Use the GM P/N 23503910 or the equivalent attaching bolt to the rear of the right cylinder head and the left front accessory/engine lift bracket.
  40. Support the transmission with a strap between the frame rails.
  41. Install a suitable lifting devise to engine.
  42. Remove the engine mount through bolts.
  43. Remove the mounts from engine and frame.
  44. Remove the engine.

Installation Procedure
  1. Install the engine into the vehicle.
  2. Install the front engine mounts bolts and washers to the frame and the engine block.
  3. Install the bellhousing bolts to the engine.
  4. Install the engine mount through bolts.

    5. Tighten
    Tighten the through mount bolt to 95 N·m (70 lb ft).

  5. Install the torque converter to the flywheel.
  6. Remove the lifting device, chain and attaching bolt.
  7. Install the block heater wiring.
  8. Install the flywheel cover.
  9. Install the starter assembly. Refer to Cranking System.

    10. Important: Replace the retaining clips any time the lines are disconnected or connected.

  10. Install the transmission cooler lines and the brackets to the engine.
  11. Install the wiring harness and the front battery cable clamp at the oil pan.
  12. Lower the vehicle.
  13. Install the A/C compressor/power steering pump bracket and the line fasteners.
  14. Install the injection pump. Refer to Diesel Fuel Injection.
  15. Install the injection lines. Refer to Diesel Fuel Injection.
  16. Install the fuel return line.
  17. Install the shift cable hold down connection.
  18. Install the upper and the lower radiator hoses on the water pump. Refer to Cooling and Radiator.
  19. Install the exhaust manifolds.
  20. Install the engine oil fill tube.
  21. Install the vacuum pump and the bracket. Refer to Vacuum Pump.
  22. Install the generator assembly.
  23. Install the lower intake manifolds.
  24. Install the coolant crossover/thermostat housing and all related hoses.
  25. Install the Turbocharger assembly. Refer to the Turbocharger.
  26. Replace the o-ring on the turbocharger before installing the upper intake manifold.
  27. Install the upper intake manifold. Refer to Intake Manifold Replacement .
  28. Install the electrical harness and all the connectors and the brackets.
  29. Install the EGR/Boost solenoids and glow plug controller.
  30. Install the engine cooling fan. Refer to Cooling and Radiator.
  31. Install the radiator support assembly using the following components:
    32. • Two ground straps
    • Headlight assemblies
    • Radiator
    • A/C condenser if equipped
  32. Connect the radiator hoses. Refer to Cooling and Radiator.
  33. Install the power steering reservoir hose.
  34. Ensure the power steering fluid is at the proper level.
  35. Install the grille assembly. Refer to the Sheet Metal and Fiberglass.
  36. Install the coolant recovery reservoir. Refer to Cooling and Radiator.
  37. Install the front bumper. Refer to Frame and Bumpers.
  38. Install the air cleaner assembly and the air intake duct.
  39. Install the engine cover.
  40. Install the battery. Refer to the Engine Electrical.
    41. • Fill the cooling system with the proper quantity and the grade of the coolant. Refer to Cooling and Radiator.
    • Change the engine oil and oil filter. Refer to Maintenance and Lubrication.
    • Recharge the A/C system. Refer to HVAC.