1996 Chevrolet G Series Van (G20) Problems

RepairPal has identified the most common problems with the 1996 Chevrolet G Series Van (G20) as reported by actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

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11
Known Problems

The fuel pump may fail causing the engine to stall and not restart. Our technicians recommend replacing the fuel filter every 30,000 miles to help prevent undue strain on the fuel pump.

The engine may develop a misfire due to worn valve seats. This fault will cause the Check Engine Light to illuminate. Our technicians tell us the misfire may or may not be felt while driving. They further recommend that both cylinder heads be removed and thoroughly inspected and repaired as necessary.

A loose or worn gas cap could be cause the Check Engine Light to illuminate.

One or more fuel injectors may become stuck closed causing an engine misfire  and the Check Engine Light to illuminate. Our technicians tell us that this problem can be caused by some fuel additives. There are special procedures which may be able to restore the affected injector. If this fails the affected injector must be replaced.

The spark plugs should be replaced every 100,000 miles. Our technicians recommend replacing the spark plug wires also at this time.

The intake manifold gasket may develop and external engine oil or coolant leak. In some cases, an internal coolant leak may occur causing coolant to mix with the engine oil. Running the engine with a coolant/oil mix may result in engine damage. Replacing the intake manifold gasket should correct this issue.

Our technicians recommend flushing the brake fluid every 60,000 miles.  Brake fluid that is dirty may cause problems in the brake system.

Extended life coolant may become contaminated and require cooling system service before the recommended 100,000 miles.
Our technicians highly recommend that the transmission is serviced every 30,000 miles to avoid problems and maintain optimal operating order.

The alternator may fail causing the battery to go dead. The charge light on the dash may or may not illuminate. The alternator may also develop an abnormal noise. A failed alternator will require replacement.

A coolant leak may develop from the water pump. This can result in an engine overheating condition. A leaking water pump will require replacement.