Chevrolet›G-Series Van›1996›Overview/chevrolet/g-series-van/1996/base/

1996 Chevrolet G-Series Van

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 1996 G-Series Van.

The 1996 Chevrolet G-Series Van specifies a 4.5-quart oil capacity filled with 5W-30 API viscosity, reflecting its full-size van platform's maintenance baseline. Reliability data shows just six total owner complaints logged, with tires emerging as the leading concern, while the model year carries zero recalls — a clean regulatory record. That combination of minimal reported issues and no factory campaigns positions the 1996 G-Series as a notably trouble-free entry in the van's production run, signaling strong durability for researchers evaluating fleet or long-term ownership prospects.

Model year1996 1995 1994 1993 1992 1991 1989 1988 1987

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity4.5 qtOEM · verified

Engine oil type5W-30 APIOEM · verified

Lug nut torque140 ft-lbsOEM · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 78 · 600 CCA battery, OE oil filter 25160561. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 78 · 600 CCAOEM · verified

Tail / brake / turnLAMPOEM · verified

OE service part numbers OEM · verified

Engine oil filter	25160561
Engine air filter	25042562
Fuel filter	25121468
Spark plug	12681665 alt 19308035
Front wiper blades	19120758
Serpentine belt	12564763 alt 12550111
Thermostat	12632948 alt 12551507

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 4.5 qt of 5W-30 API engine oil, 80W-90 · GL-5 in the differential, DOT 3 brake fluid. Torque lug nuts to 140 ft-lbs, the oil drain plug to 18.0 ft-lbs. The firing order is 1-8-4-3-6-5-7-2. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Brake Fluid	DOT 3
Differential Gear Oil	80W-90 · GL-5
Differential Gear Oil Capacity	8.5 qt
Differential Gear Oil	80W-90 · GL-5
Differential Gear Oil Capacity	5.5 qt
Differential Gear Oil	80W-90 · GL-5
Differential Gear Oil Capacity	8.5 qt
Differential Gear Oil	80W-90 · GL-5

Engine torques

Crankshaft Pulley and/or Damper Bolts	74 ft-lbs
Crankshaft Pulley and/or Damper Bolts	74 ft-lbs
Crankshaft Pulley and/or Damper Bolts	110 ft-lbs
Exhaust Manifold to Cylinder Head Bolts	40 ft-lbs
Engine Oil Pan Drain Plug	18.0 ft-lbs
Engine Oil Pan Drain Plug	18.0 ft-lbs
Engine Oil Pan Drain Plug	18.0 ft-lbs
Engine Valve Cover Bolts	9.0 ft-lbs

Chassis torques

Leaf Spring to Axle (U-bolts)	151.0 ft-lbs
Leaf Spring to Chassis Bracket	136.0 ft-lbs
Leaf Spring to Rear Shackle	92.0 ft-lbs
Leaf Spring Rear Shackle to Chassis Bracket	136.0 ft-lbs
Lug Nuts	140 ft-lbs

Ignition

Cylinder Firing Order	1-6-5-4-3-2
Cylinder Firing Order	1-8-4-3-6-5-7-2
Spark Plug Manufacturer	AC Delco
Spark Plug Gap	0.060 in
Spark Plug Torque	11-14 ft-lbs
Spark Plug Manufacturer	AC Delco
Spark Plug Gap	0.060 in
Spark Plug Torque	11.0 ft-lbs

Battery & A/C

Refrigerant	R134a
Refrigerant Capacity	3.00-4.25 lbs
Oil Group	PAG
Oil Capacity	8.00-11.00 oz
Oil Type	46
Standard BCI Group Number	78
Standard BCI Cranking Performance	600 cca
Standard BCI Group Number	78

Service checks

Pressure Test	20 psi
Radiator Cap Pressure Relief	15 psi
Thermostat Opening Temperature	188-206 °F
Fuel Pump Pressure Minimum	66.0 psi
Key ON Engine OFF (KOEO)	60-66
RPM	50-63 @ Idle rpm
Fuel Pump Pressure Minimum	66.0 psi
Key ON Engine OFF (KOEO)	60-66

Brakes

Torque to Knuckle	38 ft-lbs
Minimum Pad Thickness	Front: 0.030; Rear: 0.030 specification
Rotor Max Parallel Variation	0.005 in
Rotor Runout Limit	0.004 in
Rotor Nominal Thickness From	1.26 in / 1.535 in
Rotor Nominal Thickness To	1.26 in / 1.535 in
Rotor Minimum Machining	1.23 in / 1.48 in
Rotor Discard at or Under	1.215 in / 1.465 in

Multi-step torque procedures OEM · verified

Cylinder Head — tightening sequence 4 stages

1	20 ft. lbs.	20 ft. lbs
2	55 ft. lbs.	55 ft. lbs
3	55 ft. lbs.	55 ft. lbs
4	90 degrees	90 degrees

Cylinder Head — tightening sequence 4 stages

1	20.0 ft. lbs.	20 ft. lbs
2	55.0 ft. lbs.	55 ft. lbs
3	55.0 ft. lbs.	55 ft. lbs
4	90 degrees	90 degrees

Intake Manifold to Engine Bolts — tightening sequence 1 stages

22 ft. lbs., step 2: 30

22 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 5,000 mi.

At 5,000 mi	Tire & Wheel Assembly (rotate)
Every 5,000 mi	Brake Hydraulic System (inspect fluid level) · Driveshaft U-Joint (lubricate) · Engine Oil Filter (replace) · Power Steering System (inspect) · Steering System (inspect)
At 6,000 mi	Drive Axle Assembly (drain & refill)
At 7,500 mi	Drive Axle Assembly (drain & refill)
Every 7,500 mi	CV Joint Boot (inspect) · Differential (inspect fluid level) · Driveshaft Slip Yoke (lubricate) · Engine Oil (drain & refill) · Parking Brake Cable (lubricate) · Shift Linkage (inspect)
Every 10,000 mi	Air Intake System (inspect) · Tire & Wheel Assembly (rotate)
Every 12,000 mi	Underbody Splash Shield (inspect)
Every 15,000 mi	Radiator Fan Assembly (inspect)
Every 24,000 mi	Drive Axle Assembly (drain & refill)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

Owner complaints about the 1996 Chevrolet G-Series Van top in one area — the tires, 1 of 6 reports (17%), well ahead of the next concern. NHTSA has issued no recalls for this vehicle, so these are owner-reported concerns only. 1 of the reports describe a crash and 0 a fire — a small share of the total, but worth weighing against the tires pattern above. These are tallies of what owners actually reported to the federal government, not an editorial score — and higher-selling models naturally rack up more reports.

Open recalls

NHTSA campaigns

Service bulletins

Manufacturer communications

ODI investigations

Office of Defects Investigation

Owner complaints

1 involved a crash · 0 a fire

Owner complaints filed with NHTSA, by component

All 6 complaints on record, top 6 components.

Tires1

Structure1

Seats1

Service Brakes, Hydraulic,Air Bags1

Service Brakes, Hydraulic1

Seat Belts1

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

No recall campaigns on record with NHTSA for this vehicle as of the last data refresh.

Technical service bulletins NHTSA · verified

Showing 5 of 60 bulletins on record with NHTSA.

Bulletin	Date	Component	Summary
17-NA-073	2023-02-21	Equipment	This warranty administration bulletin provides information regarding the field action…
G-197151	2014-07-29	Fuel System, Gasoline	00064H - SPECIAL COVERAGE (REVISED PART INFORMATION). SOME CUSTOMERS MAY EXPERIENCE A…
130089009	2013-09-01	Engine And Engine Cooling	Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
000730022B	2004-12-01	Power Train	A NO REVERSE, NO SECOND GEAR, OR NO FOURTH GEAR CONDITION. TT UPDATED EH
000604003B	2003-02-01	Engine And Engine Cooling	ROUGH IDLE AFTER START, AND/OR A SERVICE ENGINE SOON (SES) LIGHT. VARIOUS MODELS…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420

Catalyst system efficiency below threshold — Bank 1

P0300

Random / multiple cylinder misfire detected

P0171

System too lean — Bank 1

P0455

Evaporative emission system leak detected — large leak

P0128

Coolant thermostat below regulating temperature

P0442

Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN

Decode a VIN to confirm the transmission and build data for a specific G-Series Van. OEM

Build data

Plant, GVWR class, engine and body data for any 17-character VIN.

Recalls

Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Group 78 battery Vehicles taking 4.5 qt Engine oil filter 25160561 Engine air filter 25042562 Fuel filter 25121468 Spark plug 12681665

Reference guides

Cross-vehicle references for the kinds of data on this page.

Vehicle recalls & TSBs OBD-II trouble codes Torque specifications Maintenance schedules Fluid capacities & specs

Frequently asked

How much oil does the 1996 G-Series Van take?

4.5 qt of 5W-30 API, per the factory manual.

Does the 1996 G-Series Van have open recalls?

NHTSA lists 0 recall campaign(s) for this model year. Check your specific vehicle by VIN.